LED Display Panel Package Geometry for Gap-Free Tiling

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Solution Overview

Problem

Existing display panels face issues with visual interference due to gaps between tiled packages, which affect the quality of the displayed image.

Innovation Solution

The encapsulation adhesive of each package is cut in opposite directions, resulting in sides that are inclined towards the same direction, allowing packages to be tiled closely without visible gaps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If packages are tiled to form display panels, then the display area is increased, but gaps between packages cause visual interference and reduce image quality

Engineering Contradiction:

Improvedisplay areaVSAvoidvisual interference from gaps

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The encapsulation adhesive is cut asymmetrically with different angles on opposite sides (first angle ≠ second angle), creating non-parallel cutting surfaces that enable closer packaging arrangement and reduce visible gaps between adjacent packages in the tiled display panel

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The solution transitions from conventional parallel cutting to three-dimensional angled cutting of the encapsulation adhesive, creating surfaces inclined at different angles relative to the substrate to optimize package alignment and minimize gaps in the tiled configuration

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If encapsulation adhesive is cut in opposite directions with different angles, then packages can be arranged more closely, but the cutting process becomes more complex

Engineering Contradiction:

Improvepackage arrangement precisionVSAvoidcutting process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The cutting process parameters are changed by specifying different cutting angles (first angle and second angle) for opposite sides of the encapsulation adhesive, enabling precise control over package arrangement while maintaining manufacturing feasibility through defined geometric parameters

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12457831B2Display panel and forming method thereof

Publication Date: 2025.10.28 AU OPTRONICS CORP

AI summary

A display panel includes a package including a substrate, LEDs and a encapsulation adhesive. The substrate includes a bottom surface, a first side and a second side. The first side and the second side are opposite sides, and the bottom surface and the first side form a first angle, the bottom surface and the second side form a second angle. The LEDs are on the substrate. The encapsulation adhesive covers the first side, the second side and the light-emitting diodes. The encapsulation adhesive has a third side adjacent to the first side and a fourth side adjacent to the second side, and the bottom surface and the third side form a third angle, the bottom surface of the first substrate and the fourth side form a fourth angle. The third angle is greater than the first angle, and the fourth angle is smaller than the second angle.