LED Display Module Glue Filling for Bubble-Free Lamp Bead Packaging
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Solution Overview
Problem
The existing methods for preparing LED display modules fail to fully exhaust air from lamp slits of LED lamp beads, leading to uneven surface luminescence and affected display effects due to differences in refractive indexes between the light-transmitting glue layer, light-transmitting film, and air.
Innovation Solution
A method involving machining an enclosure around a lamp panel to form an accommodating pool, filling with glue, performing vacuum defoaming treatment, and subsequent curing treatments to ensure the glue is fully integrated with the lamp beads, reducing bubble formation and enhancing the flatness of the LED display module surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pressure is applied to the circuit board, light-transmitting glue layer and the light-transmitting film in a preset temperature environment, then the LED module is obtained, but the air existing in lamp slits of the lamp beads cannot be fully exhausted, resulting in uneven surface luminescence
Solution Approach 1:
The patent applies vacuum defoaming treatment before the final packaging process to remove air from lamp slits in advance. This preliminary action prevents air entrapment that would cause uneven luminescence, while the subsequent packaging process remains relatively simple, thus resolving the contradiction between manufacturing precision and ease of manufacture.
Solution Approach 2:
The patent creates a vacuum environment (inert atmosphere without air) during the defoaming process to allow air to be exhausted from the lamp slits. This inert environment prevents air from interfering with the subsequent packaging and ensures uniform luminescence, while not complicating the overall manufacturing process.
2Illumination intensity
If the refractive indexes of the light-transmitting glue layer and the light-transmitting film are different from that of the air, then light transmission is affected, but air cannot be completely removed from the lamp slits using conventional packaging methods
Solution Approach 1:
The patent uses vacuum defoaming to create an air-free environment in the lamp slits before packaging. This ensures complete air removal, eliminating refractive index mismatches that would affect light transmission, and guarantees reliable light transmission efficiency throughout the LED module.
Solution Approach 2:
The patent changes the environmental parameters (pressure and temperature) during vacuum defoaming to optimize air removal from lamp slits. By controlling these parameters, the patent achieves complete air exhaustion while maintaining the integrity of the lamp beads and glue layer, thus ensuring both light transmission efficiency and reliability.
3Productivity
If the lamp beads are not fully protected from damage, then the display yield decreases, but additional assembly steps increase the manufacturing complexity
Solution Approach 1:
The patent combines the protective function with the existing packaging structure by ensuring the light-transmitting glue layer and light-transmitting film fully cover and protect the lamp beads during the packaging process. This merging of protection function into the standard packaging流程 increases display yield without adding separate protection steps, thus avoiding increased manufacturing complexity.
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 method effectively removes residual air from the LED display module, preventing bubble formation and improving the display effect by ensuring a uniform surface contact between the lamp beads and the glue, thus enhancing the overall display performance.
Implementation Method 1
performing a vacuum defoaming treatment on the lamp panel filled with the glue
Implementation Method 2
performing a first curing treatment on the defoamed lamp panel
Data Source
Figure 1
Figure 2~3
AI summary
The present disclosure provides a method for preparing an LED display module, including following steps: - step S10: machining a first enclosure around a front surface of a lamp panel; - step S30: filling the accommodating pool with glue, and performing a vacuum defoaming treatment on the lamp panel filled with the glue; - step S40: performing a first curing treatment on the defoamed lamp panel; - step S50: placing the lamp panel with the first enclosure removed in an accommodating appliance, enabling the front surface of the lamp panel with the first enclosure removed to face a bottom of the accommodating appliance, and immersing lamp beads on the lamp panel with the first enclosure removed into defoaming glue in the accommodating appliance; - step S60: applying an acting force, which faces the bottom of the accommodating appliance, to a back surface of the lamp panel with the first enclosure removed.