Patent Publication Number: US-2020286869-A1

Title: Display apparatus and manufacturing method for the same

Description:
This application claims the benefit of People&#39;s Republic of China application Serial No. 201910178295.4, filed Mar. 8, 2019, the subject matter of which is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present disclosure relates to a display apparatus and a manufacturing method for the same, and more particularly to a display apparatus having a stitching seam and a manufacturing method for the same. 
     Description of the Related Art 
     Currently, light emitting diode (LED) display apparatuses are modularized and then stitched into a large display apparatus, a stitching seam of which is not apparent when watching with a long distance. The stitching seam becomes more apparent as the watching distance decreases. In particular, when the resolution for a LED display apparatus is increased, a gap distance for each pixel is decreased. The stitching seam in the high-resolution display apparatus is also more apparent. 
     SUMMARY OF THE INVENTION 
     The present disclosure relates to a display apparatus and a manufacturing method for the same. A display effect of the display apparatus can be improved. 
     An embodiment of the present disclosure provides a display apparatus, comprising a first display device and a second display device. The first display device comprises a first circuit board, first display pixels and a first opaque rubber. The first display pixels are electrically connected on the first circuit board. The first opaque rubber comprises a first outer border rubber portion and a first spacer rubber portion. The first spacer rubber portion is in a gap space between the first display pixels. The first outer border rubber portion is outside the first display pixels. The second display device comprises a second circuit board, second display pixels and a second opaque rubber. The second display pixels are electrically connected on the second circuit board. The second opaque rubber comprises a second outer border rubber portion. The second outer border rubber portion is outside the second display pixels. The first display device and the second display device are stitched together. The first outer border rubber portion and the second outer border rubber portion are faced and adjacent to each other. The first spacer rubber portion, the first outer border rubber portion and the second outer border rubber portion have the same height. 
     Another embodiment of the present disclosure provides a display apparatus, comprising a first display device and a second display device. The first display device comprises a first circuit board, first display pixels, and a first opaque rubber. The first display pixels are electrically connected on the first circuit board. The first opaque rubber comprises a first outer border rubber portion and a first spacer rubber portion. The first spacer rubber portion is in a gap space between the first display pixels. The first outer border rubber portion is outside the first display pixels. The second display device comprises a second circuit board, second display pixels, and a second opaque rubber. The second display pixels are electrically connected on the second circuit board. The second opaque rubber comprises a second outer border rubber portion. The second outer border rubber portion is outside the second display pixels. The first display device and the second display device are stitched together. The first outer border rubber portion and the second outer border rubber portion are faced and adjacent to each other. The first circuit board and the second circuit board have a stitching seam therebetween. There is no adhesive rubber at the stitching seam. 
     A yet another embodiment of the present disclosure provides a manufacturing method for a display apparatus, comprising the following steps. A first display device is provided. The first display device comprises a first circuit board, first display pixels and a first opaque rubber. The first display pixels are on the first circuit board. The first opaque rubber is on the first circuit board. The first opaque rubber comprises a first outer border rubber portion and a first spacer rubber portion. The first spacer rubber portion is in a gap space between the first display pixels. The first outer border rubber portion is outside the first display pixels. A second display device is provided. The second display device comprises a second circuit board, second display pixels, and a second opaque rubber. The second display pixels are on the second circuit board. The second opaque rubber comprises a second outer border rubber portion. The second outer border rubber portion is outside the second display pixels. The first display device and the second display device are stitched together. The first outer border rubber portion and the second outer border rubber portion are faced and adjacent to each other. The first circuit board and the second circuit board are faced and adjacent to each other. 
     The above and other aspects of the invention will become better understood with regard to the following detailed description of the preferred but non-limiting embodiment (s). The following description is made with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  to  FIG. 6  illustrate a manufacturing method for a display apparatus according to an embodiment. 
