Pixel Structure with Two-Way Conductor Extensions for Micro LED Repair
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Solution Overview
Problem
The current production yield of pixel structures using micro light emitting diodes is low, leading to waste and high costs due to the need for reserved space for repair diodes, which complicates the manufacturing process and can distort the display effect when multiple positions require repair.
Innovation Solution
A pixel structure design featuring a two-way extension of conductors allows for the removal and replacement of micro light emitting diodes at the same position, reducing the need for multiple dies and maintaining consistent display quality before and after repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two same micro light emitting diodes are arranged at different positions in a same pixel unit for repair purposes, then the reliability of the pixel structure is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The conductor structure is designed with dual functionality: it serves as both the original connection path and the replacement connection path. The first and second conductors can respectively connect to different electrodes of the micro light emitting diode, allowing the same conductor structure to support both initial assembly and repair operations without requiring separate dedicated repair pathways.
Solution Approach 2:
The patent merges the repair function into the existing conductor structure by providing alternative connection paths within the same pixel unit. Instead of creating separate repair infrastructure, the first and second conductors are integrated into the original pixel structure, combining repair capabilities with the primary display function.
2Reliability
If two same micro light emitting diodes are arranged at different positions in a same pixel unit for repair purposes, then the reliability of the pixel structure is improved, but the area required increases
Solution Approach 1:
The patent utilizes the conductor layer dimension to provide repair capabilities. Instead of allocating additional spatial area on the substrate surface, the repair function is achieved through the three-dimensional conductor architecture, where conductors extend in multiple directions (first direction and second direction) to provide alternative connection paths within the same planar footprint.
3Reliability
If multiple micro light emitting diodes are reserved for repair at different positions, then the reliability is improved, but the display effect is easily affected and distorted
Solution Approach 1:
The conductor structure is designed with differentiated local properties: the first conductor and second conductor have different geometrical configurations and connection points tailored to their specific functions. This local optimization ensures that each conductor path maintains appropriate electrical characteristics for its role, preserving display uniformity while enabling repair.
4Ease of manufacture
If bonding material cannot be removed and reused when the micro light emitting diode is replaced, then the ease of manufacture is maintained, but the ease of repair deteriorates
Solution Approach 1:
The conductor structure is segmented into multiple independent connection paths (first conductor and second conductor), allowing selective use of connection routes. This segmentation enables repair operations to utilize alternative conductors without affecting the bonding material status of originally connected components, maintaining manufacturing simplicity while improving repairability.
Data Source
AI summary
A pixel structure including a substrate, a first conductor, a second conductor, and a plurality of dies is provided. The first conductor is disposed on the substrate and includes a plurality of first body portions extending along a first direction, a plurality of first branch portions extending along a second direction, and a plurality of second branch portions extending along the first direction. The second conductor is disposed on the substrate and includes a plurality of second body portions extending along the second direction and a plurality of third branch portions extending along the first direction. The die includes two electrodes, wherein the first branch portions are connected between the first body portions and the second branch portions, and the two electrodes are respectively connected to the first branch portions and the second body portions or respectively connected to the second branch portions and the third branch portions.