Patent Description:
Currently, the alignment marks on adjacent display panels are used to align the display devices one by one. However, the risk of cumulative shift of the panel usually occurs in this method. Therefore, this method is not suitable for multi-panel arrangement. As a result, reducing the risk of cumulative shift and finding an efficient method for multi-panel arrangement are topics to be actively studied currently. <CIT> discloses fabrication techniques for producing microdisplays. Edge treatment techniques for individual microdisplays while still part of the silicon die or wafer are also described. The use of these techniques allows the assembly microdisplays into tiled, flat-panel. <CIT> discloses a liquid crystal display, LCD, device, comprising a first LCD panel and a second LCD panel; wherein one edge of the first LCD panel is positioned in proximity and adjacent to one edge of the second LCD panel; and wherein a light shielding and electrically conductive adhesive bonds the one edge of the first LCD panel and the one edge of the second LCD panel. <CIT> discloses a large-size full-color OLED display, which comprises a color converting base plate and a display module. A green color converting film is covered on a green filter plate film; the display module is formed by assembling a plurality of display units; each display unit comprises a transparent base plate, a plurality of OLED luminescent devices and a control loop for driving the OLED luminescent devices to radiate light; the transparent base plates are seamlessly adhered onto a red filter plate film, a green filter plate film, a blue filter plate film, a black matrix grid film and a green color converting film on the color converting base plate through colloidal packing material; and each OLED luminescent device in the display unit has a filter plate film on the color converting base plate corresponding to the OLED luminescent device independently.

The present invention is provided by the appended claims. The following disclosure serves a better understanding of the present invention. Accordingly, the disclosure provides a method of manufacturing a tiled display device, the method is able to reduce the risk of cumulative shift.

According to the disclosure, in the method of manufacturing a tiled display device, a plurality of display panels are provided. Next, a plurality of alignment marks are provided. Afterwards, the plurality of display panels are tiled with reference to the plurality of alignment marks. The alignment marks are so arranged that the display panels are tiled to make all the same interpitches.

In order to make the above features and advantages of the disclosure more obvious, the following embodiment is described in detail with reference to the accompanying drawings.

The drawings illustrate exemplary embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.

The disclosure can be understood with reference to the following exemplary embodiments and the accompanying drawings. For easy understanding and simplicity of drawings, some of the drawings in the disclosure depict only a portion of the display device, and specific components in the drawings are not drawn according to actual scales.

In the drawings, common characteristics of the methods, structures and/or materials used in specific exemplary embodiments are shown. However, the drawings are not limited to the structures or features of the following embodiments and the drawings should not be interpreted to define or limit the scopes or the properties of the descriptions in the exemplary embodiments. For instance, the relative dimension, thickness, and location of each film layer, region, and/or structure may be reduced or enlarged for clarity.

Certain terms are used throughout the description and the claims to refer to particular elements. People skilled in the pertinent art shall appreciate that electronic device manufacturers may use different names to denote the same element. The disclosure does not aim at distinguishing the elements with the same function but different names.

In the description and claims, the words "having," "including," and "comprising" are open-ended and therefore should be interpreted as "including but not limited to". Moreover, "first", "second", etc. mentioned in the specification and the claims are merely used to name the discrete elements or to differentiate different ranges or embodiments and therefore should not be regarded as limiting the upper or lower bound of the number of the components/devices and should not be used to limit the manufacturing sequence of components.

The directional terminologies mentioned in the detailed description, such as "top," "bottom," "front," "back," "left," or "right", etc., are used as a reference to the orientation of the drawings being described. Accordingly, the drawings and descriptions will be regarded as being illustrative in nature but not as being restrictive.

It should be understood that when an element or a film layer is referred to as being disposed "on" another element or another film layer or "connecting/bonding" another element or another film layer, the element or the film layer may be directly located on the other element or film layer or directly connected/bonded to the other element or film layer, or there may be an intervening element or film layer between the two elements (indirect connection/bonding). By contrast, when the element or the film layer is referred to as being "directly on" or "directly connected/bonded" to another element or another film layer, there is no intervening element nor film layer between the two elements. In addition, connecting or bonding two elements to each other may indicate both elements are fixed or at least one of the elements is movable.

