iLED Display Substrate Holes for Audio and Cooling
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Solution Overview
Problem
Conventional direct-view flat-panel displays face challenges in achieving high brightness, long lifetime, and improved audio-visual experience due to limitations in aperture ratio, organic material usage, and interference with audio speakers.
Innovation Solution
The use of micro-inorganic light-emitting diodes (micro-iLEDs) with a display substrate featuring holes to allow sound transmission and improved cooling, enabling a more robust and efficient display structure with enhanced audio reproduction and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a larger aperture ratio is used in conventional displays, then brightness and lifetime are improved, but the ability to include additional features (such as audio speakers) on the display substrate is reduced
Solution Approach 1:
The display substrate is segmented into multiple functional regions: light-emitting regions containing micro-iLEDs and non-light-emitting regions containing holes for audio speakers. This segmentation allows different areas of the substrate to serve different purposes, enabling both high brightness in display areas and audio functionality in speaker areas without compromising either.
Solution Approach 2:
The invention transitions from a two-dimensional planar display structure to a three-dimensional structure with holes extending through the substrate. This dimensional change creates vertical pathways for sound transmission while maintaining the display surface area, allowing audio speakers to be positioned behind the display without reducing the aperture ratio for light emission.
2Adaptability or versatility
If audio loudspeakers are located behind the display substrate, then audio-visual verisimilitude is improved, but the display substrate interferes with sound transmission
Solution Approach 1:
The display substrate incorporates an array of holes that create a porous structure, allowing sound waves to pass through the substrate from the audio loudspeakers located behind it. This porous design enables the substrate to be simultaneously opaque to light (providing display functionality) and permeable to sound (providing audio transmission), thereby improving audio-visual verisimilitude without sound interference.
3Reliability
If micro-iLEDs are used instead of conventional light emitters, then lifetime and brightness are improved, but the manufacturing complexity increases
Solution Approach 1:
The micro-iLEDs are pre-formed on a separate semiconductor wafer using established semiconductor manufacturing processes before being transferred to the display substrate. This preliminary fabrication allows for optimized production of the light-emitting elements independently, and the subsequent transfer process integrates them into the final display structure, managing complexity through staged manufacturing.
Solution Approach 2:
A transfer mechanism serves as an intermediary between the semiconductor wafer fabrication process and the display substrate assembly process. This intermediary transfer step enables the integration of micro-iLEDs into the display structure without requiring direct fabrication on the final substrate, thereby managing manufacturing complexity through modular assembly.
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
Micro-iLEDs provide high-brightness output with increased lifetime and improved image quality, allowing for additional features like audio speakers behind the display and enhanced cooling, while maintaining a simpler and more cost-effective manufacturing process.
Implementation Method 1
A plurality of inorganic light-emitting diodes (iLEDs) are disposed on, in, or over the display substrate in a regular array in the display area
Implementation Method 2
one or more holes extending through the display substrate in the display area... configured to emit sound through the one or more holes in the display substrate
Implementation Method 3
enhanced cooling... one or more holes extending through the display substrate
Data Source
AI summary
An inorganic light-emitting diode (iLED) display comprises a display substrate comprising a display area and one or more holes extending through the display substrate in the display area and a plurality of inorganic light-emitting diodes (iLEDs) disposed on, in, or over the display substrate in a regular array in the display area. At least some of the iLEDs are disposed between at least some of the holes in the display area and at least some of the holes are between at least some of the iLEDs in the display area. The display substrate can be substantially rigid and the iLED display can a flexible black sheet laminated, affixed, or adjacent to the display substrate. One or more audio loudspeakers can be disposed adjacent to the flexible sheet with the flexible sheet disposed between the display substrate and the one or more audio loudspeakers.