MicroLED Tile Assembly for Tight Registration Pitch
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Solution Overview
Problem
The existing methods for assembling display areas using tiles face challenges in achieving precise positioning and registration pitches, leading to inefficiencies and increased failure rates due to deviations in tile dimensions and cutting techniques, which affect the quality and uniformity of the display.
Innovation Solution
A method involving the selection and sorting of tiles based on predetermined parameters such as lateral dimensions, edge straightness, and squareness, followed by precise positioning to achieve registration pitches less than or equal to 1.5 times the pixel pitch, utilizing various cutting techniques and tiling strategies to minimize deviations and enhance assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tile assembly methods are used without sorting, then assembly speed is maintained, but positioning precision and registration quality deteriorate due to tile dimension variations
Solution Approach 1:
Tiles are sorted by their dimensional parameters (length, width, diagonal) before assembly. This preliminary classification ensures that when tiles are assembled, their variations are systematically managed, achieving registration pitches within 1.5 times the pixel pitch without requiring slower post-assembly adjustments
Solution Approach 2:
The patent transforms the assembly process by changing how tile parameters are handled - instead of treating all tiles uniformly, the system categorizes tiles based on their actual measured dimensions and assigns them to different assembly queues, optimizing both precision and throughput
2Manufacturing precision
If tiles with varying dimensions are assembled without sorting, then assembly process is simple and fast, but registration pitch exceeds acceptable limits leading to display defects
Solution Approach 1:
Dimensional measurement and sorting of tiles is performed before assembly begins. This preliminary action ensures that tiles are pre-categorized by their dimensional characteristics, allowing the assembly process to proceed systematically with guaranteed registration quality without complex real-time adjustments
Solution Approach 2:
The patent introduces an intermediate sorting system that acts as a mediator between tile production and assembly. This sorting mechanism categorizes tiles by their dimensional parameters and routes them to appropriate assembly sequences, simplifying the overall process while ensuring precision
3Productivity
If cutting techniques are optimized for speed, then production efficiency increases, but tile dimension accuracy and edge straightness deteriorate
Solution Approach 1:
The patent changes the approach to tile parameters by measuring and recording actual dimensional values (length, width, diagonal, edge straightness) for each tile after cutting. This parameter data is then used to sort and categorize tiles, allowing fast cutting processes to produce acceptable tiles that are subsequently optimized through intelligent sorting rather than requiring slower, more precise cutting
Data Source
AI summary
A method of assembling a display area includes selecting a first tile from a plurality of tiles, each tile of the plurality of tiles includes a predetermined parameter and a plurality of microLEDs defining a plurality of pixels. The selecting the first tile based on a value of the predetermined parameter of the first tile. The method includes selecting a second tile from the plurality of tiles based on a value of the predetermined parameter of the second tile. The method further includes positioning the first tile and the second tile into an array defining at least a portion of the display area. A first edge of the first tile facing a second edge of the second tile. A display device including the display area assembled by the method is also provided.