The terms "about", "approximately", or "substantially", used herein are generally meant to fall within a range of <NUM>%, or <NUM>%, or <NUM>%, or <NUM>%, or <NUM>%, or <NUM>%, or <NUM>% of a given value or range.

The tiled electronic device of the disclosure is a display device, such as a touch display device, a curved display device, or a free shape display device, a foldable or flexible tiled display device or combination thereof. The tiled display device may include, for example, a light emitting diode, a fluorescence, a phosphor, other suitable display media comprising light emitting units, or a combination thereof. The light emitting diode may include, for example, an organic light emitting diode (OLED), an inorganic light emitting diode (LED), a sub-millimeter light emitting diode (mini LED), a micro light emitting diode (micro LED) or a quantum dot light emitting diode (QD, for example, QLED, QDLED), or other suitable materials or a combination thereof, but is not limited thereto. It should be noted that the tilted electronic display can be any of the aforementioned combinations, but is not limited thereto. In addition, the appearance of the tilted electronic display can be rectangular, circular, polygonal, a shape with curved edges, or other suitable shapes. The tiled electronic display may have a peripheral system such as a driving system, a control system, a light source system, a shelf system, etc. to support a display device or an antenna device. The following is an example of a tiled display device.

In the following embodiments, the same or similar elements will be given the same or similar reference numerals, and the description thereof will be omitted.

<FIG> is a flow chart illustrating the steps of a method of manufacturing a tiled display device. <FIG> is a schematic top view of a base. <FIG> is a schematic top view of a method of manufacturing a tiled display device according to an embodiment of the disclosure.

With reference to <FIG>, <FIG>, firstly, Step S10 is performed, in the Step S10, a plurality of display panels, such as display panels 100A, 100B and 100C, are provided. The display panels 100A, 100B and 100C include a plurality of light emitting units <NUM>. The plurality of display panels may provide a plurality of display images. A number of the plurality of display panels as illustrated in <FIG> should not be construed as a limitation to the disclosure. The number of the plurality of display panels can be adjusted according to practical operations.

Next, Step S20 is performed, in the Step S20, a plurality of alignment marks <NUM> are provided. At least a portion of the plurality of alignment marks <NUM> are located on a base <NUM>, the base may be used to support the plurality of display panels, such as display panels 100A, 100B and 100C as illustrated in <FIG>. At least a portion of the plurality of alignment marks <NUM> are located on the plurality of display panels, and the plurality of alignment marks <NUM> which are located on the plurality of display panels are used to match the plurality of alignment marks <NUM> located on the base <NUM> for supporting the plurality of display panels. More particularly, the plurality of alignment marks located on the plurality of display panels are mark patterns which originally exist on the light emitting units <NUM> on the substrate of the plurality of display panels. A number or a shape of the alignment marks <NUM> as illustrated in <FIG> should not be construed as a limitation to the disclosure, as long as the alignment marks <NUM> can achieve the effect of the disclosure. The number and the shape of the alignment marks <NUM> can be adjusted according to practical operations. For instance, the shape of the alignment marks <NUM> can not only be squares, but also circles or diamonds, but the disclosure should not be limited thereto. More particularly, the base is a QDCF (Quantum Dot Color Filter) substrate, The method of forming alignment marks <NUM> of the base <NUM> may include lithography process or laser process, but the disclosure is not limited thereto. The alignment marks <NUM> can be formed on the base <NUM> by lithography process, or the alignment marks <NUM> can be formed in the base <NUM> by laser process, for instance.

After the Step S20, Step S12 is performed, in the Step S12, the plurality of display panels, such as display panels 100A, 100B and 100C, are tiled with reference to the plurality of alignment marks <NUM>. More particularly, the tiling of the plurality of display panels is performed by aligning each of the plurality of display panels with reference to at least one of the plurality of alignment marks <NUM>. For instance, the plurality of display panels, such as display panels 100A, 100B and 100C as illustrated in <FIG>, can be aligned one by one with reference to at least one of the plurality of alignment marks <NUM>, or at least two of the plurality of display panels can be aligned at the same time with reference to at least one of the plurality of alignment marks <NUM>. The definition of "at the same time" means that the alignment is completed in the same step or in the same order. The number of display panels aligned each time can be adjusted according to practical operations, the method of the disclosure may be suitable for multi-panel arrangement. In addition, the tiling of the display panels is performed by aligning each of the display panels with reference to the alignment marks on the base, the risk of cumulative shift of the panel can be efficiently reduced.

