Micro LED Display Module Cover Structure for Hidden Panel Seams
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Solution Overview
Problem
Conventional display technologies, such as liquid crystal panels and OLEDs, face issues like slow response time, high power consumption, and susceptibility to burn-in, while micro LED panels using inorganic light emitting diodes offer improved brightness, resolution, and durability but require complex substrate-level display modulation and assembly.
Innovation Solution
A display apparatus comprising a substrate with inorganic light emitting diodes, a black matrix, and a cover layer that extends beyond the substrate edges to absorb external light, reducing seam visibility and improving color uniformity, is designed for large-sized displays with a modular structure that minimizes the perception of gaps between modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic light emitting diodes are used for display, then brightness, resolution, and durability are improved, but substrate-level display modulation and assembly become complex
Solution Approach 1:
The display is divided into multiple modular display modules that can be independently manufactured and then assembled. Each module contains a subset of the full electrode pattern and corresponding LED elements. This segmentation simplifies the assembly process while maintaining the overall display functionality and durability benefits of inorganic LEDs.
Solution Approach 2:
The substrate is designed with universal features including extended side surfaces and standardized electrode connections that can interface with multiple different module configurations. This universality allows the same substrate structure to support various display sizes and configurations, reducing overall system complexity.
2Area of stationary object
If display modules are arranged in a matrix configuration, then large-sized display is achieved, but gaps and seams between modules become visible
Solution Approach 1:
The side surfaces of the substrate are extended in the vertical dimension beyond the active display area. These extended surfaces are positioned to overlap with adjacent modules when arranged in a matrix, creating a three-dimensional interlocking structure that hides the gaps between modules and eliminates visible seams while maintaining large display area.
Solution Approach 2:
The extended side surfaces are covered with light-absorbing or black-colored materials that match the background, creating a composite structure that visually blends the gaps between modules. This composite approach combines the structural substrate with optical materials to achieve both mechanical support and aesthetic continuity.
3Illumination intensity
If external light enters the display module, then light interference occurs and contrast is reduced, but adding light blocking structures increases device complexity
Solution Approach 1:
The light-blocking function is merged with the structural side surfaces of the substrate. The extended side surfaces serve dual purposes: providing structural support for module assembly and blocking external light from entering the display cavity. This integration eliminates the need for separate light-blocking structures, maintaining contrast while avoiding increased complexity.
Solution Approach 2:
The extended side surfaces perform multiple functions simultaneously: structural support, light blocking, and gap hiding between modules. This multi-functionality approach achieves light interference reduction without adding dedicated light-blocking components that would increase device complexity.
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 display contrast, energy efficiency, and lifespan by reducing light interference and seam visibility, providing a seamless and unified visual experience across the display panel.
Implementation Method 1
a plurality of inorganic light emitting diodes mounted on the mounting surface and each including a pair of electrodes electrically connected to the substrate
Implementation Method 2
inorganic light emitting diodes emit light by itself in response to an electric current
Implementation Method 3
a cover bonded to the mounting surface and configured to cover the mounting surface
Implementation Method 4
an adhesive layer arranged behind the second layer to bond the cover to the mounting surface
Data Source
AI summary
Provided is a display module including a substrate including a mounting surface, a side surface, and a chamfer portion formed between the mounting surface and the side surface, a plurality of inorganic light emitting diodes mounted on the mounting surface and each including a pair of electrodes electrically connected to the substrate, a black matrix arranged between the plurality of inorganic light emitting diodes, and a cover bonded to the mounting surface and configured to cover the mounting surface, wherein the pair of electrodes are oriented in a direction opposite to a direction in which the plurality of inorganic light emitting diodes emits light, and the cover is provided to extend outward of the side surface in an extension direction of the mounting surface.