Stacked Insulating Substrates With Concave LED Mounts for Pixel Yield
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Solution Overview
Problem
Micro LEDs and mini LEDs in LED display devices face challenges in production yield due to non-implemented parts and dislocation, leading to non-luminescent pixels and delayed fast-moving image display.
Innovation Solution
A display device design with multiple insulating substrates stacked, where light emitting elements are positioned within concave portions on each substrate, allowing for compensation of non-luminescent elements and faster response times, and reducing thickness by accommodating elements in concave portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple micro LEDs or mini LEDs are implemented in LED display devices, then the display resolution and image quality are improved, but the production yield deteriorates due to non-implemented parts and dislocation
Solution Approach 1:
The patent applies beforehand cushioning by creating overlapping display regions between adjacent substrates. Each substrate's display region extends beyond its physical boundaries, so that when substrates are arranged, the overlapping regions ensure that if some LEDs are non-functional or misplaced, the overlapping area from adjacent substrates compensates for these defects, maintaining overall display quality and production yield.
Solution Approach 2:
The patent changes the spatial parameter of LED arrangement by allowing LEDs on adjacent substrates to be positioned in overlapping regions rather than strictly aligned. This parameter change enables compensation for dislocation and non-implemented parts, as the overlapping arrangement provides redundant coverage that maintains display resolution despite manufacturing variations.
2Adaptability or versatility
If multiple flexible substrates are layered for three-dimensional display, then the display capability is improved, but the device thickness increases
Solution Approach 1:
The patent applies another dimension by arranging multiple substrates in a stacked configuration where display regions overlap in the vertical dimension. This allows the substrates to be positioned closer together than traditional non-overlapping arrangements, reducing the overall device thickness while maintaining enhanced display capability through the layered structure.
Solution Approach 2:
The patent implements nesting by placing display regions of adjacent substrates within overlapping areas. The display region of one substrate is partially contained within the display region of adjacent substrates, creating a nested arrangement that reduces the total thickness required while preserving the three-dimensional display functionality.
3Ease of manufacture
If LEDs are mounted on flat surfaces, then the manufacturing process is simple, but the response time is delayed and the form factor is bulky
Solution Approach 1:
The patent applies spheroidality by forming concave portions in the substrate surfaces where LEDs are mounted. These concave, curved regions position the LEDs closer to the viewer and improve light extraction efficiency, thereby reducing response time and eliminating the need for bulky diffusers while maintaining manufacturing simplicity through standard semiconductor processing techniques.
Data Source
AI summary
According to one embodiment, a display device includes, a first insulating substrate including a first surface and a second surface, a first light emitting element disposed on the second surface, a second insulating substrate including a third surface and a fourth surface, and a second light emitting element disposed on the second insulating substrate, wherein the second insulating substrate includes a first concave portion in the third surface, at least a part of the first light emitting element is positioned inside the first concave portion, and at least a part of the second light emitting element is positioned inside the second concave portion.