<FIG> is a schematic top view of a method of manufacturing a tiled display device according to another embodiment of the disclosure.

With reference to <FIG> and <FIG>, when the Step S12 is performed, the plurality of display panels, such as display panels 100A, 100B, 100C, 100D and 100E as illustrated in <FIG>, are tiled with reference to the plurality of alignment marks <NUM>. A number of the display panels should not be construed as a limitation to the disclosure. The number of the display panels can be adjusted according to practical operations. The alignment marks <NUM> are so arranged that the plurality of display panels are tiled to make the same interpitches, such as P1 and P2, in at least one direction D1. In the embodiment, the definition of "interpitches" means a closest distance between two closest light emitting units <NUM> in any two adjacent display panels. These two closest light emitting units <NUM> can be two light emitting units of the same color or different colors. For instance, as for RGB (red, green, blue) chips, the definition of "interpitches" means the closest distance between two light emitting units <NUM> of the same color in display panels 100A and 100B. The definition of "same interpitches" means that the difference of |P2-P11| is less than or equal to P1/<NUM>. The direction D1 of the same interpitches P1 and P2 as illustrated in <FIG> should not be construed as a limitation to the disclosure. The definition of interpitches in direction D2 is similar to the definition of interpitches in direction D1. In other words, the interpitches in at least one direction may be the same no matter whether the direction is D1 or D2, but no limited thereto. The interpitches in direction D1 or D2 can also be the same as pitches of the plurality of display panels, so that the conformity of the picture can be higher when driving the tiled electronic device. The definition of "the pitches of the plurality of display panels" means the closest distance between two light emitting units <NUM> of the same color in one of the plurality of display panels. For example, as shows in <FIG>, a pitch P3 in the direction D1 is the pitch of the display panel 100A, and the interpitch P1 or P2 in direction D1 or D2 can be the same as pitch P3 of the plurality of display panels. The definition of "the interpitch P1 or P2 is the same as pitch P3" means that the difference of |P3-P1| is less than or equal to P1/<NUM> or the difference of |P3-P2| is less than or equal to P2/<NUM>. The tiling of the display panels 100A, 100B, 100C, 100D and 100E can be performed by aligning each of the display panels 100A, 100B, 100C, 100D and 100E with reference to the alignment marks <NUM> on the base <NUM>, so the risk of cumulative shift of the display panel can be efficiently reduced.

<FIG> is a schematic top view of a method of manufacturing a tiled display device according to an embodiment of the disclosure. <FIG> are schematic cross-sectional views taken along a sectional line A-A' in <FIG>.

Afterwards, with reference to <FIG>, <FIG>, <FIG>, Step S14 is performed, in the Step S14, the plurality of display panels are fixed by fixing member <NUM>. The material of the fixing member <NUM> can include adhesive material, tape, or encapsulant (epoxy resin, silicon resin, acrylic resin, polyimide resin), but the disclosure is not limited thereto. As such, in one embodiment of the disclosure, the method of manufacturing a tiled display device is accomplished, and a tiled display device is obtained. Referring to <FIG>, when the material of the base <NUM> includes glass, plastic or metal, the light L1 emits from the light emitting units <NUM> back to the base <NUM>. The display panels 100A and 100B includes a substrate <NUM>, a plurality of light emitting units <NUM> disposed on the substrate <NUM>, a driving structure (not shown) disposed on the substrate <NUM>, and a protecting film <NUM>, respectively. The driving structure may be a thin film transistor structure for example, but not limit thereto. The plurality of light emitting units <NUM> can be driven by the driving structure. As for the embodiment shown in <FIG>, the mark patterns which originally exist on the light emitting units <NUM> are used as alignment marks to match the other alignment marks <NUM> located on the base <NUM>. In other words, the alignment marks located on the plurality of display panels 100A and 100B are mark patterns which originally exist on the light emitting units <NUM> on the substrate <NUM> of the plurality of display panels 100A and 100B. A shape of the alignment marks is not limited, as long as the alignment marks can achieve the effect of the disclosure. The alignment of alignment marks <NUM> on the base <NUM> and the mark patterns on the light emitting units <NUM> can be center-to-center (as shown in <FIG>, a line AL passes through a center of the alignment mark <NUM> on the base <NUM> and a center of the mark pattern on the light emitting units <NUM>), edge-to-edge or other suitable alignment methods. Referring to <FIG>, when the material of the base <NUM> includes transparent material, the light L2 emits from the light emitting units <NUM> and passes through the base <NUM>. The transparent material may include glass, sapphire, polycarbonate, polyimide(PI), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), cyclo olefin polymer (COP), or triacetyl cellulose (TAC), etc., for example.

