Micro LED Module Bonding to Reduce Seams and Light Refraction
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Solution Overview
Problem
Current display technologies, such as liquid crystal panels and OLED panels, face issues like slow response time, high power consumption, burn-in phenomena, and difficulty in compactification, prompting the need for a more efficient and durable display solution.
Innovation Solution
A micro LED panel using inorganic light-emitting devices mounted on a substrate, with a manufacturing method involving a sacrificial layer, color filter, and laser lift-off process to reduce seam visibility, light refraction, and simplify manufacturing while preventing water penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple display modules are arranged to form a large display, then the display size is increased, but seam visibility and light refraction between modules increase
Solution Approach 1:
A bonding substrate is introduced as an intermediary component between adjacent display modules. This bonding substrate includes a bonding region that couples modules together and a light-blocking region that prevents light leakage and refraction at module boundaries. The light-blocking region acts as a mediator to eliminate the harmful optical effects at seams while maintaining the structural integrity of the multi-module display arrangement.
2Manufacturing precision
If a complex manufacturing process is used to achieve precise module alignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Alignment marks are pre-formed on both the display module substrate and the bonding substrate before the bonding process. These pre-formed alignment marks enable precise alignment to be achieved through simple visual or mechanical matching during assembly, eliminating the need for complex alignment mechanisms or procedures. The alignment marks are created in advance during the manufacturing process, so no additional complexity is added to the assembly operation.
3Ease of manufacture
If the bonding substrate extends beyond the display area, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The bonding substrate is segmented into functionally distinct regions: a bonding region that extends beyond the display area to facilitate easy module coupling and alignment, and a light-blocking region that is confined to the display area to prevent light leakage. This segmentation allows each region to perform its specific function optimally without creating unnecessary complexity in the overall device structure.
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 panel offers improved brightness, resolution, energy efficiency, and durability, reducing seam visibility and light refraction between modules, and simplifying the manufacturing process while maintaining water resistance.
Implementation Method 1
separating the base substrate from the color layer by irradiating the sacrificial layer with laser light
Data Source
AI summary
A method of manufacturing a display module of a display apparatus, includes: forming a sacrificial layer on a base substrate; forming a color filter on the sacrificial layer; forming a color layer by positioning quantum dots on the color filter; adhering to the color layer a light source substrate on which an inorganic light-emitting device is positioned so that the inorganic light-emitting device faces the color layer; and separating the base substrate from the color layer by irradiating the sacrificial layer with laser light.