Micro LED Display Panel with Molding Structure
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Solution Overview
Problem
Current display technologies face challenges in achieving compact size, high brightness, and durability while avoiding burn-in issues and high power consumption, with liquid crystal displays requiring backlights and OLEDs susceptible to burn-in.
Innovation Solution
A micro LED display panel using inorganic light-emitting diodes mounted on a substrate, with a thin film transistor layer, electrodes, and a molding structure to cover the LEDs, along with a printed circuit board and polarization layers for efficient light management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If liquid crystal panel is used, then backlight can be provided, but response time is slow and power consumption is high
Solution Approach 1:
The patent replaces the liquid crystal panel with a micro LED panel that uses inorganic light-emitting diodes. This substitution eliminates the need for a backlight system and liquid crystal molecules, directly providing self-emissive display with faster response time and lower power consumption through the inherent properties of inorganic LEDs
2Reliability
If OLED panel is used, then backlight is not required and slim thickness is achieved, but burn-in phenomenon occurs
Solution Approach 1:
The patent changes the material parameter from organic compounds (OLED) to inorganic materials (micro LED). This fundamental material parameter change provides superior reliability by eliminating burn-in phenomenon while maintaining the self-emissive property that enables slim thickness without requiring a backlight
3Illumination intensity
If micro LED panel is used, then brightness and resolution are improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the display into multiple display modules, each containing a substrate with TFT layer, inorganic LEDs, and molding. This segmentation allows for standardized manufacturing of individual modules that can be assembled into larger displays, managing complexity through modular design while achieving high brightness and resolution
Solution Approach 2:
The patent employs a nested structure where inorganic LEDs are mounted on the TFT layer, which is formed on the substrate. The molding then covers and protects these nested components. This nested arrangement integrates multiple functional layers in a compact manner, managing manufacturing complexity while achieving superior display performance
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 micro LED display panel offers improved brightness, resolution, power efficiency, and durability, providing better contrast and response time compared to LCDs and OLEDs, while avoiding burn-in and enabling compact, high-resolution displays.
Implementation Method 1
a plurality of inorganic light emitting diodes (LEDs) disposed on the TFT layer, each of the plurality of inorganic LEDs including: a pair of electrodes electrically connected to the TFT layer and disposed to face the mounting surface, and a light emitting surface configured to emit light
Data Source
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AI summary
A display module may include: (1) a substrate including a mounting surface on which a thin film transistor (TFT) layer is formed, a side surface, and a chamfer portion formed between the mounting surface and the side surface; (2) a plurality of inorganic light emitting diodes (LEDs) disposed on the TFT layer, each of the plurality of inorganic LEDs including a pair of electrodes electrically connected to the TFT layer and disposed to face the mounting surface, and a light emitting surface configured to emit light in a first direction opposite to a second direction that extends from the plurality of inorganic LEDs to the mounting surface of the substrate; and (3) a molding provided to cover the plurality of inorganic LEDs, the chamfer portion of the substrate, and the side surface of the substrate.