Modular Display Assembly for High-Resolution Micro-Element Transfer
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Solution Overview
Problem
The mass-transfer technique used in display device manufacturing limits the miniaturization of micro-elements, preventing further improvement in display resolution and restricting the application of display devices.
Innovation Solution
A method for manufacturing a display device involves providing a light emitting module, a driving module, and a light conversion module, and assembling them to form a display assembly, with the light emitting module positioned between the light conversion module and the driving module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mass-transfer technique is used to transfer micro-elements to substrate, then manufacturing process is simplified, but display resolution cannot be further improved due to limited miniaturization of micro-elements
Solution Approach 1:
The patent divides the display device into separate functional modules: a light emitting module containing micro-LEDs, a light conversion module, and a driving module. This segmentation allows each module to be optimized independently, enabling higher resolution in the light emitting module without complicating the overall manufacturing process.
Solution Approach 2:
The patent introduces a light conversion module as an intermediary between the light emitting module and the final display output. This intermediary component enables color conversion and enhancement, allowing higher resolution to be achieved through optical processing rather than requiring even smaller micro-elements.
2Manufacturing precision
If micro-elements are miniaturized to improve resolution, then display resolution is improved, but micro-elements cannot be easily transferred to substrate of small size
Solution Approach 1:
The patent segments the micro-LED array into a dedicated light emitting module that can be manufactured separately with optimized spacing and arrangement. This module can then be transferred as a complete unit to the final substrate, avoiding the difficulty of transferring individual miniaturized micro-elements.
Solution Approach 2:
The patent addresses the transfer difficulty by changing the dimensional approach: instead of transferring individual micro-elements directly to the final substrate, the micro-LEDs are first arranged in a standardized module format that can be transferred via wire bonding or other connection methods, effectively moving the problem to a different dimensional scale.
3Manufacturing precision
If more micro-elements are placed in each sub-pixel, then resolution is improved, but space in each sub-pixel is limited
Solution Approach 1:
The patent moves the resolution enhancement from the spatial dimension (packing more elements in each sub-pixel) to the optical dimension (using the light conversion module to generate additional color information). This allows high resolution without increasing the physical area of each sub-pixel.
Solution Approach 2:
The patent changes the parameter of color generation from direct emission at the micro-LED level to conversion at the light conversion module level. This parameter change allows the same physical space to produce more color information, effectively increasing resolution without requiring more micro-elements per sub-pixel.
Data Source
AI summary
The present disclosure provides a method for manufacturing a display device. The method includes providing a light emitting module, providing a driving module, providing a light conversion module, and assembling the light emitting module, the driving module, and the light conversion module to form a display assembly. The light emitting module is disposed between the light conversion module and the driving module.