Micro LED Display Panel with Moth Eye Mesh Plate
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Solution Overview
Problem
Conventional display devices face issues with high screen reflectance, seam recognition between panels, and limited durability due to slow response times, high power consumption, and burn-in phenomena associated with liquid crystal and OLED panels, while micro LED panels offer improvements but require innovative solutions for seamless integration and enhanced performance.
Innovation Solution
A display panel design featuring a thin film transistor substrate with inorganic light emitting devices, a mesh plate with a moth eye pattern, and an anisotropic conductive layer to minimize light reflection and seam recognition, using an Invar material for thermal stability and a black surface for improved contrast, along with an optical transparent adhesive for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional liquid crystal panel is used, then the display device can be manufactured with established technology, but the response time is slow and power consumption is high
Solution Approach 1:
The patent transitions from liquid crystal technology to micro LED technology, fundamentally changing the operational parameters of the display device. Micro LEDs operate with faster response times (microseconds vs. milliseconds) and lower power consumption by directly emitting light without requiring backlight units or liquid crystal rotation, thus resolving the contradiction between response speed and energy efficiency
Solution Approach 2:
The patent replaces the mechanical liquid crystal rotation system with a solid-state micro LED emission system. This substitution eliminates the need for liquid crystal molecules to physically rotate or change orientation, achieving faster response times and reduced power consumption through direct electroluminescence in inorganic semiconductor materials
2Reliability
If an OLED panel is used, then the display device can achieve good image quality, but the life is short and burn-in phenomenon occurs
Solution Approach 1:
The patent employs inorganic semiconductor materials for micro LEDs instead of organic compounds used in OLEDs. This material substitution provides superior stability and longevity, as inorganic materials are not susceptible to oxidation or degradation from light and heat exposure, thereby eliminating burn-in phenomena and extending display device life
Solution Approach 2:
The patent inverts the material selection approach by choosing durable, long-lived inorganic micro LED materials instead of short-lived organic OLED materials. This selection prioritizes longevity and stability, creating a display device that maintains consistent performance over extended periods without the burn-in issues characteristic of organic materials
3Adaptability or versatility
If multiple display panels are assembled to achieve various resolutions and sizes, then the display device can be customized, but seam recognition occurs due to gaps between panels
Solution Approach 1:
The patent extracts and addresses the gap problem by introducing a dedicated mesh plate structure positioned between display panels. This mesh plate fills the gaps and reflects stray light, effectively removing the visual disturbance of seams while preserving the modular assembly approach that enables various resolutions and sizes
Solution Approach 2:
The patent introduces a mesh plate as an intermediary element between adjacent display panels. This mesh plate serves as a mediator that optically connects the panels by reflecting stray light and filling gaps, thereby eliminating seam recognition while allowing the modular panel assembly structure to maintain its versatility for different resolutions and sizes
4Strength
If the mesh plate is made thick to improve structural stability, then the mounting process is simplified, but the inorganic light emitting devices cannot protrude sufficiently
Solution Approach 1:
The patent applies local quality by making the mesh plate thin in the regions where light emission is required, allowing inorganic light emitting devices to protrude sufficiently. The mesh plate maintains adequate structural stability through its overall design and material selection, while local thinning ensures proper device protrusion for optimal optical 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 solution effectively reduces screen reflectance, enhances contrast and image quality, minimizes thermal deformation, and improves durability and reliability by providing a seamless display with improved mounting processes.
Implementation Method 1
A moth eye pattern including a plurality of micro protrusions may be formed on the reflective surface
Implementation Method 2
an anisotropic conductive layer provided on the mounting surface and electrically connecting the plurality of inorganic light emitting devices to the thin film transistor substrate
Implementation Method 3
The mesh plate may include an Invar material
Data Source
AI summary
A display device includes a thin film transistor substrate including a mounting surface on which a plurality of electrode pads are formed, a plurality of inorganic light emitting device groups each forming a pixel and each including a plurality of inorganic light emitting devices respectively mounted on the mounting surface, and a mesh plate including a plurality of openings in which the plurality of inorganic light emitting device groups are respectively positioned, and a partition wall covering at least one portion of a non-mounted area between the plurality of inorganic light emitting device groups. The mesh plate includes an attaching surface facing the mounting surface and a reflective surface which is opposite the attaching surface. A moth eye pattern including a plurality of micro protrusions is formed on the reflective surface.