LED Display Assembly With Equal-Thickness Driver and Emitter Transfer
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Solution Overview
Problem
The challenge lies in manufacturing a display apparatus with light-emitting diodes (LEDs) while maintaining low manufacturing costs, high yield, and quality, as existing methods are complex and costly.
Innovation Solution
The solution involves a display apparatus comprising a circuit substrate with a driving unit and a light-emitting unit of equal thickness, fabricated using a low temperature poly-silicon process, where the driving unit and light-emitting unit are transferred together to the circuit substrate using a one-time process, allowing for easier assembly and testing, and replacement if necessary, using a solder with a melting point lower than 260°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods are used for display apparatus with LEDs, then manufacturing complexity and cost increase, but manufacturing precision and quality may be maintained
Solution Approach 1:
The patent merges the driving unit and light-emitting unit into a single integrated structure with equal thickness, allowing them to be transferred together in one-time process. This integration simplifies the manufacturing process while maintaining the functional quality of the display apparatus.
Solution Approach 2:
The patent prepares the driving unit and light-emitting unit in advance with equal thickness design before transfer to the circuit substrate. This preliminary preparation ensures that the units can be easily assembled and tested together, reducing manufacturing complexity while maintaining quality standards.
2Productivity
If traditional transfer processes are used for driving unit and light-emitting unit, then multiple transfer steps are required, but assembly precision can be maintained
Solution Approach 1:
The patent combines the transfer process for both the driving unit and light-emitting unit into a single operation. By designing both units with equal thickness, they can be transferred together in one-time process, significantly improving manufacturing efficiency and reducing process complexity.
Solution Approach 2:
The patent performs preliminary preparation of the driving unit and light-emitting unit with matching dimensions before the transfer process. This advance preparation enables the units to be transferred together as a coordinated assembly, streamlining the manufacturing process.
3Ease of operation
If units of different thickness are used, then assembly difficulty increases, but functional performance can be achieved
Solution Approach 1:
The patent applies homogeneity by designing the driving unit and light-emitting unit with equal thickness. This uniform dimension makes the units easier to assemble together while maintaining their functional performance, as the homogeneous structure facilitates proper alignment and connection.
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 approach simplifies the manufacturing process, reduces costs, and enhances the yield and quality of the display apparatus by ensuring the driving and light-emitting units are of equal thickness, facilitating easier integration and testing.
Implementation Method 1
using a solder with a melting point lower than 260°C
Data Source
AI summary
A display apparatus, including a circuit substrate, a driving unit and a light-emitting unit is provided. The driving unit is disposed on the circuit substrate. The light-emitting unit is disposed on the circuit substrate. A thickness of the driving unit is substantially the same as a thickness of the light-emitting unit.