LED Display Panel Pitch Layout for Seamless Substrate Splicing

Solution Overview

Problem

Existing LED display panels face issues with inconsistent spacing between LED lights due to mechanical inaccuracies and tolerances during substrate splicing, leading to overly large splicing seams that affect display quality.

Innovation Solution

The LED display panel addresses this by arranging LED devices in a way that their pitch gradually decreases from the splicing seam towards the edges in specific regions, ensuring consistent spacing and reducing the splicing distance, thereby minimizing the appearance of large seams and enhancing visual effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If LED sub-substrates are spliced together to form large display panels, then the display area is increased, but splicing seams appear and cause inconsistent spacing between LED lights

Engineering Contradiction:

Improvedisplay areaVSAvoidspacing consistency

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating a transition region near the splicing seam where the pitch between LED lights is gradually adjusted. Specifically, in the first region adjacent to the splicing seam, the pitch between LED lights is set to be less than the target pitch D1, while in the second region farther from the seam, the pitch equals the target pitch D1. This local differentiation compensates for the splicing tolerance ΔA1 and maintains overall spacing consistency.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the pitch parameter in the transition region to resolve the contradiction. By setting the pitch in the first region to be smaller than the target pitch D1 (specifically D1-ΔA1 or less), and maintaining the pitch at target pitch D1 in the second region, the patent compensates for the splicing tolerance ΔA1. This parameter adjustment ensures that the cumulative pitch across the splicing seam matches the expected value, thereby maintaining spacing consistency.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If uniform pitch is maintained across all LED devices, then manufacturing is simplified, but splicing seams become more visible due to tolerance accumulation

Engineering Contradiction:

Improvepitch uniformityVSAvoidsplicing seam visibility

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating a transition region near the splicing seam where the pitch between LED lights is gradually adjusted. Specifically, in the first region adjacent to the splicing seam, the pitch between LED lights is set to be less than the target pitch D1, while in the second region farther from the seam, the pitch equals the target pitch D1. This local differentiation compensates for the splicing tolerance ΔA1 and maintains overall spacing consistency.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent converts the harmful effect of splicing tolerance into a benefit by intentionally designing a transition region where pitch variation compensates for the tolerance. The pitch difference caused by splicing tolerance ΔA1 is offset by adjusting the pitch in the first region to be smaller, thereby converting the manufacturing tolerance from a harmful factor into a means of achieving seamless splicing.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If splicing tolerance is reduced to maintain precision, then spacing consistency improves, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvespacing consistencyVSAvoidpitch variation structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies local quality by creating a transition region near the splicing seam where the pitch between LED lights is gradually adjusted. Specifically, in the first region adjacent to the splicing seam, the pitch between LED lights is set to be less than the target pitch D1, while in the second region farther from the seam, the pitch equals the target pitch D1. This local differentiation compensates for the splicing tolerance ΔA1 and maintains overall spacing consistency.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies partial action by implementing pitch adjustment only in specific regions (first and second regions) adjacent to the splicing seam, rather than across the entire display panel. This localized approach maintains spacing consistency where it matters most (near the seams) while keeping the majority of the panel simple and uniform, thereby avoiding excessive manufacturing complexity.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS12132030B2Light emitting diode (LED) display panel

Publication Date: 2024.10.29 SHENZHEN CHINA STAR OPTOELECTRONICS SEMICON DISPLAY TECH CO LTD

AI summary

An LED display panel is provided by the present application. Two adjacent LED devices located on both ends of a first splicing seam have a first splicing distance therebetween, and the first splicing distance is defined as D1+ΔA1. A first region is disposed with a plurality of first LED devices thereon. A pitch between at least portions of two adjacent first LED devices gradually decreases from an end close to the first splicing seam to an end away from the first splicing seam in the first region in a first direction, and a pitch between any two adjacent first LED devices is less than the first splicing distance and greater than a first target pitch.