Modular Micro-LED Molding Layer for Seam Concealment
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Solution Overview
Problem
Modular display apparatuses using micro LEDs suffer from visible seams between joined modules, which can reduce user immersion and recognition of the display as a cohesive unit, especially under external lighting due to higher diffuse reflection ratios at seam areas.
Innovation Solution
A display apparatus with a patterned molding layer is introduced, featuring grooves and molding pieces that form boundary lines uniformly at narrower intervals, creating an optical illusion to conceal the seams and enhance the sense of integration, while also protecting the LEDs from external environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If modular displays are joined together to manufacture a display apparatus, then productivity and ease of manufacture are improved, but visible seams are formed between modules which worsen the visual quality and user immersion
Solution Approach 1:
A patterned molding layer is introduced as an intermediary element between adjacent modular displays. This molding layer includes grooves and molding pieces that create boundary lines to mask the seams formed by joining modules. The patterned structure acts as a visual mediator that conceals the junction between modules while allowing the modular manufacturing approach to continue
Solution Approach 2:
The molding layer is configured to have optical properties that differ from the display surface, creating visual boundaries that mask seams. The patterned structure utilizes optical effects (such as light refraction, reflection, or absorption differences) to make the seam areas less visible, effectively using optical property changes to hide the junction between modules
2Area of stationary object
If modular displays are joined together to create a large display, then the display area is increased, but the seams between modules become more visible under external lighting due to higher diffuse reflection ratios
Solution Approach 1:
The patterned molding layer serves as an intermediary optical element that modifies how external light interacts with the seam areas. The grooves and molding pieces create controlled optical paths that reduce diffuse reflection from seam areas, making them less visible under external lighting conditions while allowing the large display area to function properly
3Difficulty of detecting and measuring
If a patterned molding layer is added to conceal seams, then the visibility of seams is reduced, but the device complexity and manufacturing steps increase
Solution Approach 1:
The molding layer is designed to serve multiple functions simultaneously: it conceals seams between modules, protects the edges of modular displays, and provides structural support for mounting. By combining multiple functions into a single component, the patent reduces the need for additional separate elements, thereby limiting the increase in device complexity while achieving seam concealment
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 patterned molding layer effectively reduces the visibility of seams, improving user immersion and the overall perception of the display as a single integrated unit, while providing enhanced protection and durability to the LEDs.
Implementation Method 1
A display apparatus with a patterned molding layer is introduced, featuring grooves and molding pieces that form boundary lines uniformly at narrower intervals, creating an optical illusion to conceal the seams
Implementation Method 2
A display apparatus with a patterned molding layer is introduced, featuring grooves and molding pieces that form boundary lines uniformly at narrower intervals, creating an optical illusion to conceal the seams and enhance the sense of integration, while also protecting the LEDs from external environments
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A display apparatus and a manufacturing method thereof. The display apparatus includes a chassis, a plurality of modular displays disposed and tiled on the chassis, each of the plurality of modular displays including a plurality of light emitting diodes (LEDs) constituting each of a plurality of pixels, and a patterned molding layer formed on the each of the plurality of modular displays, wherein the patterned molding layer is formed to correspond to a boundary line between modular displays adjacent to each other among the plurality of modular displays.