Some content of this application is unavailable at the moment.
If this situation persist, please contact us atFeedback&Contact
1. (WO2018038967) DISPLAY MODULES WITH LASER WELD SEALS AND MODULAR DISPLAY
Note: Text based on automatic Optical Character Recognition processes. Please use the PDF version for legal matters

[161]

WHAT IS CLAIMED IS:

1. An apparatus, comprising:

at least one module, each module comprising:

a first substrate;

a second substrate disposed over the first substrate;

the module having a periphery;

an array of pixels disposed between the first substrate and the second substrate, and inside the periphery, each pixel having an active area and an inactive area;

the array of pixels having a first intra-modular separation distance between the active area of adjacent pixels in a first direction;

a laser weld hermetically sealing the first substrate to the second substrate along a portion of the periphery, such that the laser weld is disposed between the active area of the pixels and the periphery, and the distance between the active area of the pixels and the periphery in the first direction is not more than 50% of the first intra-modular separation distance.

2. The apparatus of claim 1, wherein:

along the portion of the periphery, the entire width of the laser weld is within 500 μπι of the periphery.

3. The apparatus of claim 2, wherein:

along the portion of the periphery, the entire width of the laser weld is within 200 μπι of the periphery.

4. The apparatus of claim 3, wherein:

along the portion of the periphery, the entire width of the laser weld is within 100 μπι of the periphery.

5. The apparatus of claim 1, wherein:

along the portion of the periphery, the distance between the laser weld and the active area of the array of pixels is at least 50% of the width of the laser weld.

6. The apparatus of claim 5, wherein:

along the portion of the periphery, the distance between the laser weld and the active area of the array of pixels is at least 100% of the width of the laser weld.

7. The apparatus of claim 6, wherein:

along the portion of the periphery, the distance between the laser weld and the active area of the array of pixels is at least 200% of the width of the laser weld.

8. The apparatus of claim 1, wherein:

along the portion of the periphery, the laser weld has a width less than 500 μιη.

9. The apparatus of claim 8, wherein:

along the portion of the periphery, the laser weld has a width less than 200 μιη.

10. The apparatus of claim 9, wherein:

along the portion of the periphery, the laser weld has a width less than 100 μιη.

11. The apparatus of claim 1, wherein:

along the portion of the periphery, the distance between the laser weld and the periphery is not more than 50 μιη.

12. The apparatus of claim 1, wherein:

along the portion of the periphery, the laser weld directly bonds the first substrate to the second substrate.

13. The apparatus of claim 1, wherein:

the portion of the periphery is the entire periphery.

14. The apparatus of claim 1, wherein:

each module is a rectangle having a first linear edge and a third linear edge in the first direction, and a second linear edge and a fourth linear edge in a second direction perpendicular to the first direction; and

the array of pixels comprises an array of light emitting devices having the first intra-modular separation distance in the first direction, and a second intra-modular separation distance in the second direction.

15. The apparatus of claim 14, wherein:

the first intra-modular separation distance is not more than 2000 μιη; the second intra-modular separation distance is not more than 2000 μιη; along the second and fourth linear edges, the distance between the periphery and the active area of the array of pixels in the first direction is not more than 1000 μπι; and

along the first and third linear edges, the distance between the periphery and the active area of the array of pixels in the second direction is not more than 1000 μπι.

16. The apparatus of claim 14, wherein:

the first intra-modular separation distance is not more than 1500 μπι; the second intra-modular separation distance is not more than 1500 μηι; along the second and fourth linear edges, the distance between the periphery and the active area of the array of pixels in the first direction is not more than 750 μπι; and

along the first and third linear edges, the distance between the periphery and the active area of the array of pixels in the second direction is not more than 750 μπι.

17. The apparatus of claim 14, wherein:

the first intra-modular separation distance is not more than 1250 μπι; the second intra-modular separation distance is not more than 1250 μηι; along the second and fourth linear edges, the distance between the periphery and the active area of the array of pixels in the first direction is not more than 625 μπι; and

along the first and third linear edges, the distance between the periphery and the active area of the array of pixels in the second direction is not more than 625 μπι.

