Color-Agnostic Pixel Repair Layout for Faulty Emitter Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display technologies face challenges in constructing displays with no faulty pixels, as manufacturing processes can result in faulty light emitters, which are difficult and costly to address, especially in large, high-resolution displays where even a single faulty pixel can be visible.
Innovation Solution
A pixel structure with a color-agnostic repair site that allows for the replacement of faulty light emitters using micro-transfer printed LEDs, where a repair light emitter can be connected to the pixel controller through a repair wire, enabling the repair of faulty pixels without increasing the display area and maintaining high resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If displays are constructed with high resolution and large number of pixels, then display quality is improved, but the probability of faulty pixels increases and manufacturing yield decreases
Solution Approach 1:
The patent applies preliminary action by incorporating repair sites and repair light emitters into the pixel structure during manufacturing, before any faults occur. This allows pre-prepared replacement components to be integrated into the display, enabling subsequent repair of faulty pixels without requiring external intervention or display disassembly.
Solution Approach 2:
The patent changes the structural parameters of the pixel by adding repair sites and repair light emitters alongside the primary light emitters. This structural modification enables the display to accommodate and replace faulty pixels while maintaining the original high-resolution parameters, thus resolving the contradiction between high pixel density and fault probability.
2Reliability
If faulty pixels are repaired by replacing light emitters, then pixel reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies universality by designing repair light emitters that are identical or substantially similar to the primary light emitters. This allows the same manufacturing processes, materials, and assembly techniques to be used for both primary and repair light emitters, minimizing the increase in manufacturing complexity despite the addition of repair functionality.
Solution Approach 2:
The patent segments the pixel structure into primary light emitter sites and separate repair sites, allowing independent testing and replacement of individual light emitters. This segmentation enables targeted repair of only the faulty components rather than requiring replacement of entire pixel assemblies, thus limiting the increase in manufacturing complexity.
3Ease of repair
If repair sites are added to each pixel, then ease of repair is improved, but display area and pixel density are reduced
Solution Approach 1:
The patent applies the nested doll principle by integrating repair sites within the existing pixel structure footprint. The repair light emitters are positioned in repair sites that share the same pixel area as the primary light emitters, allowing repair functionality to be nested within the original display geometry without requiring additional display area.
Solution Approach 2:
The patent resolves the area constraint by transitioning to a different dimensional arrangement, where repair sites are positioned adjacent to or overlapping with primary light emitter sites in the same pixel plane. This allows multiple light emitters (primary and repair) to coexist within the same two-dimensional pixel footprint, maintaining display area while enabling repair functionality.
Data Source
AI summary
A pixel with a color-agnostic repair site includes a pixel controller, a first site for a first light emitter electrically connected to the pixel controller with a first wire, a second site for a second light emitter electrically connected to the pixel controller with a second wire different from the first wire, and a repair site for a repair light emitter. A repair wire can independently electrically connect the repair site to the pixel controller. A repair wire can electrically connect the repair site to the first wire or to the second wire with a jumper. The repair site can electrically connect to the first wire or to the second wire. A first repair wire can electrically connect the repair site to the first wire, a second repair wire can electrically connect the repair site to the second wire, and one of these wires can be cut.