LED display module and method of manufacturing LED display module

Abstract

The subject matter of the present invention provides an LED display module and a method of manufacturing an LED display module in which light emitters / light emitter packages are optically spaced apart from each other by a high opacity filler extending in a direction over a top of a polarizer and in some cases covering portions of a top surface of the polarizer.

Description

Technical Field

[0001] The present invention generally relates to passively polarized three-dimensional (3D) stereoscopic light emitting diode (LED) display modules and systems. Background Art

[0002] In the physical world, each eye presents a slightly different image to the brain. Stereoscopic display systems attempt to recreate this visual experience using polaroids that present a different view to each eye of the viewer. The viewer can see both views by looking through two corresponding polaroids in the form of glasses or any other form of eyewear, such as contact lenses that transmit different views to the correct eye.

[0003] Early attempts to recreate the real-world visual 3D experience employed devices similar to corrective goggles, including differently colored lenses. A monitor or projector projected two views onto a single screen, each color-coded to complement one or the other goggle lens. Using color to isolate viewing channels often resulted in headaches for viewers.

[0004] Recent 3D designs have focused on creating a 3D viewing experience within a traditional cinema environment using devices centered around displays on lenticular screens constructed from fabric. However, limited stereoscopic viewing advancements have occurred outside of the cinema environment, including on billboards and other public media / advertising delivery devices. In general, it would be desirable to provide a 3D viewing experience using a wider range of devices, billboards, LED cinema screens, stadium screens, and / or other LED display devices. Summary of the Invention

[0005] The present subject matter provides devices, systems, and methods in which a light emitter and a polarizer attached to the light emitter are optically isolated from each other by a high-opacity filler that extends above and upwardly from the top edge (periphery) of the polarizer, thereby improving optical isolation and image resolution. Typically, a low-opacity protective layer is placed over the polarizer and the high-opacity filler.

[0006] In a preferred embodiment, the individual pixels perceived by the viewer are associated with multiple groups of light emitters. As used herein, alternatively, each group of light emitters may be just a single emitter, multiple emitters, or a light emitter package. The light emitters are preferably light emitting diodes (LEDs). In the case where a group of light emitters has only a single emitter, the emitter is advantageously configured to selectively emit multiple colors. In the case where a group of light emitters has multiple emitters, each of the emitters preferably emits a different color. In the light emitter package, the LED or other light emitter is contained within a defined structure. Various types of light emitter packages are contemplated herein, including but not limited to the following types of packages, such as glass on board (GOB), chip on board (COB), and surface mount devices (SMD).

[0007] The extension of the high opacity filler above the top edge of the polarizer does reduce the total amount of light leaving the polarizer, and therefore would be completely non-obvious to one of ordinary skill in the art. Nevertheless, the applicant has discovered that doing so provides significantly better optical isolation and image fidelity.

[0008] In another aspect of the inventive subject matter, the polarizer can be tilted so that the high opacity filler is wider (horizontally) at the top of the polarizer than at the bottom. Here again, one of ordinary skill would not consider adopting this practice because doing so narrows the top surface of the polarizer through which polarized light can escape.

[0009] All types of polarizers are contemplated, including linear (left and right) polarizers and circular (left and right) polarizers, wherein the polarizer is a circular polarizer comprising a quarter-wave plate disposed above the linear polarizer, the quarter-wave plate being either tilted or not, but preferably narrower (horizontally) than the linear polarizer below it. This size difference allows the high-opacity filler to be thicker at the top of the polarizer, further improving its ability to absorb unpolarized light.

[0010] Multiple groups of light emitters or light emitter packages, along with their corresponding polarizers, high-opacity fillers, and low-opacity coatings, are preferably matrixed in a module in a checkerboard or other desired arrangement. A module can contain any suitable number of light emitter groups or light emitter packages and attached polarizers, including, for example, 20, 64, 100, or even 1,000 or more groups of light emitters or light emitter packages. Hundreds, thousands, or even tens of thousands of modules can be arranged in a display.

[0011] Various resources, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, taken in conjunction with the accompanying drawings, in which like reference numerals represent like components. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a prior art vertical cross-section of an LED module comprising multiple groups of light emitters mounted on a substrate.

[0013] Figure 2 A vertical cross-section of an LED module comprising a first light emitter package, a second light emitter package, and their attached circular polarizers (left and right) mounted and electrically connected to a substrate, wherein the packages are optically separated by a high opacity filler extending over the top of the polarizers, and a low opacity coating is laminated over the high opacity filler and exposed portions of the polarizers.