18. The apparatus of claim 14, wherein:

the first intra-modular separation distance is not more than 1000 μπι; the second intra-modular separation distance is not more than 1000 μηι;

along the second and fourth linear edges, the distance between the periphery and the active area of the array of pixels in the first direction is not more than 500 μηι; and

along the first and third linear edges, the distance between the periphery and the active area of the array of pixels in the second direction is not more than 500 μπι.

19. The apparatus of claim 14, wherein:

the first intra-modular separation distance is not more than 750 μπι;

the second intra-modular separation distance is not more than 750 μπι; along the second and fourth linear edges, the distance between the periphery and the active area of the array of pixels in the first direction is not more than 375 μπι; and

along the first and third linear edges, the distance between the periphery and the active area of the array of pixels in the second direction is not more than 375 μπι.

20. The apparatus of claim 14, wherein:

the first intra-modular separation distance is not more than 500 μπι;

the second intra-modular separation distance is not more than 500 μπι; along the second and fourth linear edges, the distance between the periphery and the active area of the array of pixels in the first direction is not more than 250 μπι; and

along the first and third linear edges, the distance between the periphery and the active area of the array of pixels in the second direction is not more than 250 μπι.

The apparatus of claim 14, wherein:

the first intra-modular separation distance is not more than 300 μπι;

the second intra-modular separation distance is not more than 300 μπι; along the second and fourth linear edges, the distance between the periphery and the active area of the array of pixels in the first direction is not more than 150 μπι; and

along the first and third linear edges, the distance between the periphery and the active area of the array of pixels in the second direction is not more than 150 μπι.

22. The apparatus of claim 14, wherein:

the at least one module includes a first module and a second module; the first module is joined to the second module along the second linear edge of the first module and the fourth linear edge of the second module; an inter-modular separation distance between the active area of a pixel of the first module and the active area of adjacent pixel of the second module in the first direction is not more than 20% different than the intra-modular separation distance of the first module in the first direction and the intra- modular separation distance of the second module in the first direction;

23. The apparatus of claim 14, wherein:

the apparatus comprises a display,

the display comprises:

a two dimensional array of the modules;

a two dimensional array of pixels spread across the two dimensional array of modules, having a plurality of rows in the first direction and a plurality of columns in the second direction; wherein:

in each row, in the first direction, the separation distance between the active area of each pair of adjacent pixels, whether intermodular or intra-modular, is not more than 10% different than the average inter-modular separation distance;

in each column, in the second direction, the separation distance between the active area of each pair of adjacent pixels, whether inter-modular or intra-modular, is not more than 10% different than the average inter-modular separation distance;

for each line along which two modules are joined, the separation distance between the active area of adjacent pixels across the line in a first direction perpendicular to the line is not more than 10% different from the average separation distance between the active area of pixels within each of the two modules in the first direction.

24. The apparatus of claim 1, wherein:

the separation distance between the light emitting devices within a pixel in a first direction is 10 to 400 μπι.

The apparatus of claim 14, wherein:

the module is a rectangle, and each side of the rectangle has a length less than 10 cm.

The apparatus of claim 1, wherein the apparatus includes only one module, and one module includes only one first substrate and one second substrate.

The apparatus of claim 1, further comprising:

a plurality of electrical connections formed through the first substrate to the array of light emitting devices.

The apparatus of claim 1, further comprising:

a plurality of electrical connections from the periphery of the module to the array of light emitting devices.

The apparatus of claim 1, wherein:

the light emitting devices are selected from the group consisting of: organic light emitting devices, hybrid quantum dot organic light emitting devices, and quantum dot organic light emitting devices.

A method, comprising:

laser welding a second substrate having a periphery to a first substrate by forming at least one laser weld between the second substrate and the first substrate;

wherein:

along at least a portion of the periphery, the entire width of the laser weld is within 500 μπι of the periphery; and

an array of light emitting devices is disposed between the first substrate and the second substrate, and inside the periphery.

The method of claim 30, wherein:

a thin UV absorbing film on the first substrate or the second substrate absorbs UV laser energy during the welding process.

The method of claim 30, wherein:

at least one of the first substrate or the second substrate absorbs sufficient UV laser energy during the laser process to form the laser weld.

The method of claim 30, wherein:

the laser weld hermitically seals the array of light emitting devices between the first substrate and the second substrate; and

the laser weld extends along the entire periphery, and is within 500 μπι of the periphery along the entire periphery.