Display Module Resin and Molding Structure for Hidden Panel Seams
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Solution Overview
Problem
Existing display technologies face challenges in transferring light-emitting devices of various colors onto a substrate without optical distortion or loss, and in creating a seamless large-screen display without visible seams between substrates.
Innovation Solution
A display module structure featuring transparent resins surrounding light-emitting devices and an opaque molding layer covering partial surfaces, with the molding layer hiding seams and protecting the devices from optical distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If light-emitting devices are mounted directly on a substrate to create a large-screen display, then the display area is increased, but boundary lines or seams between neighboring substrates become visible
Solution Approach 1:
An opaque molding layer is introduced as an intermediary element between adjacent substrates. This molding layer fills the gaps and boundary regions between substrates, preventing light from leaking through the seams and making them invisible from the front viewing angle, thus eliminating the visible boundary lines while maintaining the large display area
Solution Approach 2:
The molding layer is applied selectively only in the boundary regions between substrates, not across the entire substrate surface. This localized application maintains the transparency and optical quality of the display areas while providing seam coverage only where needed at the interfaces between adjacent substrates
2Reliability
If transparent resins are used to surround light-emitting devices, then physical protection is improved, but light transmittance may be reduced
Solution Approach 1:
The transparent resin is applied locally to surround only the side surfaces and upper surfaces of the light-emitting devices, deliberately avoiding coverage of the lower surfaces and the light-emitting apertures. This selective application provides mechanical protection and structural support while maintaining optimal light transmittance from the devices
Solution Approach 2:
The transparent resin acts as a protective intermediary layer between the light-emitting devices and the external environment, providing mechanical support and protection without significantly impeding light transmission. The resin's optical properties are selected to minimize light loss while maximizing protective functionality
3Shape
If the opaque molding layer covers the entire top surface of transparent resins, then seam hiding is improved, but light emission from light-emitting devices is blocked
Solution Approach 1:
The opaque molding layer is applied selectively to cover only the boundary regions and side surfaces of the transparent resins, while deliberately leaving the upper surfaces and light-emitting apertures exposed. This localized application strategy ensures that seams are hidden from side and rear views while light emission from the devices remains unobstructed in the forward direction
Data Source
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AI summary
A display module is provided. The display module includes a plurality of substrates; a plurality of light-emitting devices mounted on each of the plurality of substrates; a plurality of transparent resins that surrounds the plurality of light-emitting devices; and an opaque molding layer that is disposed on the plurality of substrates between the plurality of transparent resins and covers partial surfaces of the plurality of transparent resins.