[0014] Figure 3 is a vertical cross-section of a portion of a prior art module having two light emitter packages and attached circular polarizers (left and right), and wherein the light emitter packages are mounted and electrically connected on a PCB or other substrate.

[0015] Figure 4 A vertical cross-section of a portion of a module including a first light emitter package and a second set of light emitter packages with corresponding tilted circular polarizers (left and right), wherein the quarter-wave plate is smaller than the underlying linear polarizer, and wherein the light emitter packages are electrically connected to or mounted on a PCB or other substrate. The horizontal dimension of the quarter-wave plate is significantly smaller than the underlying linear polarizer.

[0016] Figure 5 A vertical cross-section of a portion of a module comprising a first light emitter package and a second light emitter package having diffusers beneath corresponding circular polarizers (left and right), and wherein the light emitter packages are electrically connected to or mounted on a PCB or other substrate.

[0017] Figure 6 A vertical cross-section of a portion of a module including a first light emitter package and a second set of light emitter packages with corresponding circular polarizers (left and right), wherein the light emitter packages are electrically connected to or mounted on a PCB or other substrate and optically separated by a high-opacity filler extending over the tops of the polarizers. A low-opacity coating is laminated over the high-opacity filler and exposed polarizers.

[0018] Figure 71 is a vertical cross-section of a portion of a module including a first light emitter package and a second light emitter package with corresponding circular polarizers (left and right), wherein the light emitter packages are electrically connected to or mounted on a PCB or other substrate and optically separated by a high-opacity filler extending across the top of the polarizers. The high-opacity filler extends over the top of the polarizers and obscures a portion of the exposed top edge of the polarizers. A low-opacity coating is laminated over the high-opacity filler and the exposed polarizers.

[0019] Figure 8 yes Figure 7 Close-up of a part of the module.

[0020] Figure 9 Similar to Figure 7 , except that there is a diffuser above the adhesive.

[0021] Figure 10 is a top perspective view of a module including a first light emitter package and a second light emitter package with corresponding circular polarizers (left and right), the first light emitter package and the second light emitter package being electrically connected to or mounted on a PCB or other substrate, wherein the light emitter packages are optically separated by a high opacity filler extending over the tops of the polarizers so that it obscures the edges of the polarizers prior to adding a low opacity coating. DETAILED DESCRIPTION

[0022] The following discussion provides a number of exemplary embodiments of the present subject matter. Although each embodiment represents a single combination of inventive elements, the present subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment includes elements A, B, and C, and a second embodiment includes elements B and D, the present subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

[0023] The present design can be used to overcome the problems of previous designs by providing a module comprising multiple light emitter / polarizer assemblies bonded together by one or more high-opacity fillers. To improve optical isolation and image fidelity, the high-opacity filler extends above and upwards from the top edge of the polarizer and / or is wider (horizontally) at the top of the polarizer than at the bottom. Multiple modules can be easily combined into a stereoscopic display system.

[0024] All types of packaged LED packages or unpackaged light emitters can be used in the finished design. Considered light emitters include RGB semiconductors or diodes, RGBY semiconductors or diodes, RGBC (Cyan) semiconductors or diodes, RGB plus infrared semiconductors or diodes, digital RGB, surface mount device LED packages (SMD), chip-on-board (COB) LED packages, glass-on-board (GOB) LED packages, quantum dot LEDs, and micro-LEDs.

[0025] Figure 1 1 is a prior art vertical cross-section of a portion of a module 100 including multiple groups of light emitters 110 mounted on a substrate 105. Each of the multiple groups of light emitters 110 includes a red-emitting semiconductor or diode 112, a green-emitting semiconductor or diode 113, and a blue-emitting semiconductor or diode 114. A coating 120 is present around each group of light emitters 110.

[0026] Data / power lines (not shown) are connected to each light emitter. Data and power connections are well known to those of ordinary skill in the art and can be embedded in the substrate. Data and power can use the same or different connections.

[0027] Figure 2 FIG2 is a vertical cross-section of an LED module 200 including four light emitter packages 210A, 210B, 210C, and 210D mounted on a substrate 205. Each of the light emitter packages 210A, 210B, 210C, and 210D includes a red-emitting semiconductor or diode 212, a green-emitting semiconductor or diode 213, and a blue-emitting semiconductor or diode 214. Data / power lines (not shown) are connected to the light emitters through the substrate. Data and power connections are well known to those skilled in the art and may be embedded within the substrate.

