Micro LED Module Tiling Structure to Reduce Linear Display Defects
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Solution Overview
Problem
The challenge in manufacturing LED displays is the difficulty in handling and mounting millions of small micro LEDs, which leads to poor manufacturing yield and workability due to their small form factor and susceptibility to damage, resulting in linear defects when tiled on a display substrate.
Innovation Solution
The use of tile-shaped micro LED modules, where each module includes a substrate with recessed lower bodies and a top plate, allowing for interstitial second modules to reduce linear defects by overlapping substrates and positioning LEDs to emit light through gaps, thereby improving yield and workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If individual micro LED chips are arranged in each sub-pixel, then color display capability is improved, but the number of LED chips increases and mounting time increases
Solution Approach 1:
Multiple sub-pixels (R, G, B) are merged into a single micro LED module that contains multiple micro LEDs of different colors on one substrate. This combining approach reduces the total number of separate mounting operations while maintaining full color display capability across all sub-pixels.
Solution Approach 2:
The display is segmented into modular micro LED modules that can be manufactured separately and then mounted as units. Each module contains multiple micro LEDs organized into sub-pixels, allowing parallel manufacturing and reduced mounting complexity compared to individual chip placement.
2Area of stationary object
If micro LEDs are mounted on large-area display substrate, then complete screen coverage is achieved, but manufacturing yield decreases and workability deteriorates
Solution Approach 1:
The large display substrate is divided into multiple smaller micro LED modules. Each module can be manufactured, tested, and handled independently, reducing the risk of defects across the entire screen and improving overall manufacturing yield through modular production.
Solution Approach 2:
The micro LED module substrate acts as an intermediary carrier that consolidates multiple micro LEDs. This intermediate structure simplifies handling and mounting procedures while ensuring complete coverage of the display substrate through systematic arrangement of modules.
3Productivity
If micro LED modules are tiled on display substrate, then mounting efficiency is improved, but linear defects appear between modules
Solution Approach 1:
Micro LED modules are designed with nested or interlocking structures where substrates overlap or fit together. The second micro LED module is disposed between first micro LED modules with substrate overlap, creating a seamless tiling pattern that eliminates visible linear defects while maintaining mounting efficiency.
Solution Approach 2:
The module arrangement uses asymmetric positioning where second micro LED modules are strategically placed between first modules at specific intervals. This asymmetric tiling pattern disrupts the regularity of defect formation and improves visual uniformity across the display surface.
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 first substrate includes a lower body and a top plate located on the lower body. The lower body is recessed from an edge of the top plate, and the second micro LED module is disposed between recessed lower bodies of adjacent first micro LED modules.