3D Direct-Written LED Retaining Walls for Precise Display Panel Printing
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Solution Overview
Problem
Current methods for manufacturing LED retaining walls lack precision and efficiency, particularly in narrow gaps between LEDs, leading to inconsistent widths and heights, which affects the luminous performance and color purity of display screens.
Innovation Solution
A printing device and method that includes a motion control system, adsorption apparatus, measuring system, Z-axis controller, and multi-needle module for precise control and direct-writing 3D printing of LED retaining walls on substrates, enabling consistent width and height production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional photolithographic process is used to manufacture retaining walls, then manufacturing steps can be completed, but manufacturing efficiency is extremely low (more than 100 minutes per panel) and consistency of widths and heights cannot be ensured
Solution Approach 1:
The patent replaces the traditional photolithographic process with a 3D direct-writing printing system that uses a movable printing needle to directly deposit material layer by layer. This substitution eliminates the need for complex photolithography steps (gluing/exposure/developing) and enables rapid, precise manufacturing of retaining walls with consistent dimensions.
Solution Approach 2:
The patent changes the manufacturing approach from planar photolithography to three-dimensional direct writing. By controlling the printing needle's movement in three dimensions and the material deposition parameters, the system achieves both high precision (consistent widths and heights) and high productivity (rapid manufacturing).
2Ease of manufacture
If silk-screen printing is used to manufacture retaining walls, then printing can be performed, but multi-alignment difficulty is high and repeated printing and curing are required
Solution Approach 1:
The patent replaces silk-screen printing with a 3D direct-writing system that uses a movable printing needle to deposit material directly onto the substrate. This eliminates the need for screens, alignment marks, and repeated printing cycles, significantly reducing alignment complexity and device complexity.
Solution Approach 2:
The patent transitions from two-dimensional silk-screen printing to three-dimensional direct writing. The printing needle can move in three dimensions and deposit material with precise spatial control, enabling single-step formation of retaining walls with complex geometries without alignment issues.
3Ease of manufacture
If transfer printing is used to manufacture retaining walls, then printing can be performed, but transfer printing alignment difficulty is high and line transfer printing is difficult
Solution Approach 1:
The patent replaces transfer printing with a 3D direct-writing system that deposits material directly at the target location. This eliminates the transfer step entirely, removing alignment difficulties associated with transferring patterns from a master template to the substrate.
Solution Approach 2:
The patent extracts and eliminates the transfer step from the manufacturing process. By using direct writing, the system deposits material directly onto the substrate at the precise location where retaining walls are needed, without requiring a separate transfer process.
4Productivity
If traditional printing methods are used, then printing can be performed, but printing width-height ratio is small requiring repeated printing
Solution Approach 1:
The patent enables printing of retaining walls with large width-height ratios by using three-dimensional direct writing. The movable printing needle can build structures vertically layer by layer, allowing the formation of tall retaining walls in a single continuous printing process without requiring repeated printing cycles.
Solution Approach 2:
The patent achieves continuous manufacturing of retaining walls with large width-height ratios through uninterrupted 3D direct writing. The printing needle continuously deposits and builds material layer by layer, maintaining continuous useful action throughout the printing process without interruption or repetition.
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
The solution enhances manufacturing efficiency and precision of LED retaining walls, improving contrast and preventing light leakage, with significant benefits for both Mini-LED and Micro-LED products.
Implementation Method 1
a vacuum sucker, all of which are arranged from bottom to top
Data Source
AI summary
Provided are a printing device and a method for an LED retaining wall of a display panel. The device includes a motion control system, an adsorption apparatus, a measuring system, a Z-axis controller, a target multi-needle module and a target station. The motion control system is configured to control printing of a target LED retaining wall on an upper surface of a target substrate on the target station. The adsorption apparatus is configured to make a lower surface of the target substrate adsorbed onto a sucker by a vacuum pump. The measuring system includes a sensor and a sensor controller, and the sensor is configured to measure flatness data of the target substrate. The Z-axis controller is configured to control a printing receiving distance between the target multi-needle module and the upper surface of the target substrate. The target multi-needle module includes printer heads and fluid control systems, and the fluid control systems are configured to supply preset air pressure parameters to the printer heads. The target station is configured to accommodate the target substrate so as to make the target multi-needle module perform laminated printing of the target LED retaining wall on the upper surface of the target substrate. By the adoption of the printing device and method for the LED retaining wall of the display panel provided by the present disclosure, the manufacturing efficiency and precision of the LED retaining wall are improved.