Display Electrode Reconnection for Misaligned Pixel Repair

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Solution Overview

Problem

Display devices often suffer from dark spot defects due to misalignment of light-emitting elements, leading to reduced reliability and increased manufacturing costs, as existing repair methods involve replacing defective elements rather than reconfiguring the electrical connections.

Innovation Solution

The display device incorporates a substrate with multiple electrodes and dummy electrodes, allowing for the separation and reconnection of electrical paths using laser welding to reverse the direction of current flow in defective light-emitting elements, thereby converting reverse-connected elements into functional light sources.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If light-emitting elements are misaligned during manufacturing, then dark spot defects occur in pixels, but replacing defective elements increases manufacturing costs and reduces reliability

Engineering Contradiction:

Improvedisplay device reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of replacing misaligned light-emitting elements, the patent inverts the electrical connection direction by reversing the anode and cathode connections. This allows previously defective elements to function correctly, converting manufacturing defects into functional components and reducing waste while improving reliability

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the electrical connection parameters by swapping the anode and cathode connections of misaligned light-emitting elements. This parameter inversion transforms the electrical flow direction, enabling defective elements to operate properly without physical replacement, thereby reducing manufacturing costs and improving device reliability

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional repair methods replace defective light-emitting elements, then dark spot defects are eliminated, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvepixel functionalityVSAvoidrepair process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies connection inversion by swapping the anode and cathode connections of misaligned light-emitting elements through the electrode structure. This electrical inversion repairs defective pixels without requiring element replacement, simplifying the repair process and reducing device complexity while maintaining pixel functionality

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces dummy electrodes as intermediary elements that facilitate the connection inversion process. These dummy electrodes serve as mediators to redirect electrical connections from misaligned light-emitting elements, enabling repair without direct manipulation of the defective elements themselves and reducing repair complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If misaligned light-emitting elements are discarded, then defect-free pixels are maintained, but material waste increases and productivity decreases

Engineering Contradiction:

Improvepixel qualityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the electrical connection parameters of misaligned light-emitting elements by inverting the anode and cathode connections. This parameter transformation allows previously defective elements to meet quality standards, increasing the yield of usable pixels and improving manufacturing efficiency without compromising pixel quality

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of discarding misaligned light-emitting elements, the patent recovers them by inverting their electrical connections through the electrode structure. This recovery process converts defective elements into functional pixels, reducing material waste and increasing manufacturing productivity while maintaining pixel quality standards

Inventive Principle:

Principle #34Discarding and recovering

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 method enhances the reliability of the display device by repurposing defective elements as effective light sources, reducing waste and manufacturing costs by avoiding the need for element replacement.

Implementation Method 1

a first bridge electrode connecting one end of the first dummy electrode to the second sub-electrodes, and connecting another end of the first dummy electrode to the third electrode through laser welding

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS20240332459A1Display device and repair method thereof

Publication Date: 2024.10.03 SAMSUNG DISPLAY CO LTD

AI summary

A display device according to one or more embodiments may include a substrate, a first electrode and a third electrode integrally formed to be electrically connected to each other, and a second electrode and a fourth electrode integrally formed to be electrically connected to each other, the first, second, third, and fourth electrodes being spaced apart from each other above the substrate, a first dummy electrode and a second dummy electrode spaced apart from each other above the substrate, and electrically insulated from the first, second, third, and fourth electrodes, and a light-emitting element electrically connected to the first and second electrodes.