         FIG. 7  illustrates a cross-section view of a display apparatus according to another embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  to  FIG. 6  illustrate a manufacturing method for a display apparatus according to an embodiment. 
     Referring to  FIG. 1 , light emitting units, such as light emitting units  104 R, light emitting units  104 G, and light emitting units  104 B, are disposed on a first circuit board  102 . The light emitting unit may comprise a light emitting diode. In an embodiment, the light emitting unit  104 R is a red light emitting diode, the light emitting unit  104 G is a green light emitting diode, and the light emitting unit  104 B is a blue light emitting diode. In an embodiment, the light emitting units may be micro light emitting diodes disposed on the first circuit board  102  by a mass transferring method. The micro light emitting diode may have a diagonal length of 1 μm to 100 μm. For example, the light emitting unit  104 R, the light emitting unit  104 G, and the light emitting unit  104 B may be electrically connected to the first circuit board  102  through a wire bonding method. It is described that in the present disclosure the first circuit board  102  is not limited to any material, and may be a glass circuit board, a plastic circuit board, and so on, for example. 
     Referring to  FIG. 2 , a mask  106  may be formed on the light emitting unit  104 R, the light emitting unit  104 G, and the light emitting unit  104 B. 
     Referring to  FIG. 3 , a first opaque rubber  108  may be disposed on a portion of the first circuit board  102  not covered by the mask  106 . The first opaque rubber  108  may be formed by disposing a curable rubber material by a spraying method, and then performing a curing step. The first opaque rubber  108  may be formed by other suitable methods, such as a coating method, an injecting method, etc. In an embodiment, the first opaque rubber  108  may comprise a black rubber or a grey rubber, for example. For example, a material for the first opaque rubber  108  may comprise a silicone resin such as silicone, or an encapsulating material such as an epoxy resin, or other suitable materials. 
     Referring to  FIG. 4 , the mask  106  is removed so as to form a first display device  100 . 
       FIG. 4A  shows a plan view of the first display device  100  according to an embodiment.  FIG. 4  may be a cross-section view drawn along a AB section line in  FIG. 4A . Referring to  FIG. 4  and  FIG. 4A , the first display device  100  comprises first display pixels, such as a first display pixel  110   11 , a first display pixel  110   12 , a first display pixel  110   13 , a first display pixel  110   14 , a first display pixel  110   21 , a first display pixel  110   22 , a first display pixel  110   23 , a first display pixel  110   24 , a first display pixel  110   31 , a first display pixel  110   32 , a first display pixel  110   33 , a first display pixel  110   34 , a first display pixel  110   41 , a first display pixel  110   42 , a first display pixel  110   43 , and a first display pixel  110   44 . Each of the first display pixels may comprise the light emitting unit  104 R, the light emitting unit  104 G, and the light emitting unit  104 B. 
     The first display pixels may be surrounded and framed by the first opaque rubber  108 . The first opaque rubber  108  may comprise a first outer border rubber portion. The first outer border rubber portion is outside the first display pixels. Referring to  FIG. 4A , for example, a first outer border rubber portion  112 U is on an upper side of the light emitting units  104 R, the light emitting units  104 G, and the light emitting units  104 B of the first display pixel  110   11 , the first display pixel  110   12 , the first display pixel  110   13 , and the first display pixel  110   14  arranged in order along a first direction D 1 . A first outer border rubber portion  112 L is on a left side of the light emitting units  104 R of the first display pixel  110   11 , the first display pixel  110   21 , the first display pixel  110   31 , and the first display pixel  110   41  arranged in order along a third direction D 3 . A first outer border rubber portion  112 R is on a right side of the light emitting units  104 B of the first display pixel  110   14 , the first display pixel  110   24 , the first display pixel  110   34 , and the first display pixel  110   44  arranged in order along the third direction D 3 . A first outer border rubber portion  112 D is on a lower side of the light emitting units  104 R, the light emitting units  104 G, and the light emitting units  104 B of the first display pixel  110   41 , the first display pixel  110   42 , the first display pixel  110   43 , and the first display pixel  110   44  arranged in order along the first direction D 1 . 
