LED Display Pin Layout for Burr-Free Substrate Cutting
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Solution Overview
Problem
The existing LED display technology faces issues with burr defects during the cutting process due to misaligned pins connected by straight connecting wires that are not perpendicular to the cutting line, leading to uneven cuts and manufacturing challenges.
Innovation Solution
The LED display device array incorporates a connecting wire structure with a linear segment that intersects and is perpendicular to the cutting line, ensuring an even cut and avoiding burr defects, along with a cover plate and encapsulant design to enhance mechanical strength and prevent vapor ingress, and a metal identifier for reliable chip positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight connecting wires are used to connect misaligned pins, then the manufacturing process is simple, but burr defects occur during cutting due to uneven cuts
Solution Approach 1:
The connecting wire is designed with different segment characteristics: the first and second connecting segments are straight lines for simplicity, while the third connecting segment is specifically configured to be perpendicular to the cutting line to ensure clean cutting. This local differentiation resolves the contradiction by applying different geometric properties to different portions of the same component based on their functional requirements.
Solution Approach 2:
The connecting wire is divided into multiple segments (first, second, and third connecting segments) with different geometric characteristics. This segmentation allows each portion to optimize for its specific function: straightforward connectivity and precise perpendicular cutting, eliminating burr defects while maintaining manufacturing simplicity.
2Productivity
If the connecting wire is cut along the cutting line, then the display units are separated, but uneven cuts produce burr defects
Solution Approach 1:
The third connecting segment is specifically designed to be perpendicular to the cutting line, ensuring that when the substrate is cut along the cutting line, this segment produces a clean, even cut without burrs. This localized geometric optimization allows mass production to proceed efficiently while maintaining high cutting surface quality.
3Adaptability or versatility
If multiple pin assemblies are disposed on the substrate, then the display device functionality is improved, but the risk of vapor ingress and mechanical weakness increases
Solution Approach 1:
Multiple pin assemblies are integrated onto a single substrate, sharing common structural support and encapsulation. This merging approach maintains the functionality of multiple display units while improving reliability through unified protection against vapor ingress and collective mechanical strength, preventing the proportional increase in vulnerability that would occur with separate assemblies.
Data Source
AI summary
An LED display device array includes a substrate, at least two display units disposed on the upper surface of the substrate, and pin assemblies disposed on the lower surface of the substrate and in one-to-one correspondence with the at least two display units, a cutting line is disposed on the substrate between any two adjacent pin assemblies. Each of the pin assemblies includes at least two pins, and the at least two pins are a first pin and a second pin separately. A first pin in a pin assembly is misaligned with a second pin in an adjacent pin assembly, and the first pin and the second pin are connected to each other by a connecting wire. The connecting wire has a linear connecting segment, and the connecting segment of the connecting wire intersects with the cutting line and is perpendicular to the cutting line.