Micro-LED Sub-Pixel Repair Through Intensity Averaging
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Solution Overview
Problem
Current LED display fabrication methods face challenges in efficiently repairing defective LEDs within LED panels, leading to suboptimal display performance and increased production costs.
Innovation Solution
The method involves bonding LEDs to a backplane, inspecting for defective LEDs, and using sub-pixel isolation structures and color conversion materials to create a pixel array where operational LEDs can be adjusted in intensity and color conversion materials are strategically deposited to compensate for defective pixels, thereby enhancing display performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional LED panel fabrication methods are used, then production efficiency is maintained, but defective LEDs cannot be repaired leading to reduced display performance and increased waste
Solution Approach 1:
The patent divides the LED panel into individually addressable sub-pixels, allowing defective LEDs to be identified and compensated for on a pixel-by-pixel basis. This segmentation enables targeted repair strategies rather than requiring complete panel replacement or complex rework processes.
Solution Approach 2:
The patent modifies display parameters by adjusting the intensity and color of operational sub-pixels to compensate for defective LEDs. By changing these visual parameters, the system can mask defects and maintain overall display quality without physical repair of the defective components.
2Reliability
If defective LEDs are replaced, then display quality is improved, but production time and cost increase
Solution Approach 1:
The patent performs defect identification and compensation strategy development during the assembly process itself, rather than requiring post-assembly repair operations. This preliminary action allows defective LEDs to be accounted for before final panel completion, eliminating time-consuming replacement operations later.
Solution Approach 2:
The patent creates a digital map or model of the LED panel that records the location and characteristics of all LEDs, including defective ones. This copying approach allows the system to plan and execute compensation strategies without physical intervention, maintaining production speed while ensuring display quality.
3Manufacturing precision
If intensity averaging is used to compensate for defective LEDs, then display uniformity is improved, but the complexity of control increases
Solution Approach 1:
The patent implements a control system that serves multiple functions: it identifies defective LEDs, calculates compensation strategies, adjusts operational parameters, and monitors display quality. This multi-functional approach consolidates what could be separate complex systems into a single integrated solution, managing complexity while achieving uniformity.
Solution Approach 2:
The patent employs feedback mechanisms where the system continuously monitors the actual display output and adjusts the intensity of operational sub-pixels accordingly. This closed-loop control automatically compensates for defects and maintains uniformity without requiring complex manual intervention or overly sophisticated control algorithms.
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 the effective repair of defective LEDs, improving display efficiency and reducing production costs by enabling the use of operational LEDs to maintain high-quality image output.
Implementation Method 1
color conversion material disposed in each well
Implementation Method 2
one or more LEDs, each LED having at least one LED electrode coupled a respective backplane electrode
Data Source
AI summary
Embodiments of the present disclosure relates to LED pixels and methods of fabricating LED pixels. The device includes a backplane, the backplane including a plurality of backplane electrodes, one or more LEDs, each LED having at least one LED electrode coupled a respective backplane electrode of the plurality of backplane electrode, at least two pixels, each pixel including sub-pixel isolation (SI) structures disposed over the LEDs, the SI structures defining wells of sub-pixels of each pixel, where a respective pixel includes three operational sub-pixels, each operational sub-pixel having an operational LED and a color conversion material disposed in each well, a defective LED sub-pixel, the defective LED sub-pixel having a defective LED, and where one of the at least two pixels has two operational sub-pixels having a same color conversion material disposed in each well.