Edge-Wrapped Flex Circuits for Bezel-Free Display Tiling
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Solution Overview
Problem
Current display technologies face challenges in achieving bezel-free display tiles with efficient electrical interconnects, as existing methods like metallized through glass vias are expensive and complex, and there is a need for seamless tiling without metallized vias while maintaining pixel pitch across tile boundaries.
Innovation Solution
The use of edge-wrapped flex circuits with conductive coatings and adhesive polymeric films to connect row and column drivers on the edges of display tiles, eliminating the need for bezels and allowing for close proximity of pixel elements to the edges, thereby enabling seamless tiling and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallized through glass vias (TGVs) are used to achieve electrical interconnects in display tiles, then electrical connectivity between front and back sides is achieved, but manufacturing cost and process complexity increase significantly
Solution Approach 1:
The patent extracts the electrical interconnection function from the traditional through-glass via approach and relocates it to the edge portions of the display tile. By placing drivers and conductors at the edges rather than requiring through-glass penetration, the complex metallization process is eliminated while maintaining electrical connectivity between pixel elements and control circuits.
Solution Approach 2:
The patent transitions from a vertical through-glass interconnection approach to a horizontal edge-based interconnection approach. Instead of routing conductors through the thickness of the glass substrate, the solution moves the interconnection plane to the edge surfaces, allowing drivers and conductors to be positioned in a different spatial dimension that avoids the need for complex via formation.
2Area of stationary object
If drivers and electronic components are placed on the edge portions of display tiles, then bezel size can be minimized for aesthetic purposes, but electrical interconnection and component mounting become more difficult
Solution Approach 1:
The patent segments the display tile into distinct functional zones: pixel elements on the front surface and drivers/conductors on the edge portions and back side. This spatial segmentation allows the bezel to be minimized since electronic components are relocated away from the visible front surface, while manufacturing remains feasible through edge-based assembly techniques.
Solution Approach 2:
The patent introduces edge portions as intermediary structures that bridge the front surface pixel elements and the back side control circuits. These edge portions serve as mediators that accommodate drivers and conductors, enabling compact bezel design while providing accessible locations for electrical interconnection and component mounting.
3Shape
If pixel elements are located in close proximity to the edges of display tiles to achieve bezel-free design, then aesthetic appearance and tiling capability improve, but electrical interconnection complexity increases
Solution Approach 1:
The patent extracts the electrical interconnection function from the pixel element vicinity and relocates it to the edge portions. By separating the pixel elements from their control circuits and placing the latter at the edges, the design achieves compact pixel positioning near tile boundaries without the complexity of routing conductors through or near the pixel elements themselves.
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
This solution allows for bezel-free display tiles with improved mechanical reliability, reduced manufacturing complexity, and cost savings by eliminating glass hole drilling and copper metallization, while maintaining pixel pitch across tile boundaries, facilitating seamless tiling and enhanced display performance.
Implementation Method 1
The display tile includes an adhesive polymeric film that adheres the flex circuit to the edge surface
Implementation Method 2
edge-wrapped flex circuits with conductive coatings to connect row and column drivers
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Display tiles comprising pixel elements on a first surface of a substrate connected by an electrode, a driver located opposite the first surface, and a connector wrapped around an edge surface of the substrate connecting the driver to the pixel elements. Displays comprised of display tiles and methods of manufacturing display tiles and displays are also disclosed.