Modular Pixel Module Assembly for Faster LED Transfer and Repair
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Solution Overview
Problem
The transfer of LEDs to a display panel substrate is time-consuming and prone to defects, leading to high costs due to the difficulty in repairing individual pixels, which often results in discarding entire display apparatuses.
Innovation Solution
A pixel module design featuring a linking substrate with interconnection regions and non-interconnection regions, allowing for easier transfer and repair of unit pixels, with a multilayer structure and reduced pixel spacing, and a display apparatus that includes molding members and adhesive layers for protection and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If micro-sized LEDs are individually mounted on the display panel substrate, then the display apparatus can be manufactured, but the process takes a lot of time and many defects such as poor bonding occur
Solution Approach 1:
The display panel is divided into multiple pixel modules, each containing multiple sub-pixels mounted on a common substrate. This segmentation allows parallel processing of multiple pixels simultaneously, reducing total mounting time while maintaining bonding quality through standardized module assembly procedures
Solution Approach 2:
Multiple sub-pixels are pre-mounted on a pixel module substrate before being transferred to the final display panel substrate. This preliminary assembly allows for quality control and testing at the module level, ensuring bonding quality is achieved before final installation, thereby reducing rework and defects
2Ease of repair
If pixels are mounted directly on the display panel substrate, then the display can be assembled, but it is difficult to repair defects and entire pixels must be discarded
Solution Approach 1:
The display is segmented into independent pixel modules that can be individually replaced. When a defect occurs, only the specific pixel module needs to be replaced rather than the entire display panel, significantly improving repairability and reducing waste
Solution Approach 2:
A pixel module substrate acts as an intermediary between the display panel substrate and individual sub-pixels. This intermediate layer allows for modular replacement, where defective pixel modules can be easily detached and replaced without affecting other pixels, thereby improving repairability while maintaining overall display reliability
3Manufacturing precision
If the interval between pixels is reduced, then the display resolution is improved, but the manufacturing complexity increases
Solution Approach 1:
The display is divided into pixel modules with standardized spacing. This modular approach allows for precise pixel spacing to be achieved through repeated module placement rather than individual pixel positioning, reducing manufacturing complexity while maintaining high precision
Solution Approach 2:
The pixel spacing parameter is optimized by adjusting the module design and interconnection structure. By changing the physical parameters of the module substrate and connection methods, precise pixel spacing can be achieved without proportionally increasing manufacturing complexity
Data Source
AI summary
A pixel module and a display apparatus having the same are provided. A display apparatus according to an embodiment includes a panel substrate and a plurality of pixel modules disposed on the panel substrate, in which each of the pixel modules includes a linking substrate including at least one interconnection region and a non-interconnection region adjacent to the interconnection region and a plurality of unit pixels disposed on each of the interconnection regions of the linking substrate.