Micro LED Module Bridging Layout to Eliminate Tiling Defects
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of LED displays using micro LEDs is hindered by the difficulty in handling and mounting millions of small chips, leading to poor workability and manufacturing yield due to their small form factor and susceptibility to damage, as well as the appearance of linear defects when tiling micro LED modules.
Innovation Solution
The use of tile-shaped micro LED modules, where a second substrate bridges adjacent first substrates, reducing the appearance of linear defects by ensuring continuous coverage and improved workability through strategic placement and connection of micro LEDs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If micro LEDs are mounted individually on the display substrate, then the display can be assembled, but the handling difficulty and damage risk increase due to the small form factor
Solution Approach 1:
The display substrate is divided into multiple tile-shaped modules, each containing a grid of micro LEDs. This segmentation allows each tile to be handled as a single unit rather than individual micro LEDs, dramatically improving handling ease while maintaining the ability to form a complete display when tiles are assembled together.
Solution Approach 2:
The tile-shaped module acts as an intermediary between the individual micro LEDs and the final display assembly. By grouping micro LEDs into tiles with shared control circuits and power lines, the system simplifies handling and reduces damage risk while preserving the functionality of individual micro LED control.
2Quantity of substance
If millions of micro LEDs are mounted on a large-area display substrate, then the complete display is formed, but the workability deteriorates due to the large number of components
Solution Approach 1:
The large display substrate is segmented into multiple tile-shaped modules, each containing a manageable grid of micro LEDs (e.g., 8x8 or 16x16). This reduces the operational complexity from handling millions of individual components to handling a manageable number of tile units, significantly improving workability while maintaining the required display resolution.
Solution Approach 2:
Multiple micro LEDs are merged into single tile modules with shared control infrastructure. Each tile contains multiple micro LEDs organized in rows and columns with common power lines and control circuits, reducing the number of independent mounting operations required while preserving individual micro LED functionality.
3Ease of operation
If tile-shaped micro LED modules are arranged on the display substrate, then the workability improves, but linear defects appear between adjacent modules
Solution Approach 1:
Adjacent tiles are merged through shared control circuits and power lines that extend across tile boundaries. This merging eliminates visual discontinuities and linear defects at tile edges by ensuring continuous electrical connectivity and uniform light emission across the entire display surface, while tiles remain physically separate for ease of assembly.
Solution Approach 2:
The shared control circuits and power lines act as intermediaries that bridge adjacent tiles, ensuring continuous functionality and visual uniformity across tile boundaries. This intermediary infrastructure eliminates linear defects by providing seamless electrical and optical continuity between modules.
4Device complexity
If a single substrate controls multiple micro LEDs, then the number of control circuits is reduced, but the substrate size increases
Solution Approach 1:
The control function is segmented and distributed across multiple tiles rather than concentrated in a single large substrate. Each tile contains its own control circuits for a subset of micro LEDs, reducing the area required per substrate while maintaining overall system functionality through coordinated control of multiple tiles.
Solution Approach 2:
The control architecture transitions from a single-plane large substrate to a multi-plane tiled structure. Control circuits are distributed across multiple smaller substrates arranged in a two-dimensional array, reducing the area of each individual substrate while maintaining the ability to control a large total number of micro LEDs through hierarchical control structures.
Data Source
AI summary
A display apparatus includes a display substrate, first micro LED modules arranged on the display substrate, and at least one second micro LED module disposed between the first micro LED modules. Each of the first micro LED modules includes a first substrate and micro LEDs disposed on the first substrate. The second micro LED module includes a second substrate and micro LEDs disposed on the second substrate. The second substrate bridges two adjacent first substrates.