OLED Stuck-On Pixel Elimination via Targeted Irradiation
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Solution Overview
Problem
In the manufacturing of OLED devices, defective pixels that remain energized below the threshold level, known as stuck-on pixels, are difficult to identify and eliminate, often requiring entire arrays to be discarded due to contamination or processing issues.
Innovation Solution
A method and system for selectively identifying and degrading stuck-on OLED pixels by applying an energizing signal above the threshold, reducing it below the threshold level, and irradiating the defective pixels with specific intensity, wavelength, and duration of radiation to degrade the organic material, thereby rendering them inoperative.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing processes are used for OLED arrays, then production can proceed with standard processing, but defective pixels cannot be identified and eliminated, requiring entire arrays to be discarded
Solution Approach 1:
The patent applies preliminary action by implementing a testing and identification process early in the manufacturing sequence, before final assembly and packaging. Defective pixels are detected during the manufacturing process itself through systematic testing, allowing for early elimination of stuck-on pixels before they compromise the entire array. This preliminary detection and elimination approach prevents the need to discard complete arrays due to a few defective pixels.
2Reliability
If entire OLED arrays are discarded due to stuck-on pixels, then zero tolerance for defective pixels is maintained, but manufacturing costs and waste increase significantly
Solution Approach 1:
The patent applies segmentation by treating each pixel or sub-pixel as an independent testable and treatable unit within the larger OLED array. Instead of viewing the array as a single monolithic component where one defect compromises the whole, the method segments the array into individual pixels that can be independently identified, tested, and eliminated if defective. This segmentation allows selective remediation of only the problematic pixels while preserving the rest of the array.
Solution Approach 2:
The patent applies discarding and recovering by selectively eliminating only the defective stuck-on pixels through targeted irradiation or other elimination methods, while recovering and retaining the functional pixels in the same array. This selective discarding approach recovers the value of the majority of pixels that are not defective, transforming what would have been a total loss (discarding the entire array) into a partial loss that maintains manufacturing efficiency and reduces waste.
3Manufacturing precision
If irradiation is applied to eliminate stuck-on pixels, then defective pixels can be precisely degraded, but control over irradiation parameters is critical to avoid affecting adjacent pixels
Solution Approach 1:
The patent applies local quality by directing irradiation or other elimination treatments specifically at the location of identified stuck-on pixels, with parameters optimized for local effect rather than uniform treatment of the entire array. The irradiation is localized to the defective pixel region, with intensity, duration, and positioning controlled to achieve degradation of the organic material in the stuck-on pixel while leaving adjacent functional pixels unaffected. This localized approach ensures precise defect elimination without collateral damage.
Solution Approach 2:
The patent applies feedback by implementing a testing and identification step that provides information about which specific pixels are defective before applying the irradiation treatment. The system identifies the location and characteristics of stuck-on pixels, then uses this feedback information to guide the irradiation process, adjusting parameters such as target position, irradiation intensity, and exposure duration based on the specific defect characteristics. This feedback loop ensures that irradiation is applied only where needed and with appropriate parameters to avoid affecting adjacent pixels.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for early identification and elimination of defective pixels during the production process, reducing unnecessary costs and ensuring higher quality OLED arrays by precisely degrading only the defective pixels without affecting adjacent ones, thus maintaining the integrity of the entire display.
Implementation Method 1
irradiating the stuck-on OLED pixel to degrade the organic material in the stuck-on OLED pixel
Data Source
AI summary
A method for manufacturing an organic light emitting diode (OLED) array is provided that includes applying an energizing signal to at least one of the OLED pixels in the array. The energizing signal exceeds a threshold level. The method also includes reducing the energizing signal and identifying an OLED in the array that continues to remain energized. The method further includes irradiating the identified OLED to degrade the organic material in the OLED. A method of performing quality control in a manufacturing process of an OLED array is provided. The method includes determining an intensity, a time and a wavelength of radiation sufficient to render an OLED of the OLED array inoperative by degrading organic material in the OLED. A system of performing quality control in a manufacturing process of an OLED array is provided. A computer-readable medium having stored thereon computer-executable instructions is provided.