Black Molding Layer for Inorganic LED Display Manufacturing
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Solution Overview
Problem
Inorganic light emitting diodes mounted on a substrate face challenges such as low bonding reliability, speckle noise, and visibility of seams between unit modules due to tilting, which affect image quality and viewing angles.
Innovation Solution
A manufacturing method involving a black molding layer with a low refractive index is applied around the inorganic light emitting diodes to improve bonding reliability and reduce speckle noise, with the layer blocking light emission through side surfaces to minimize viewing angle issues and conceal seams between modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If inorganic light emitting diodes are mounted on a substrate, then high luminance and high resolution are achieved, but bonding reliability is low and speckle noise occurs
Solution Approach 1:
A black molding layer is introduced as an intermediary substance between the inorganic light emitting diode and the substrate. This layer serves multiple functions: it enhances bonding reliability by providing a stable adhesive interface, reduces speckle noise by optimizing optical pathways, and prevents direct contact issues between the LED and substrate while maintaining electrical and thermal connectivity
2Manufacturing precision
If inorganic light emitting diodes are mounted on a substrate, then high resolution is achieved, but speckle noise is generated
Solution Approach 1:
The black molding layer acts as an optical intermediary that modifies light pathways. By positioning and configuring this layer, speckle noise is reduced through controlled light scattering and reflection patterns, while the high resolution display capabilities are preserved through precise optical management
3Ease of manufacture
If inorganic light emitting diodes are mounted on a substrate, then direct mounting is achieved, but physical protection is insufficient without optical distortion
Solution Approach 1:
The black molding layer is designed to perform multiple functions simultaneously: it provides physical protection to the inorganic light emitting diode, maintains optical clarity without causing distortion, enables direct mounting simplicity, and enhances bonding reliability. This multi-functional approach eliminates the need for separate protective structures that could complicate the manufacturing process
4Reliability
If inorganic light emitting diodes are mounted on a substrate, then simple protection is achieved, but image quality is insufficient
Solution Approach 1:
The black molding layer is applied selectively in specific regions around the inorganic light emitting diode rather than uniformly across the entire substrate. This localized application provides protection where needed while preserving optical quality in display regions, preventing image quality degradation through precise spatial control of the protective layer's properties
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
The solution enhances the bonding reliability of inorganic light emitting diodes, reduces speckle noise, and prevents seams between adjacent modules from being visible, thereby improving image quality and reducing right and left viewing angles.
Implementation Method 1
black molding layer having a low refractive index... When the black molding layer is formed to surround the side surface of the inorganic light emitting diode, light generated from the inorganic light emitting diode may be blocked by the black molding layer
Implementation Method 2
black molding layer having the low refractive index... effectively reduce the speckle noise
Data Source
Figure 1~2
Figure 3
Figure 4~5b
AI summary
A manufacturing method of a display apparatus includes mounting a plurality of inorganic light emitting diodes on a substrate, forming a black molding layer having a low refractive index and configured to surround the plurality of inorganic light emitting diodes such that front light emitting surfaces of the plurality of inorganic light emitting diodes that are directed to a front side of the display apparatus are exposed, and assembling a plurality of unit modules each comprising the substrate, the plurality of inorganic light emitting diode, and the black molding layer to be adjacent to each other.