Display Panel Bonding Structure for Precise Pixel Alignment
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Solution Overview
Problem
Mechanical clamping structures in LED display technology have limited dimensional accuracy, leading to uneven gaps and unaligned pixels when splicing display panels, which affects the display effect, especially as pixel size decreases.
Innovation Solution
A display device with high positioning accuracy is achieved by using a positioning substrate and connection structures that include a fixing member, a first connection member, and a second connection member, allowing for precise bonding and adjustment of display panels, ensuring uniform gaps and aligned pixels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical clamping structures are used to splice display panels, then the device complexity is reduced and ease of manufacture is improved, but the positioning accuracy and manufacturing precision deteriorate
Solution Approach 1:
A positioning substrate is introduced as an intermediary component between display panels to achieve precise positioning. The positioning substrate includes positioning structures that accurately locate each display panel, resolving the contradiction by mediating the connection between panels while maintaining manufacturing ease through modular assembly
Solution Approach 2:
The connection structure is segmented into multiple functional components: positioning structures for accurate location, bonding structures for secure attachment, and adjustment structures for fine-tuning. This segmentation allows each component to optimize its specific function while maintaining overall ease of manufacture through standardized modular parts
2Device complexity
If mechanical clamping structures are used to splice display panels, then the device complexity is reduced, but the display quality and homogeneity deteriorate due to uneven gaps and unaligned pixels
Solution Approach 1:
The positioning substrate acts as a mediator that ensures uniform spacing and alignment between display panels. It includes positioning structures that maintain consistent gaps and alignment features that ensure pixels are properly aligned across panel boundaries, thereby stabilizing the overall display quality without significantly increasing device complexity
Solution Approach 2:
The patent replaces simple mechanical clamping with a more sophisticated system combining positioning structures, bonding structures, and adjustment mechanisms. This substitution transitions from purely mechanical connection to a hybrid system that incorporates precise geometric features and controlled bonding processes to achieve better display quality
3Manufacturing precision
If bonding structures are used instead of mechanical clamping, then the positioning accuracy is improved, but the ease of manufacture and repairability deteriorate
Solution Approach 1:
The connection structure is divided into positioning structures for accurate location, bonding structures for secure attachment, and adjustment structures for fine-tuning. This segmentation allows the bonding process to focus on precision while other components handle assembly ease, resolving the contradiction between manufacturing precision and ease of manufacture
Solution Approach 2:
The adjustment structures provide dynamic capability to the otherwise static bonding connection. These structures allow for fine-tuning of panel positions after bonding, maintaining positioning accuracy while enabling easier adjustment and potential reconfiguration during manufacturing and maintenance
4Manufacturing precision
If bonding structures are used instead of mechanical clamping, then the positioning accuracy is improved, but the ease of repair deteriorates
Solution Approach 1:
The connection structure is segmented into distinct positioning, bonding, and adjustment components. This segmentation allows repair operations to target specific components without affecting the entire assembly, maintaining positioning accuracy while improving ease of repair by enabling modular replacement of failed elements
Solution Approach 2:
The adjustment structures provide dynamic capability that facilitates repair operations. By allowing fine-tuning of panel positions after bonding, these structures enable easier realignment and adjustment during repair processes, offsetting the reduced ease of repair from using bonding instead of mechanical connections
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 ensures high positioning accuracy of display panels, improving the display effect and allowing for easy maintenance and cost-effective mass production, even with small pixel sizes like Micro-LEDs and Mini-LEDs.
Implementation Method 1
a bonding structure, used to bond the first connection member to the second connection member, so that the display panel is fixed on the positioning substrate by bonding
Data Source
AI summary
A display device of embodiments of the present disclosure includes: a plurality of display panels each having a display side and a back side opposite to each other; a positioning substrate facing the back side of the display panel; and a plurality of connection structures, each of the plurality of display panels corresponding to at least one connection structure and being fixed on the positioning substrate by bonding through its corresponding connection structure(s); wherein each connection structure includes: a fixing member connected to the back side of the display panel; a first connection member detachably connected to the fixing member; and a second connection member detachably connected to the positioning substrate, and configured to be bonded to the first connection member through a first bonding structure, so that the display panel is fixed on the positioning substrate by bonding.