Flexible Chixel Display Layout for Seamless Large-Area Panels
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Solution Overview
Problem
Current manufacturing techniques for large flexible displays are not scalable, resulting in heavy, expensive, non-flexible, and power-hungry devices, which are difficult to produce and maintain.
Innovation Solution
The development of a flexible display using self-contained pixel-containing chips (chixels) arranged on a flexible substrate with a modular design, allowing for customizable flexibility and uniform sub-pixel spacing, which reduces the visibility of gaps and enhances display resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional manufacturing techniques are used for large displays, then display size is increased, but weight increases and flexibility is lost
Solution Approach 1:
The display is divided into multiple independent chixel modules, each containing a subset of pixels. These modular chixels are arranged on a flexible substrate with bend gaps between them, allowing the large display to be segmented into manageable units that reduce overall weight while maintaining large area coverage.
2Area of stationary object
If traditional manufacturing techniques are used for large displays, then display size is increased, but flexibility is reduced
Solution Approach 1:
The display is segmented into modular chixel units with bend gaps between them, enabling the large display to flex without compromising structural integrity. This segmentation allows the display to adapt to curved surfaces and flexible mounting configurations while maintaining large display area.
Solution Approach 2:
The chixel modules are mounted on a flexible substrate that allows the display to bend and conform to different shapes. The thin-film construction of individual chixels enables the entire large display to maintain flexibility despite its size.
3Adaptability or versatility
If chixel size is decreased to increase flexibility, then number of bend gaps increases and flexibility improves, but manufacturing complexity increases
Solution Approach 1:
The display is segmented into standardized chixel modules of optimized size that balance flexibility requirements with manufacturing feasibility. Each chixel is a self-contained unit with standardized dimensions, allowing modular assembly while maintaining manageable manufacturing complexity.
Solution Approach 2:
The chixel dimensions and spacing parameters are optimized to achieve the desired flexibility threshold. By adjusting the chixel size and bend gap spacing to specific parameter ranges, the display achieves sufficient flexibility without requiring excessively small chixel sizes that would complicate manufacturing.
4Adaptability or versatility
If chixel size is decreased to increase flexibility, then display flexibility improves, but gap visibility may increase
Solution Approach 1:
The bend gaps between chixels are designed with specific local characteristics - their width and positioning are optimized to minimize visual impact while maintaining flexibility. The gaps are strategically placed and dimensioned to reduce visibility without compromising the flexibility benefits of having multiple small chixel units.
Data Source
AI summary
A display includes a plurality of pixel chips, chixels, provided on a substrate. The chixels and the light emitters thereon may be shaped, sized and arranged to minimize chixel, pixel, and sub-pixel gaps and to provide a seamless look between adjacent display modules. The substrate may include light manipulators, such as filters, light converters and the like to manipulate the light emitted from light emitters of the chixels. The light manipulators may be arranged to minimize chixel gaps between adjacent chixels.