[0028] Above the first and third light emitter packages 210A and 210C are adhesive 220 and a left circular polarizer including a first linear polarizer 232A and a first quarter wave plate (QWP) 234A. Above the second and fourth light emitter packages 210B and 210D are adhesive 220 and a right circular polarizer including a second linear polarizer 232B and a second quarter wave plate (QWP) 234B.

[0029] Other embodiments of the device may use only linear polarizers (left and right) instead of circular polarizers (left and right). Each of the light emitter packages 210A, 210B, 210C, 210D and the associated polarizers are optically separated by a high-opacity filler 240 that extends slightly upward over the top of the circular polarizers 230A, 230B. A low-opacity coating 250 is laminated over the high-opacity filler 240 and the exposed polarizers 230A, 230B.

[0030] Figure 3 3 is a vertical cross-section of a portion of a prior art module 300 including a first set of light emitter packages 310A and a second set of light emitter packages 310B of different colors mounted on a substrate 305. Each of the light emitter packages 310A, 310B includes a red-emitting semiconductor or diode 312, a green-emitting semiconductor or diode 313, and a blue-emitting semiconductor or diode 314. Data / power lines (not shown) are embedded in the PCB and electrically connected to each of the light emitter packages 310A, 310B and provide data and power to the light-emitting semiconductors or diodes 312, 313, 314. Above the light emitter package 310A is an adhesive 320 and a left circular polarizer 330A including a first linear polarizer 332A and a quarter-wave plate (QWP) 334A. Over the light emitter package 310B are adhesive 320 and right circular polarizers 330B, 330A including a first linear polarizer 332BA and a quarter wave plate (QWP) 334B.

[0031] Figure 4 4 is a vertical cross-section of a module 400 including a first light emitter package 410A, a second light emitter package 410B, and a third light emitter package 410C mounted on a substrate 405. Each of the light emitter packages 410A, 410B, and 410C includes a red-emitting semiconductor or diode 412, a green-emitting semiconductor or diode 413, and a blue-emitting semiconductor or diode 414. Data / power lines (not shown) are embedded in the PCB and electrically connected to each light emitter package 410A, 410B, and 410C and provide data and power to the light-emitting semiconductors or diodes 412, 413, and 414. Above the first light emitter package 410A and the third light emitter package 410C are an adhesive 420 and a left circular polarizer 430A including a first linear polarizer 432A and a first quarter-wave plate (QWP) 434A. Over the second light emitter package 410B is adhesive 420 and a right circular polarizer 430B including a second linear polarizer 432B and a second quarter wave plate (QWP) 434B.

[0032] In this embodiment, the sides of the circular polarizers 430A, 430B are sloped so that the quarter wave plates 434A, 434B are narrower (horizontally) than the corresponding linear polarizers 432A, 434B below them. An optional high-opacity filler 440 extends over the tops of the circular polarizers 430A, 430B. Figure 4 It should be construed such that the optional high opacity filler 440 may even extend around the edges of the circular polarizers 430A, 430B. A low opacity coating (not shown) is over the exposed circular polarizers 430A, 430B and high opacity filler 440 .

[0033] Figure 5 5 is a vertical cross-sectional image of a portion of a module 500 including a first light emitter package 510A, a second light emitter package 510B, and a third light emitter package 510C mounted on a substrate 505. Each of the LED packages 510A, 510B, and 510C includes a red-emitting semiconductor or diode 512, a green-emitting semiconductor or diode 513, and a blue-emitting semiconductor or diode 514. Data / power lines (not shown) are embedded in the PCB and electrically connected to each light emitter package 510A, 510B, and 510C and provide data and power to the light-emitting semiconductors or diodes 512, 513, and 514. Above the first and third light emitter packages 510A, 510C are an adhesive 520, a diffuser 525, and a left circular polarizer 530A including a first linear polarizer 532A and a first quarter-wave plate (QWP) 534A. Over the second light emitter package 510B are adhesive 520 , a diffuser 525 , and a right circular polarizer 530B including a second linear polarizer 532B and a second quarter wave plate (QWP) 534B.

