Tiled Display Substrate Bending With Pattern Holes for Seam Reduction
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Solution Overview
Problem
Large-sized display devices face increased defect rates and reduced productivity due to the number of pixels, leading to a sense of disconnection and reduced immersion when using tiled display devices with visible seams between connected displays.
Innovation Solution
A tiled display device design that bends a substrate to minimize the boundary area between display devices by bonding a flexible film and source driver at the rear surface, utilizing pattern holes and fan-out lines to improve ring-on-ring and bending strength, thereby reducing the visibility of seams and enhancing image immersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a large-sized display device is manufactured with increased number of pixels, then the display area and resolution are improved, but the defect rate increases and productivity deteriorates
Solution Approach 1:
The large display device is divided into multiple smaller display panels that are tiled together to form the complete large-screen display. Each panel is manufactured separately with a manageable number of pixels, maintaining high productivity and low defect rates, while the overall display area is achieved through the combination of multiple panels.
2Area of moving object
If multiple display devices are connected to form a tiled display, then the display area is expanded, but visible seams and boundary portions reduce the sense of immersion
Solution Approach 1:
The non-display area containing the seam and boundary portions is extracted and relocated to the rear surface of the display panel. This is achieved by bending the substrate in the boundary region and positioning the flexible film and source driver there, thereby removing the visual distraction from the front view and improving the sense of immersion.
Solution Approach 2:
The seam and boundary elements are moved from the two-dimensional front display surface to the three-dimensional rear surface of the panel through substrate bending. This dimensional relocation allows the seam to exist physically while being visually hidden, maintaining both the tiled structure and the immersive viewing experience.
3Reliability
If the substrate is bent to minimize the coupling area, then the visibility of seams is reduced, but the structural strength may be compromised
Solution Approach 1:
The substrate exhibits different properties in different regions: the display area maintains its original flat and strong structure, while the boundary region is bent to relocate the seam to the rear surface. This localized structural modification achieves the goal of reducing seam visibility without compromising the overall structural integrity of the display panel.
Solution Approach 2:
The display panel employs a composite structure combining a rigid substrate for the display area with a flexible substrate in the boundary region. This composite construction allows the boundary portion to be bent for seam relocation while the main display area retains its structural strength and rigidity.
Data Source
AI summary
A tiled display device includes a plurality of display devices including a plurality of display areas including pixels, and a coupling area between adjacent display areas from among the plurality of display areas. Each of the plurality of display devices includes: a substrate including a first portion configured to support the display area, a second portion extending from the first portion to be bent, and a third portion extending from the second portion, a display layer on the first portion of the substrate and including the pixels, a connection line at an edge of the first portion of the substrate and connected to the plurality of pixels, a pad portion on the third portion of the substrate, a fan-out line on the second portion of the substrate and connected between the pad portion and the connection line, and pattern holes penetrating the second portion of the substrate.