MicroLED Tile Sorting for Tight Display 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 simulation strategies to optimize tile assembly and reduce failure rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tiles are assembled using conventional methods without sorting, then assembly process is simpler and faster, but positioning precision and registration pitch deteriorate due to deviations in tile dimensions
Solution Approach 1:
Tiles are sorted based on their dimensional parameters (lateral dimension, edge straightness, squareness) before assembly. This preliminary classification ensures that tiles with compatible dimensions are grouped together, enabling precise positioning and registration pitch control during the subsequent assembly process without requiring complex real-time adjustments
2Manufacturing precision
If tiles are sorted and selected based on predetermined parameters, then positioning precision and display uniformity improve, but assembly time and process complexity increase
Solution Approach 1:
The sorting of tiles based on lateral dimension, edge straightness, and squareness is performed in advance before assembly. This preliminary classification creates optimized tile groups that can be assembled efficiently, reducing the time penalty during the actual assembly process while maintaining high registration pitch precision
Solution Approach 2:
The invention changes the approach from attempting to achieve precision during assembly to pre-classifying tiles based on their dimensional parameters. By sorting tiles according to their lateral dimension, edge straightness, and squareness values, the system transforms the precision achievement from a real-time control problem to a pre-processing classification problem, thereby reducing assembly time
3Reliability
If conventional assembly methods are used, then assembly process is simpler, but failure rate increases due to tile dimension deviations
Solution Approach 1:
Tiles undergo preliminary sorting based on their dimensional parameters (lateral dimension, edge straightness, squareness) before assembly. This pre-classification identifies and groups tiles with compatible dimensions, ensuring that only suitable tile combinations are assembled together, thereby significantly reducing assembly failures due to dimensional mismatches
Solution Approach 2:
The system measures and records the actual dimensional parameters of each tile (lateral dimension, edge straightness, squareness) and uses this feedback information to sort and select appropriate tile pairs. This feedback mechanism ensures that tiles are matched based on their actual characteristics rather than nominal values, improving assembly success rate
4Manufacturing precision
If tiles are not sorted by predetermined parameters, then assembly process is faster and simpler, but display quality and visual uniformity deteriorate
Solution Approach 1:
Tiles are pre-sorted based on their dimensional parameters to ensure uniformity in the final display. By classifying tiles according to lateral dimension, edge straightness, and squareness before assembly, the system guarantees consistent tile alignment and spacing, achieving high display uniformity without compromising assembly efficiency
Solution Approach 2:
The invention changes the assembly strategy from random or nominal-based selection to parameter-based sorting. By measuring and sorting tiles according to their actual dimensional parameters (lateral dimension, edge straightness, squareness), the system ensures that only tiles with compatible dimensions are assembled together, thereby achieving high display uniformity while maintaining reasonable assembly efficiency
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.