[0034] In this embodiment, the sides of the circular polarizers 530A, 530B are vertical. An optional high opacity filler 540 extends over the tops of the circular polarizers 530A, 530B. Figure 5 It should be construed so that the optional high opacity filler 540 can extend even around the edges of the circular polarizers 530A, 530B. A low opacity coating (not shown) is over the exposed circular polarizers 530A, 530B and high opacity filler 540 .

[0035] Figure 66 is a vertical cross-section of a portion of a module 600 including a first light emitter package 610A, a second light emitter package 610B, and a third light emitter package 610C mounted on a substrate 605. Each of the light emitter packages 610A, 610B, and 610C includes a red-emitting semiconductor or diode 612, a green-emitting semiconductor or diode 613, and a blue-emitting semiconductor or diode 614. Data / power lines (not shown) are embedded in the PCB and electrically connected to each light emitter package 610A, 610B, and 610C and provide data and power to the light-emitting semiconductors or diodes 612, 613, and 614. Above the first light emitter package 610A and the third light emitter package 610C are an adhesive 620 and a left circular polarizer 630A including a first linear polarizer 632A and a first quarter-wave plate (QWP) 634A. Over the second light emitter package 610B is adhesive 620 and a right circular polarizer 630B including a second linear polarizer 632B and a second quarter wave plate (QWP) 634B. A low opacity coating 650 is laminated over the high opacity filler 640 and the exposed polarizers 630A, 630B.

[0036] In this embodiment, the sides of the circular polarizers 630A, 630B are vertical and there is no diffuser. A high opacity filler 640 extends over the top of the circular polarizers 630A, 630B.

[0037] Figure 7 7 is a vertical cross-section of a portion of a module 700 including a first light emitter package 710A, a second light emitter package 710B, and a third light emitter package 710C mounted on a substrate 705. Each of the light emitter packages 710A, 710B, and 710C includes a red-emitting semiconductor or diode 712, a green-emitting semiconductor or diode 713, and a blue-emitting semiconductor or diode 714. Data / power lines (not shown) are embedded in the PCB and electrically connected to each light emitter package 710A, 710B, and 710C and provide data and power to the light-emitting semiconductors or diodes 712, 713, and 714. Above the first light emitter package 710A and the third light emitter package 710C are an adhesive 720 and a left circular polarizer 730A including a first linear polarizer 732A and a first quarter-wave plate (QWP) 734A. Over the second light emitter package 710B is adhesive 720 and a right circular polarizer 730B including a second linear polarizer 732B and a second quarter wave plate (QWP) 734B. A low opacity coating 750 is laminated over the high opacity filler 740 and the exposed polarizers 730A, 730B.

[0038] In this embodiment, the sides of the circular polarizers 730A and 730B are vertical and lack a diffuser. A small portion 742 of the high-opacity filler 740 extends over the top edge of the polarizers 730A and 730B and obscures a portion of the outer edge of the polarizers 730A and 730B. A low-opacity coating 750 is laminated over the high-opacity filler 740 and 742 and the exposed polarizers 730A and 730B.

[0039] Figure 8 yes Figure 7 Close-up of a part of the module.

[0040] Figure 9 910A, 910B, and 910C are mounted on a substrate 905. Each of the light emitter packages 910A, 910B, and 910C includes a red-emitting semiconductor or diode 912, a green-emitting semiconductor or diode 913, and a blue-emitting semiconductor or diode 914. Data / power lines (not shown) are embedded in the PCB and electrically connected to each of the light emitter packages 910A, 910B, and 910C, providing data and power to the light-emitting semiconductors or diodes 912, 913, and 914. Above the first and third light emitter packages 910A, 910C are adhesive 920, a diffuser 925, and a left circular polarizer 930A including a first linear polarizer 932A and a first quarter-wave plate (QWP) 934A. Over the second light emitter package 910B is adhesive 920, diffuser 925, and a right circular polarizer 930B including a second linear polarizer 932B and a second quarter wave plate (QWP) 934B. A low opacity coating 950 is laminated over the high opacity filler 940 and the exposed polarizers 930A, 930B.

[0041] In this embodiment, the sides of the circular polarizers 930A and 930B are vertical. A small portion 942 of the high-opacity filler 940 extends above the top edge of the polarizers 930A and 930B and obscures a portion of the outer edge of the polarizers 930A and 930B. A low-opacity coating 950 is laminated over the high-opacity fillers 940 and 942 and the exposed polarizers 930A and 930B.