     The first opaque rubber  108  may also comprise first spacer rubber portions. The first spacer rubber portion is in a gap space between the first display pixels. For example, a first spacer rubber portion  114   11  is on the first circuit board  102  between the light emitting unit  104 B of the first display pixel  110   11  and the light emitting unit  104 R of the first display pixel  110   12 . A first spacer rubber portion  114   12  is on the first circuit board  102  between the light emitting unit  104 B of the first display pixel  110   12  and the light emitting unit  104 R of the first display pixel  110   13 . A first spacer rubber portion  114   13  is on the first circuit board  102  between the light emitting unit  104 B of the first display pixel  110   13  and the light emitting unit  104 R of the first display pixel  110   14 . A first spacer rubber portion  114   21  is on the first circuit board  102  between the first display pixel  110   11  and the first display pixel  110   21 . A first spacer rubber portion  114   31  is on the first circuit board  102  between the first display pixel  110   21  and the first display pixel  110   31 . A first spacer rubber portion  114   41  is on the first circuit board  102  between the first display pixel  110   31  and the first display pixel  110   41 . In an embodiment, the first spacer rubber portions may have the same width. For example, widths of the first spacer rubber portion  114   11 , the first spacer rubber portion  114   12 , and the first spacer rubber portion  114   13  in the first direction D 1  may be identical to each other. Widths of the first spacer rubber portion  114   21 , the first spacer rubber portion  114   31 , and the first spacer rubber portion  114   41  in the third direction D 3  may be identical to each other. The characteristic and the disposition for the other first spacer rubber portions can be deduced by analogy. 
     In an embodiment, the first outer border rubber portion and the first spacer rubber portion of the first opaque rubber  108  may have the same height. Otherwise, an upper surface of the first outer border rubber portion and an upper surface of the first spacer rubber portion may be at the same height level. In an embodiment, a width of the first outer border rubber portion may be one-half of a width of the first spacer rubber portion. For example, a width of the first outer border rubber portion  112 L in the first direction D 1  may be one-half of a width of the first spacer rubber portion  114   11  in the first direction D 1 . In an embodiment, a width of the first outer border rubber portion  112 U in the third direction D 3  may be one-half of a width of the first spacer rubber portion  114   21  in the third direction D 3 . 
     Referring to  FIG. 5 , a second display device  200  is provided. The second display device  200  may comprise a second circuit board  202 , a second opaque rubber  208 , and second display pixels. For example, the second display pixels comprise a second display pixel  210   11 , a second display pixel  210   12 , a second display pixel  210   13 , and a second display pixel  210   14  arranged in order along the first direction D 1 . Each of the second display pixels may comprise a light emitting unit  204 R, a light emitting unit  204 G, and a light emitting unit  204 B. In an embodiment, the light emitting unit  204 R is a red light emitting diode, the light emitting unit  204 G is a green light emitting diode, and the light emitting unit  204 B is a blue light emitting diode. In an embodiment, the light emitting units may be micro light emitting diodes disposed on the second circuit board  202  by a mass transferring method. In an embodiment, the light emitting units of the second display pixels may be electrically connected onto the second circuit board  202  through a wire bonding method. It is described that in the present disclosure the second circuit board  202  is not limited to any material, and may be a glass circuit board, a plastic circuit board, and so on, for example. 
