Reflective Cavities in Display Panel Frame Areas
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Solution Overview
Problem
The integration of multiple LCDs to form a large-size commercial display is hindered by thick frames, which can break the display image and result in unsatisfactory performance due to discontinuous view angles caused by differing light field shapes between LCDs and LEDs.
Innovation Solution
A display panel design that includes a first and second substrate, a sealant, a display array, a planarization layer with reflective cavities, and a micro-LED array at the frame area. The micro-LEDs are disposed in the reflective cavities, and the reflective cavities are designed to tune the light path of the micro-LEDs to match the light field shape of the LCDs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If thick frames are used to merge multiple LCDs, then the structural stability is improved, but the display image is broken and view angle discontinuity occurs
Solution Approach 1:
The patent changes the optical parameters of the frame area by introducing reflective cavities with specific geometric parameters (depth-to-width ratio between 0.2 to 0.3, sidewall angles between 25 to 45 degrees) to control light reflection. This transforms the frame area from a simple structural component to an optical element that shapes light paths, thereby achieving both structural stability and display performance without view angle discontinuity.
Solution Approach 2:
The reflective cavities act as an intermediary structure between the micro-LEDs and the external environment. These cavities with reflective surfaces mediate the light paths from the frame area micro-LEDs to match the light field shape of the display area LCDs, serving as an optical bridge that eliminates view angle discontinuity while maintaining structural integrity.
2Shape
If micro-LEDs are used at the frame area, then the light field shape can be matched, but the view angle discontinuity problem occurs due to different light field shapes between LCDs and LEDs
Solution Approach 1:
The patent employs curved reflective surfaces within the reflective cavities to control and shape the light paths. The curved geometry of the reflective cavities (with specific sidewall angles and depth-to-width ratios) enables the micro-LEDs to emit light in a pattern that matches the LCD light field shape, thereby achieving continuous view angles across the tiled display.
Solution Approach 2:
By precisely controlling the geometric parameters of the reflective cavities (depth-to-width ratio between 0.2 to 0.3, sidewall angles between 25 to 45 degrees), the patent optimizes the light reflection characteristics. This parameter optimization ensures that the light field shape from micro-LEDs matches that of LCDs, eliminating view angle discontinuity.
3Reliability
If reflective cavities are introduced to tune light paths, then the view angle continuity is improved, but the device complexity increases
Solution Approach 1:
The patent merges the reflective cavity structure with the existing planarization layer and substrate structure. The reflective cavities are formed within the planarization layer, combining multiple functions (planarization, light reflection, and structural support) into a single integrated component, thereby reducing overall device complexity while achieving view angle continuity.
Solution Approach 2:
The reflective cavities serve multiple functions simultaneously: they act as light guiding structures, provide structural support for the micro-LEDs, and contribute to the overall planarization of the display surface. This multi-functionality reduces the need for separate components, thereby managing device complexity while improving view angle continuity.
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 solution effectively addresses the issue of view angle discontinuity by aligning the light field shape of the micro-LEDs at the frame area with that of the LCDs at the display area, thereby enhancing display performance and maintaining a seamless image across the tiled display.
Implementation Method 1
a planarization layer disposed on an outer surface of the first substrate and including a plurality of reflective cavities... a surface of each of the reflective cavities is disposed with a reflective layer
Data Source
AI summary
A display panel includes a first substrate, a second substrate, a sealant configured to mount the first substrate and the second substrate at a frame area; a display array disposed at a display area of the first substrate and the second substrate, in which the display area is surrounded by the frame area, a planarization layer disposed on an outer surface of the first substrate and including a plurality of reflective cavities, and a micro-LED array disposed at the frame area and including a plurality of micro-LEDs. The micro-LEDs are disposed in the reflective cavities.