Sub-Pixel Repair Layout for High-Density Display Panels
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Solution Overview
Problem
Current display devices face challenges in easily repairing defective sub-pixels, particularly in high-resolution displays, which complicates the manufacturing process and increases costs due to the need for separate repair areas and additional components.
Innovation Solution
A display device design that incorporates emission sub-pixels with a light emitting element and a transistor, along with a first reflective layer connected to the transistor, and a repair sub-pixel with a second reflective layer and a connection layer that can be electrically connected to the first reflective layer, allowing for the easy replacement or repair of defective sub-pixels by transferring a repair light emitting element only when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a separate repair area is provided for defective sub-pixels, then repair capability is improved, but device area and manufacturing complexity increase
Solution Approach 1:
The patent merges the repair sub-pixel structure with the normal emission sub-pixel structure by using the same layered components (reflective layer, connection layer, light emitting element) that can serve dual purposes: normal light emission and repair functionality. This eliminates the need for separate repair areas while maintaining repair capability.
Solution Approach 2:
The reflective layer and connection layer are designed to serve multiple functions: they participate in normal light emission during operation and can be reconfigured to enable repair mode when defects occur. This multi-functionality allows a single area to handle both display and repair needs without requiring additional dedicated repair zones.
2Ease of repair
If a separate repair area is provided for defective sub-pixels, then repair capability is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent combines the repair functionality into the existing sub-pixel manufacturing process by using the same layered structure (reflective layer, connection layer, light emitting element) that is already being manufactured. This approach eliminates the need for separate repair area manufacturing processes, thereby reducing overall manufacturing complexity and costs.
3Manufacturing precision
If repair area is minimized, then pixel density is improved, but repair capability may be compromised
Solution Approach 1:
The patent makes the sub-pixel components universal by designing the reflective layer, connection layer, and light emitting element to function in both normal emission mode and repair mode. This allows the same physical space to serve dual purposes, maintaining high pixel density while preserving full repair capability through functional versatility rather than spatial separation.
4Ease of repair
If separate repair line is provided, then repair capability is improved, but manufacturing costs increase
Solution Approach 1:
The patent merges repair functionality into the standard manufacturing line by using the same process to create both emission and repair capabilities. The reflective layer, connection layer, and light emitting element are manufactured using identical processes whether for normal display or repair purposes, eliminating the need for a separate repair manufacturing line and associated costs.
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 minimizes the repair area and manufacturing costs by enabling selective transfer of a repair light emitting element, allowing for efficient repair of defective sub-pixels within a high-resolution display without the need for a separate repair line, thus maintaining high pixel density and display quality.
Implementation Method 1
a first reflective layer disposed between the light emitting element and the transistor in the emission sub-pixel
Data Source
AI summary
A display device in one aspect includes a plurality of sub-pixels having an emission sub-pixel and a repair sub-pixel. The display device further includes a light emitting element disposed in the emission sub-pixel and a transistor disposed in the emission sub-pixel. The display device further includes a first reflective layer disposed between the light emitting element and the transistor in the emission sub-pixel, and electrically connected to the transistor. The display device also includes a second reflective layer disposed in the repair sub-pixel, and a connection layer disposed below the first reflective layer and the second reflective layer to overlap the first reflective layer and the second reflective layer. Therefore, defective sub-pixels can be easily repaired.