     The second opaque rubber  208  comprises a second outer border rubber portion  212 L, a second outer border rubber portion  212 R, a second outer border rubber portion  212 U, a second outer border rubber portion  212 D and second spacer rubber portions. The second outer border rubber portion  212 L, the second outer border rubber portion  212 R, the second outer border rubber portion  212 U, and the second outer border rubber portion  212 D are outside the second display pixels. For example, a second spacer rubber portion  214   11  is on the second circuit board  202  between the light emitting unit  204 B of the second display pixel  210   11  and the light emitting unit  204 R of the second display pixel  210   12 . A second spacer rubber portion  214   12  is on the second circuit board  202  between the light emitting unit  204 B of the second display pixel  210   12  and the light emitting unit  204 R of the second display pixel  210   13 . A second spacer rubber portion  214   13  is on the second circuit board  202  between the light emitting unit  204 B of the second display pixel  210   13  and the light emitting unit  204 R of the second display pixel  210   14 . In an embodiment, the second spacer rubber portions may have the same width. For example, the second spacer rubber portion  214   11 , the second spacer rubber portion  214   12 , and the second spacer rubber portion  214   13  may have the same width in the first direction D 1 . The characteristic and the disposition for the other second spacer rubber portions can be deduced by analogy. 
     In an embodiment, the second outer border rubber portion and the second spacer rubber portion of the second opaque rubber  208  may have the same height in a second direction D 2 . Otherwise, an upper surface of the second outer border rubber portion and an upper surface of the second spacer rubber portion may be at the same height level. Upper surfaces of the second outer border rubber portion and the second spacer rubber portion of the second opaque rubber  208  are above upper surfaces of the light emitting unit  204 R, the light emitting unit  204 G, and the light emitting unit  204 B (such as the light emitting diodes). In an embodiment, the second opaque rubber  208  comprises a black rubber or a grey rubber. For example, a material for the second opaque rubber  208  may comprise a silicone resin such as silicone, or an encapsulating material such as an epoxy resin, or other suitable materials. The first direction D 1 , the second direction D 2  and the third direction D 3  may be perpendicular to each other substantially. In an embodiment, the first direction D 1  may be the X-axis direction, the second direction D 2  may be the Z-axis direction, and the third direction D 3  may be the Y-axis direction. 
     In an embodiment, the element disposition and/or the manufacturing method of the second display device  200  may be similar to or identical to the element disposition and/or the manufacturing method of the first display device  100 . However, the present disclosure is not limited thereto. In another embodiment, the first display device  100  and the second display device  200  may be different in the element disposition and/or the manufacturing method. 
     Next, the first display device  100  and the second display device  200  are disposed on a substrate board  316 , and the first display device  100  and the second display device  200  are stitched together. In an embodiment, the first circuit board  102  and the second circuit board  202  are adhered on the substrate board  316  through an adhesive layer, and the first display device  100  and the second display device  200  have a stitching seam  311  therebetween with no adhesive rubber at the stitching seam  311 . In detail, the stitching seam  311  is defined between a rubber sidewall surface of the first outer border rubber portion  112 L and a rubber sidewall surface of the second outer border rubber portion  212 R facing to and adjacent to the rubber sidewall surface of the first outer border rubber portion  112 L. There is no adhesion between the first outer border rubber portion  112 L and the second outer border rubber portion  212 R. The stitching seam  311  is also defined between a board sidewall surface of the first circuit board  102  and a board sidewall surface of the second circuit board  202  facing to and adjacent to the board sidewall surface of the first circuit board  102 . There is no adhesion between the first circuit board  102  and the second circuit board  202 . In an embodiment, the stitching seam  311  is formed by adjoining the first outer border rubber portion  112 L and the second outer border rubber portion  212 R, and/or is formed by adjoining the first circuit board  102  and the second circuit board  202 . The stitching seam  311  may be an air space. 
