Hierarchical Sub-Pixel Structure for Defect-Tolerant Display Panels
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Solution Overview
Problem
As display panels with higher resolutions are adopted, the number of display defects increases due to processing accuracy issues, potentially reducing yield and increasing manufacturing costs, as current standards struggle to maintain defects within allowable ranges.
Innovation Solution
A display panel design where each pixel is composed of multiple sub-pixels, with a first sub-pixel comprising multiple second sub-pixels of the same color, each having a light-emitting layer between electrodes, allowing for normal operation even if one second sub-pixel is defective, enabling switching to a lower resolution standard during manufacturing if defects exceed allowable limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If display panels are manufactured with higher resolution standards, then image quality and detail are improved, but the number of display defects increases due to processing accuracy issues
Solution Approach 1:
Each pixel is divided into multiple first sub-pixels of different colors, and each first sub-pixel is further divided into multiple second sub-pixels of the same color. This segmentation allows the display panel to maintain high resolution while providing redundancy, so that if some second sub-pixels have defects, the first sub-pixel can still function normally, thereby reducing the impact of manufacturing defects on overall display quality
Solution Approach 2:
The patent introduces a hierarchical sub-pixel structure where pixels are composed of first sub-pixels, which are in turn composed of second sub-pixels. This parameter change in organizational structure allows the system to achieve both high resolution and defect tolerance by operating at different hierarchical levels depending on defect distribution
2Productivity
If the number of display defects exceeds allowable ranges, then yield and manufacturing cost are adversely affected, but switching to lower resolution standards reduces image quality
Solution Approach 1:
The display panel system can dynamically switch between operating modes: high-resolution mode using individual second sub-pixels when defect rates are low, and low-resolution mode using aggregated first sub-pixels when defect rates are high. This dynamic adaptability allows the system to maintain acceptable yield while preserving image quality by selecting the appropriate resolution level based on actual defect distribution
Solution Approach 2:
The patent enables flexible parameter adjustment by allowing the display to operate at different effective resolution levels. When defects are within acceptable ranges, the full high-resolution mode is used. When defects exceed thresholds, the system can switch to utilizing first sub-pixels as the basic display units, effectively operating at a lower resolution that accommodates the defect rate while maintaining manufacturing yield
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 design suppresses the reduction in manufacturing yield by ensuring display defects fall within acceptable ranges, even at higher resolutions, by allowing inspection and adjustment of manufacturing standards to accommodate defects, thereby maintaining product quality and reducing costs.
Implementation Method 1
An organic EL panel has a plurality of pixels arranged in a matrix of rows and columns. Each pixel is composed of a plurality of sub-pixels emitting light of different colors. The colors of light are typically red (R), green (G), and blue (B).
Data Source
AI summary
Provided is a display panel having a plurality of pixels arranged in a matrix of rows and columns. Each of the pixels is composed of a plurality of first sub-pixels emitting light of different colors. Each of the first sub-pixels is composed of a plurality of second sub-pixels emitting light of the same color. Each of the second sub-pixels includes: a first electrode; a second electrode above the first electrode; and a light-emitting layer between the first electrode and the second electrode.