[0042] Figure 1010 is a top perspective view of a module 1000 comprising nine components 1100 of a light emitter package 1010 arranged in a checkerboard pattern, along with associated polarizers 1020L, 1020R, after which a protective low-opacity coating is added. A high-opacity filler 1040 extends between the light emitter package 1010 and the associated polarizers 1020L, 1020R, and portions 1042 of the high-opacity filler 1042 extend over the edges of the polarizers 1020L, 1020R. These nine components are arranged on top of a substrate 1005.

[0043] Each of the high-opacity fillers 240, 440, 540, 640, 740, 940, 1040 extends between adjacent groups of light emitters and extends upward past the top of the corresponding quarter-wave plate or other polarizer (e.g., 230A, 230B, 730A, 730B, 940A, 940B). Extending the high-opacity filler from the substrate to at least the height of the top of the quarter-wave plate reduces the amount of nonlinearly polarized light that passes through the quarter-wave plate.

[0044] In addition, extending the high opacity filler from the substrate up past the top of the polarizer even further reduces the escape of unpolarized light out of the leading edge of the polarizing material or lens. This reduces crosstalk from adjacent light emitters / light emitter packages and increases stereo contrast. High stereo contrast relates directly to high-resolution stereo LED displays. Stereo contrast is established by dividing the brightness value of a given light emitter / package during polarization-cancelled light or dark activation by the uncancelled light or light state of that polarized light emitter / package (light state ÷ dark state = stereo contrast: 1).

[0045] Still further, the high opacity filler 742, 942, 1042 extends upwardly over the edge of the polarizer to obscure a small portion of the surface of the quarter wave plate or other polarizer. Applicant's theory is that the outer perimeter of the top surface of the polarizer material or lens will tend to have a lower level of polarization than inner sections thereof that are not directly adjacent the edge. Thus, the high opacity filler cannot absorb all of the refracted unpolarized light that escapes the sides of the polarizer material or lens. The outer edges of the polarizer material lose the ability to effectively polarize light during the process of producing the polarizer material that is attached to the surface of the light emitter. The effectiveness of the polarized light emitter is greatly reduced by allowing unpolarized perimeter light to escape the top edge of the polarizer. Therefore, allowing the high opacity filler to extend over the top of the polarizer surface, and preferably creating a lip extending around the edge of the polarizer over a small portion of the polarizer material or lens, greatly increases the effectiveness of the polarized light emitted from the device.

[0046] In tests, the inventors have seen a significant increase in stereo contrast, up to four times the stereo contrast of a polarizer without a high-opacity filler lip extending above the edge of the polarizer material. In this way, at least 45% of the light exiting the device passes through the polarizer, and more preferably at least 75% or even at least 90% of the light exiting the device passes through the polarizer. High-opacity filler 240, 440, 540, 640, 740, 940, 1040 is preferably silicone or another resin, and is preferably made opaque by including graphene, ferrous metal, or acrylic pigment.

[0047] The low opacity coating 250, 650, 750, 950 is preferably substantially transparent to at least visible light. Suitable materials for the low opacity coating include two-part room temperature curing or UV curing resins.

[0048] The optional diffuser 525, 925 can enhance the three-dimensional effect in at least two ways. First, without a diffuser, light from the light emitter may tend to "blow through" the polarizer, resulting in a ghosting effect that can detract from the viewing experience. Second, the addition of the diffuser spreads the light, resulting in a reduced lumen per square millimeter value that enhances the polarization effect. In various contemplated embodiments, the diffuser can be placed above the polarizer to reduce glare and increase the effective viewing angle.

[0049] It should be clear to those skilled in the art that, in addition to those already described, more modifications are possible without departing from the inventive concepts herein. Therefore, the subject matter of the present invention is not limited except within the scope of the appended claims. In addition, when interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. Specifically, the terms "comprises" and "comprising" should be interpreted as representing elements, parts or steps in a non-exclusive manner, indicating that the elements, parts or steps mentioned can exist, or utilize, or be combined with other elements, parts or steps that are not explicitly mentioned. In the case where the specification claims refer to at least one thing pointed out from the group consisting of A, B, C ... and N, the text should be interpreted as requiring only one element from the group, rather than A plus N or B plus N, etc.