       FIG. 5A  shows a plan view of an embodiment as the first display device  100  and the second display device  200  are stitched together.  FIG. 5  may be a cross-section view drawn along a CD section line in  FIG. 5A . Referring to  FIG. 5  and  FIG. 5A , heights of the first spacer rubber portion and the first outer border rubber portion of the first display device  100  are identical to heights of the second spacer rubber portion and the second outer border rubber portion of the second display device  200 . Otherwise, widths of the first spacer rubber portion  114   11 , the first spacer rubber portion  114   12 , the first spacer rubber portion  114   13 , the first spacer rubber portion  114   21 , the first spacer rubber portion  114   31 , and the first spacer rubber portion  114   41  are identical to a total width of the first outer border rubber portion and the second outer border rubber portion. In other words, a width of each of the first spacer rubber portions is identical to a total of widths of the first outer border rubber portion and the second outer border rubber portion. In embodiments, upper surfaces of the first opaque rubber  108  and the second opaque rubber  208  are above upper surfaces of the light emitting units (such as the light emitting unit  104 R, the light emitting unit  104 G, the light emitting unit  104 B, the light emitting unit  204 R, the light emitting unit  204 G, and the light emitting unit  204 B), by which interference between adjacent display pixels can be avoided, and the visual perception at the stitching seam  311  can be improved. 
     In embodiments, a whole cross-sectional profile of the first outer border rubber portion and the second outer border rubber portion stitched together is identical to a cross-sectional profile of the adjacent first spacer rubber portion and a cross-sectional profile of the adjacent second spacer rubber portion, by which an substantial uniform optical effect can be provided to the display pixel adjacent to the stitching seam  311 , and it also improves the visual perception at the stitching seam  311 . For example, referring to  FIG. 5 , a cross-sectional profile of the first spacer rubber portion  114   11  may be identical to a whole cross-sectional profile of the first outer border rubber portion  112 L and the second outer border rubber portion  212 R disposed adjacent to the first outer border rubber portion  112 L. The first spacer rubber portion  114   11 , the first spacer rubber portion  114   12 , the first spacer rubber portion  114   13 , the second spacer rubber portion  214   11 , the second spacer rubber portion  214   12 , and the second spacer rubber portion  214   13  may have the same cross-sectional profile. 
     Referring to  FIG. 6 , a protecting layer  318  may be disposed on the first display device  100  and the second display device  200 . The protecting layer  318  may cover the light emitting unit  104 R, the light emitting unit  104 G, and the light emitting unit  104 B of the first display device  100 , and the light emitting unit  204 R, the light emitting unit  204 G, and the light emitting unit  204 B of the second display device  200 . The protecting layer  318  may also cover on the first opaque rubber  108  of the first display device  100  and the second opaque rubber  208  of the second display device  200 . The protecting layer  318  may be formed by disposing a curable rubber material by a spraying method, and then performing a curing step. The protecting layer  318  may be formed by other suitable methods, such as a coating method, an injecting method, etc. The protecting layer  318  can provide protection effect to the element covered by the protecting layer  318 , avoiding influence from moisture, air, etc., for example. 
       FIG. 7  illustrates a cross-section view of a display apparatus according to another embodiment, which is different from the display apparatus shown in  FIG. 6  with the following description. A protecting layer  418  having a sheet shape is disposed on the upper surface of the first opaque rubber  108  and the upper surface of the second opaque rubber  208 . A material of the protecting layer  418  may comprise a glass, or a plastic, etc., for example. There may be an air space between the protecting layer  418  and the light emitting unit  104 R, the light emitting unit  104 G, the light emitting unit  104 B, the light emitting unit  204 R, the light emitting unit  204 G, and the light emitting unit  204 B. The protecting layer  418  also can provide protection effect to the element (light emitting unit) covered by the protecting layer  418 . 
     Accordingly, in the present invention, the first display device and the second display device are stitched together, and the first outer border rubber portion of the first display device and the second outer border rubber portion of the second display device are faced and adjacent to each other, by which the visual sensation resulted from the stitching seam can be reduced, and the display effect can be improved. Furthermore, the upper surfaces of the first opaque rubber and the second opaque rubber are above the upper surfaces of the light emitting units, by which interference between adjacent display pixels can be avoided, and the visual perception at the stitching seam can be improved. 
     While the invention has been described by way of example and in terms of the preferred embodiment (s), it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures.