Tiled Display Module Alignment for Seamless Large-Screen Assembly
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Solution Overview
Problem
Tiled display devices face issues with visible seams due to assembly tolerances, which detract from the appearance and require additional equipment for planarization, making them less efficient and aesthetically pleasing.
Innovation Solution
A display device configuration where multiple display modules are coupled to a frame with a protection layer and cover film, and fixing members with protrusions and insertion holes, allowing for precise spacing and alignment without separate planarization equipment, ensuring uniform separation distances between modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple display modules are tiled together to form large-screen displays, then the display area is increased, but assembly tolerances cause visible seams between modules
Solution Approach 1:
The display system is divided into multiple independent display modules, each with its own protection layer and cover film. These modules are tiled together to form large-screen displays while maintaining individual structural integrity, allowing for modular assembly and reduced cumulative tolerance errors.
Solution Approach 2:
A frame structure serves as an intermediary component between adjacent display modules. This frame provides precise positioning features including protrusions and insertion holes that maintain uniform separation distances, acting as a mediator that compensates for assembly tolerances and prevents visible seams.
2Manufacturing precision
If separate planarization equipment is used to eliminate seams between modules, then the appearance quality is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
Planarization features are built into the display module structure during manufacturing. The protection layer covers side lines on the substrate side surface, and the cover film is positioned at a predetermined height, creating a pre-planarized surface that eliminates the need for additional post-assembly planarization equipment.
Solution Approach 2:
The protection layer and cover film are integrated into the display module structure itself, combining the functions of substrate protection, side line coverage, and surface planarization into a single unified component system, thereby eliminating the need for separate planarization equipment.
3Ease of manufacture
If display modules are assembled without precise spacing control, then the assembly process is simplified, but visible seams and poor appearance result
Solution Approach 1:
The frame structure incorporates self-aligning features with protrusions on the frame and corresponding insertion holes on the display modules. These features automatically guide and constrain the modules to precise positions with uniform separation distances, making the assembly process simple while ensuring high precision spacing control.
4Manufacturing precision
If additional planarization components are added to eliminate seams, then the appearance quality is improved, but the device complexity and cost increase
Solution Approach 1:
The protection layer and cover film are integrated into the display module structure itself, combining the functions of substrate protection, side line coverage, and surface planarization into a single unified component system, thereby eliminating the need for separate planarization components.
Data Source
AI summary
A display device includes a frame and display modules coupled to the frame. Each of the display modules includes a display panel including a protection layer for covering a side line formed on a side surface of a substrate of the display panel, and a cover film disposed on a first or front surface of the display panel. The display modules are spaced apart from each other when they are coupled to the frame, and a separation distance between the side surfaces of the protection layers and a separation distance between the side surfaces of the cover films of the plurality of display modules are the same.