Sparse LED Window Display Lamination for Optical Transparency
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Solution Overview
Problem
Current micro-LED display technologies face challenges in efficiently integrating LEDs into curved or irregularly shaped surfaces and maintaining optical properties of substrates, such as transparency or reflectivity, while providing protection and minimizing additional cover layers.
Innovation Solution
A sparse array of LEDs is disposed on a transparent flexible substrate, which is then laminated onto a rigid substrate with an adhesive layer, allowing the LEDs to be encapsulated and protecting them from the environment, while maintaining the optical properties of the substrate and enabling application on non-traditional surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sparse array of LEDs is disposed on a transparent flexible substrate and laminated onto a rigid substrate, then the LEDs are protected from the environment and can be applied on non-traditional surfaces, but the substrate's optical properties may be degraded and additional cover layers are required
Solution Approach 1:
The transparent flexible substrate serves multiple functions simultaneously: it provides mechanical support for the LED array, maintains optical transparency for light emission, and acts as an adhesive bonding layer between the LED array and the rigid substrate. This multi-functionality eliminates the need for separate protection layers while preserving optical properties.
Solution Approach 2:
The patent utilizes a thin transparent flexible substrate that encapsulates the LED array. This thin film approach provides protection against environmental factors while minimizing interference with light transmission, thereby maintaining the substrate's optical properties without requiring additional thick cover layers.
2Reliability
If additional cover layers are added to protect LEDs, then protection is improved, but device complexity and number of layers increase
Solution Approach 1:
The transparent flexible substrate is designed to perform multiple functions in one layer: structural support, environmental protection, and optical transmission. By consolidating these functions into a single multi-functional layer, the patent reduces the total number of layers required while maintaining adequate LED protection.
Solution Approach 2:
The patent merges the protection function with the substrate itself rather than adding separate protection layers. The transparent flexible substrate is bonded directly to the rigid substrate, creating an integrated structure where the substrate serves as both the mounting platform and the protection barrier, thereby reducing device complexity.
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 allows for efficient light emission on surfaces with additional functions, such as reflectivity or transparency, without degrading the substrate's optical properties and reduces the need for additional protection layers, enhancing the versatility of micro-LED displays.
Implementation Method 1
a rigid substrate adhered to the transparent flexible substrate via an adhesive layer in which the sparse array of LEDs is encapsulated
Data Source
AI summary
A vehicular display that contains a sparse array of light-emitting diodes (LEDs), system, and method of fabrication are disclosed. The vehicular display includes at least one tile disposed in a vehicle to provide a display of internal and external information. 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 a vehicle window while still enabling a viewer to see through the window.