Sparse LED Array Lamination for Transparent Curved Displays
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Solution Overview
Problem
Existing LED array technologies face challenges in maintaining optical properties of surfaces due to the presence of LEDs, which can alter the appearance of substrates, and there is a need for flexible and protective encapsulation methods that allow LED arrays to be applied to curved or irregularly shaped substrates.
Innovation Solution
The use of a sparse array of LEDs disposed on a transparent flexible substrate, encapsulated by an adhesive layer, which is laminated onto a rigid substrate, allowing for protection and maintaining the optical properties of the surface, and enabling application to curved or irregular shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional rigid substrates are used for LED arrays, then structural stability is improved, but compatibility with curved or irregularly shaped surfaces deteriorates
Solution Approach 1:
The patent uses a flexible substrate (such as a flexible printed circuit board) to replace traditional rigid substrates, enabling the LED array to be bent and conform to curved or irregularly shaped surfaces while maintaining structural integrity and electrical connectivity
Solution Approach 2:
The patent introduces a reconfigurable LED array system where the substrate can dynamically change its shape between flat and curved states, allowing the same structure to adapt to different mounting surfaces and applications
2Reliability
If additional protection layers are added to protect LEDs, then environmental protection is improved, but optical properties of the surface deteriorate
Solution Approach 1:
The patent employs transparent or translucent protection layers that are optically matched to minimize light interference, allowing the protective coating to provide environmental protection while maintaining the original optical properties and light transmission characteristics of the LED array
Solution Approach 2:
The patent uses composite material structures where the protection layer is integrated with the substrate and LED assembly, creating a unified structure that provides both mechanical protection and optical transparency without requiring separate additional layers
3Loss of substance
If sparse LED arrays are used, then material usage is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements preliminary positioning features and alignment marks on the flexible substrate before LED mounting, enabling precise placement of LEDs in sparse arrays through pre-prepared guide structures that simplify the assembly process and maintain high positioning accuracy
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
This configuration maintains the optical properties of the surface by allowing most light to pass through, while providing protection to the LEDs and enabling application to non-flat surfaces, enhancing flexibility and compatibility with various substrates.
Implementation Method 1
a rigid substrate adhered to the transparent flexible substrate via an adhesive layer in which the sparse array of microLEDs is encapsulated
Data Source
AI summary
A display that contains a sparse array of light-emitting diodes (LEDs), including a related system and method of fabrication are disclosed. The display includes at least one panel disposed in or on a transparent material to provide a display on one or both sides of the material. Each tile has a transparent flexible substrate, a sparse array of LEDs disposed on the transparent flexible substrate, a rigid substrate adhered to the transparent flexible substrate via an adhesive layer in which the sparse array of LEDs is encapsulated, and a driver disposed on an edge of the tile and configured to drive the LEDs. The LEDs are sparse enough to enable information to be displayed through the transparent material while still enabling a viewer to see through the transparent material.