Claims

1. An LED display module, comprising: substrate; a matrix of at least a first group of light emitters and a second group of light emitters spaced apart, the matrix electrically attached to and extending above the substrate; a first polarizer and a second polarizer, wherein the first polarizer and the second polarizer are respectively arranged above the first group of light emitters and the second group of light emitters; wherein the polarity of the first polarizer is different from that of the second polarizer; a high-opacity filler extending between the first group of light emitters and the second group of light emitters, the high-opacity filler being disposed at a height extending past a top of each of the first polarizer and the second polarizer; and A low-opacity coating is disposed over the first and second polarizers and the high-opacity filler.

2. The display module according to claim 1, wherein The first group of light emitters and the second group of light emitters are housed in a light emitter package.

3. The display module according to claim 1, wherein: The high-opacity filler extends over the tops of the first and second polarizers such that the high-opacity filler obscures at least 0.5% of edges of top surfaces of the first and second polarizers. The display module according to claim 1 , wherein: Each of the first group of light emitters and the second group of light emitters emits at least three different colors.

5. The display module according to claim 1, wherein: Each of the first and second groups of light emitters includes a single light emitting element addressable to produce a wavelength range between 400 nanometers and 750 nanometers. The display module according to claim 1 , wherein: Each of the first and second groups of light emitters includes a plurality of light emitting elements that are collectively addressable to produce a wavelength range between 400 nanometers and 750 nanometers. 7 . The display module according to claim 1 , further comprising a first diffuser and a second diffuser respectively disposed below the first polarizer and the second polarizer.

8. The display module according to claim 7, wherein: The high opacity filler is arranged around the first group of light emitters, the first diffuser and the first polarizer so that at least 45% of the combined total intensity of light between 400 nanometers and 750 nanometers that exits the matrix from the first group of light emitters passes through the first polarizer.

9. The display module according to claim 1, wherein: Each of the first group of light emitters and the second group of light emitters is respectively far away from the first polarizer and the second polarizer.

10. The display module according to claim 1, wherein: The first polarizer and the second polarizer polarize light in different circular polarization directions, respectively.

11. The display module according to claim 1, wherein: The first polarizer and the second polarizer polarize light in left and right directions, respectively.

12. The display module according to claim 1, wherein: The first polarizer is one of a total even number of left-direction polarizers.

13. The display module according to claim 1, wherein: The first polarizer is one of a total odd number of left-direction polarizers.

14. The display module according to claim 1, wherein: The first polarizer is one of a plurality of left-direction polarizers, and the second polarizer is one of a plurality of right-direction polarizers, and the left polarizers and the right polarizers are arranged in a checkerboard pattern.

15. The display module according to claim 1, wherein The first polarizer is one of a plurality of left-direction polarizers, and the second polarizer is one of a plurality of right-direction polarizers, and the left polarizers and the right polarizers are arranged in alternating rows.

16. The display module according to claim 1, wherein The first polarizer and the second polarizer are included in a polarizing film.

17. The display module according to claim 1, wherein: The high opacity filler includes a resin.

18. The display module according to claim 1, wherein The high-opacity filler opaquely transmits less than 80% of the light between 400 nanometers and 750 nanometers transmitted by the low-opacity coating for a total light intensity of less than 20 lumens.

19. The display module according to claim 1, wherein: The high-opacity filler opaquely transmits less than 50% of the light between 400 nanometers and 750 nanometers transmitted by the low-opacity coating for a total light intensity of less than 20 lumens.

20. The display module according to claim 1, wherein The high-opacity filler opaquely transmits less than 20% of the light between 400 nanometers and 750 nanometers transmitted by the low-opacity coating for a total light intensity of less than 20 lumens.

21. The display module according to claim 1, wherein Each of the first group of light emitters and the second group of light emitters is housed within a surface mounted device LED package.

22. The display module according to claim 1, wherein The matrix includes at least 100 groups of light emitters.

23. The display module according to claim 1, wherein The matrix includes at least 1000 groups of light emitters.

24. The display module of claim 1, physically coupled to at least 99 other instances of the display module of claim 1.

25. The display module according to claim 1, wherein The first group of light emitters and the second group of light emitters generate infrared light.

26. A method for manufacturing an LED display module, comprising: depositing a light emitter package over the substrate; depositing a polarizer over the light emitter package; depositing a high opacity filler between the light emitter packages, up to the top of the polarizer and above the polarizer; A low-opacity filler is deposited over the high-opacity filler and the exposed portion of the polarizer.

27. The method of claim 26, further comprising depositing the high-opacity filler over portions of the top surface of the polarizer.

Images