Custom Display Panel Construction from Pixel Sheets
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Solution Overview
Problem
Conventional methods for producing custom-sized liquid-crystal displays (LCDs) are impractical for small production volumes due to the need for large-scale economies of scale, as they require identical copies and are not economical for small or custom-sized displays in small quantities.
Innovation Solution
A method to construct custom-sized displays by extracting a region of pixels from a larger sheet, preparing the edges for electrical signal contact, and attaching driver circuitry to operate the excised pixels, allowing for the creation of various display sizes from a general-purpose sheet of pixels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to produce custom-sized LCDs, then manufacturing precision and performance consistency are maintained, but production costs increase and productivity decreases for small production volumes
Solution Approach 1:
The patent divides a large sheet of pixels into multiple smaller display regions, each capable of being independently configured as a custom-sized display. This segmentation allows a single production run to yield multiple different display sizes from the same parent sheet, reducing costs for small production volumes while maintaining manufacturing precision through standardized fabrication processes.
Solution Approach 2:
The patent creates a universal sheet of pixels that can be configured to produce multiple different display sizes and specifications. The same parent sheet can be divided and configured to create various custom displays, making the manufacturing process multi-functional and adaptable to different customer requirements without requiring separate production lines for each size.
2Reliability
If conventional methods are used to produce custom-sized LCDs, then display performance is consistent, but lead times increase for custom orders
Solution Approach 1:
The patent performs preliminary fabrication of a complete sheet of pixels with all necessary conductive lines and pixel structures before the final customization step. This preliminary action allows the majority of the manufacturing process to be completed using standardized, high-precision processes, ensuring performance consistency. The customization (cutting and configuring) occurs after the main fabrication, significantly reducing lead times for custom orders.
3Manufacturing precision
If conventional methods are used to produce custom-sized LCDs, then quality control is maintained, but minimum order quantities increase
Solution Approach 1:
The patent segments a single large sheet into multiple smaller displays, allowing one production run to satisfy multiple small orders. This reduces the minimum order quantity requirement because the fixed costs of precision manufacturing are distributed across multiple end products from the same parent sheet, making it economical to produce small quantities of custom displays while maintaining quality control.
4Manufacturing precision
If conventional methods are used to produce custom-sized LCDs, then design specifications are met, but adaptability to different sizes decreases
Solution Approach 1:
The patent creates a universal parent sheet with a comprehensive network of conductive lines and pixel structures that can be adapted to create multiple different display configurations. The standardized fabrication process maintains manufacturing precision, while the flexible segmentation and configuration capabilities provide adaptability to various display sizes and specifications, resolving the contradiction between precision and versatility.
Data Source
AI summary
The disclosed embodiments generally relate to a method, system and apparatus for forming a custom-sized display panel. An exemplary method to form a custom display from a large sheet of pixels includes: providing a sheet of pixels having a TFT substrate, a liquid crystal layer and a second substrate, the sheet of pixels having a first perimeter, the liquid crystal medium interposed between the TFT substrate and the second substrate; forming a display panel from the sheet of pixels, the display panel having a display panel perimeter, the second display having a first edge defined by the TFT substrate extending beyond the second substrate to thereby expose an electrical trace on the TFT substrate; sealing the liquid crystal layer on the first edge; conductively exposing the electrical trace on the TFT substrate; and forming a column driver line on the TFT substrate to communicate a driver signal to the second display.