LED Display Pixel Blocks With Diffusers for Easier Bonding
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Solution Overview
Problem
The challenge lies in the difficulty of bonding small display pixels to a slab due to the need for precise electric connections, which increases manufacturing time and cost as the number of pixels increases, particularly in active array displays with light-emitting diodes.
Innovation Solution
The solution involves grouping display pixels into blocks with optoelectronic circuits and diffusing structures, using sheaths and separation elements to manage light distribution and electric connections, allowing for smaller pixel dimensions while maintaining effective emission surfaces and reducing the number of bonding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the dimensions of display pixels are decreased to reduce manufacturing costs, then the quantity of semiconductor materials decreases, but the bonding difficulty increases due to precision requirements for electric connections
Solution Approach 1:
The invention groups multiple display pixels into a single display block containing multiple light-emitting diodes that can be bonded as one unit to the slab. This segmentation approach reduces the total number of bonding operations while maintaining small individual pixel dimensions, thereby reducing semiconductor material usage without proportionally increasing bonding precision requirements.
Solution Approach 2:
Multiple display pixels are merged into a single display block structure where multiple light-emitting diodes are integrated together. This merging allows the entire block to be bonded as one unit rather than individually bonding each pixel, reducing the cumulative bonding precision requirements while preserving the small size benefits of individual pixels.
2Measurement precision
If the number of display pixels is increased to improve display resolution, then the display quality improves, but the manufacturing time and cost increase due to more bonding operations
Solution Approach 1:
The display is segmented into multiple display blocks, each containing multiple pixels. By increasing the number of pixels within each block rather than increasing the total number of separate pixels to be bonded, the invention achieves higher display resolution without a proportional increase in bonding operations, thus maintaining manufacturing productivity.
Solution Approach 2:
Multiple pixels are merged into integrated display blocks that function as unified units. This merging strategy allows the display resolution to be increased by adding more pixels within each block while the bonding operation count increases much more slowly, improving productivity relative to the resolution gain.
3Loss of substance
If display pixels are made smaller to reduce material usage, then manufacturing costs decrease, but the light emission surface area decreases affecting display brightness
Solution Approach 1:
Multiple small light-emitting diodes are merged within a single display block structure. While each individual LED remains small to minimize semiconductor material usage, the combined light emission surface area of multiple LEDs within the block compensates for the small individual size, maintaining adequate brightness while reducing overall material consumption.
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 approach enables efficient light emission from smaller pixels with reduced manufacturing complexity and cost, while minimizing optical crosstalk and improving pixel distinction, thus enhancing display quality and efficiency.
Implementation Method 1
diffusing structures covering the optoelectronic circuit, each diffusing structure being in contact with a portion of the first emission surface and having a second surface of emission of the light radiations of the light-emitting diodes
Data Source
AI summary
A display block including an optoelectronic circuit including-light-emitting diodes of at least two display pixels and having a first surface of emission of the light radiations of the light-emitting diodes; and diffusing structures covering the optoelectronic circuit, each diffusing structure being in contact with a portion of the first emission surface and having a second surface of emission of the light radiations of the light-emitting diodes of one of the display pixels, the ratio of the sum of the areas of the second emission surfaces to the area of the first emission surface being greater than 2.