Micro LED Module Tiling With Inclined Edges to Hide Seams
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Solution Overview
Problem
The manufacturing of LED displays with micro LED modules is hindered by the difficulty in handling and mounting millions of small micro LEDs, leading to poor workability and manufacturing yield due to their small form factor and susceptibility to damage, as well as the appearance of linear defects when tiling micro LED modules with manufacturing tolerances.
Innovation Solution
The use of tile-shaped micro LED modules with inclined side surfaces facing each other, which can overlap or have identical inclination directions, to prevent the visibility of boundary regions and improve manufacturing yield and workability by reducing linear defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If micro LEDs are used to create high-resolution displays, then display resolution is improved, but handling and mounting difficulty increases due to small form factor
Solution Approach 1:
The display is divided into multiple tile-shaped micro LED modules, each containing multiple micro LEDs. This segmentation allows the modules to be manufactured, tested, and handled as larger, more manageable units rather than individual micro LEDs, while still achieving high overall display resolution through the aggregation of many modules.
Solution Approach 2:
Multiple micro LEDs are integrated within each tile-shaped module, creating a nested structure where smaller functional units (micro LEDs) are contained within larger manageable units (modules). This nesting approach maintains the high resolution benefits of individual micro LEDs while enabling easier handling at the module level.
2Productivity
If tile-shaped micro LED modules are used to improve workability, then manufacturing yield is improved, but linear defects appear at boundary regions between modules
Solution Approach 1:
The side surfaces of adjacent micro LED modules are configured with different orientations (e.g., first module has side surface at first orientation, second module has side surface at second orientation). This asymmetric configuration prevents the formation of straight, visible boundary lines between modules, thereby reducing linear defects while maintaining manufacturing yield benefits.
Solution Approach 2:
Instead of addressing boundary visibility in the planar dimension, the solution introduces a dimensional change by orienting side surfaces at different angles. This transforms the boundary appearance from a problematic two-dimensional line defect into a three-dimensional feature that is less visually apparent, effectively reducing linear defects.
3Measurement precision
If individual LED chips are arranged in each sub-pixel, then color accuracy is improved, but the number of mounting operations increases
Solution Approach 1:
Multiple micro LEDs (red, green, and blue) are combined within single tile-shaped modules. This merging reduces the total number of separate mounting operations required, as entire modules containing multiple color-emitting micro LEDs can be mounted together rather than mounting individual micro LEDs separately, thereby improving mounting process efficiency while maintaining color accuracy.
Data Source
AI summary
A display apparatus is provided. The display apparatus includes a display substrate, a first micro LED module disposed on the display substrate, and a second micro LED module disposed on the display substrate and adjacent to the first micro LED module. The first micro LED module and the second micro LED module have side surfaces facing each other. The side surfaces facing each other of the first micro LED module and the second micro LED module are inclined in an identical direction with respect to an upper surface of the display substrate.