Flexible Substrate Tiling for Electronic Devices
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Solution Overview
Problem
Existing methods for forming large or special-shaped electronic devices through tiling smaller units are inefficient due to challenges in connecting flexible substrates, particularly in creating a flexible tiled LED display device with a conductive pattern layer that effectively connects multiple electronic units.
Innovation Solution
The use of a supporting substrate with a flexible substrate extending beyond its edges to form extension regions, where a conductive pattern layer connects electronic units, allowing for the tiling of electronic devices with a display region and external driving circuits, enabling mass production and cost-effective assembly of larger electronic apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible substrate is used to enable flexible tiled LED display device, then flexibility is improved, but connecting multiple flexible LED display boards together becomes more difficult
Solution Approach 1:
The flexible substrate is divided into a display region and extension regions. The extension regions extend beyond the edges of the supporting substrate and are specifically designed for connection purposes, while the display region maintains flexibility for the LED display function. This segmentation allows different parts of the substrate to serve different functions, resolving the contradiction between flexibility and connectability.
Solution Approach 2:
The extension region acts as an intermediary element between the display region and the connection interface. It provides a dedicated area for conductive patterns and connection structures without interfering with the flexibility of the main display area, thus facilitating easier connection of multiple boards while preserving flexibility.
2Ease of operation
If flexible substrate extends beyond supporting substrate edges to form extension regions, then connection capability is improved, but substrate area utilization decreases
Solution Approach 1:
The flexible substrate is segmented into a display region (for LED units) and extension regions (for connections). This clear functional division allows the extension regions to be optimized for connection capability while the display region maximizes area utilization for the primary function, resolving the trade-off between connection capability and area utilization.
3Reliability
If conductive pattern layer extends to bent portion of flexible substrate, then electrical connectivity is improved, but manufacturing complexity increases
Solution Approach 1:
The conductive pattern layer is designed to extend to the bent portion of the flexible substrate in advance, before the actual bending and tiling process. This preliminary extension ensures that electrical connectivity is maintained through the bent region, and the manufacturing process can proceed with standard patterning techniques without requiring complex post-processing or alignment steps.
Data Source
AI summary
An electronic device comprises a supporting substrate, a flexible substrate disposed on the supporting substrate, a plurality of electronic units and a conductive pattern layer. The flexible substrate is bent from a front side to a back side of the supporting substrate, and a portion of the flexible substrate is disposed on the back side of the supporting substrate. The electronic units are disposed within a display region of the flexible substrate. The conductive pattern layer extends from the display region to the portion of the flexible substrate, and the conductive pattern layer electrically connects at least two of the electronic units.