<FIG> is a schematic top view of a method of manufacturing a tiled display device not according to the claimed invention. <FIG> are schematic cross-sectional views taken along a sectional line B-B' in <FIG>.

With reference to <FIG>, <FIG>, <FIG>, in another method not according to the claimed invention, Step S30 is performed, in the Step S30, a mother substrate <NUM> is prepared. A material of the mother substrate <NUM> includes glass, plastic or metal. After the Step S30, Step S16 is performed, the mother substrate <NUM> is attached to the plurality of display panels, such as display panels 100A, 100B, 100C, and 100D as illustrated in <FIG> and <FIG>, through fixing member <NUM>. The material of the fixing member <NUM> can include adhesive material, tape, or encapsulant (epoxy resin, silicon resin, acrylic resin, polyimide resin), but the disclosure is not limited thereto. The alignment marks <NUM> includes portions <NUM>-<NUM> and <NUM>-<NUM>. Portions <NUM>-<NUM> are alignment marks additionally made on the substrate <NUM> during the same process of at least one layers of the driving structure, and portions <NUM>-<NUM> are alignment marks located on the base <NUM>. As shown in <FIG> and <FIG>, the portions <NUM>-<NUM> on the substrate <NUM> are used to match the portions <NUM>-<NUM> located on the base <NUM>. The alignment of the portions <NUM>-<NUM> on the substrate <NUM> and the portions <NUM>-<NUM> located on the base <NUM> can be center-to-center (as shown in <FIG>, a line AL passes through a center of the portion <NUM>-<NUM> on the substrate <NUM> and a center of the portion <NUM>-<NUM> located on the base <NUM>), edge-to-edge or other suitable alignment methods. Referring to <FIG> and <FIG>, Step S18 is performed, the base <NUM> is separated from the mother substrate <NUM> and the plurality of display panels 100A and 100B, because the adhesion between the base <NUM> and the plurality of display panels may be weaker than the adhesion through attachment member <NUM> between the mother substrate <NUM> and the plurality of display panels due to adhesion material selection. More particularly, the method of separation includes <NUM>) The display panels 100A and 100B are temporarily adhered to the base <NUM>, and the base <NUM> can be separated from the mother substrate <NUM> and the plurality of display panels 100A and 100B by thermal processing or UV exposing or <NUM>) The display panels 100A and 100B are temporarily fixed on the base <NUM> by vacuum, and the base <NUM> can be separated from the mother substrate <NUM> and the plurality of display panels 100A and 100B by closing the vacuum. As such, referring to <FIG>, the method of manufacturing a tiled display device is accomplished, and a tiled display device <NUM> is obtained. The upward light L emits from the light emitting units <NUM> of the display panels 100A and 100B, as shown in the direction of light L in <FIG>. In other configurations, the downward light L (the opposite direction of light L in <FIG>) emits from the light emitting units <NUM> of the display panels 100A and 100B, and the emitted light L can passes through the mother substrate <NUM>. In further another configurations, the display panels 100A and 100B module can be turned upside down, so that the light L of the light emitting units <NUM> can pass through the mother substrate <NUM>, but not limited thereto.

Claim 1:
A method of manufacturing a tiled display device, comprising:
providing a plurality of display panels (100A, 100B, 100C, 100D, 100E), the plurality of display panels (100A, 100B, 100C, 100D, 100E) including a plurality of light emitting units (<NUM>);
providing a plurality of alignment marks (<NUM>), wherein
at least a portion of the plurality of alignment marks (<NUM>) are located on a base (<NUM>) for supporting the plurality of display panels (100A, 100B, 100C, 100D, 100E), and at least another portion of the plurality of alignment marks (<NUM>) are mark patterns which exist on the light emitting units of the plurality of display panels (100A, 100B, 100C, 100D, 100E),
the base is a quantum dot color filter; and the method further comprises
tiling the plurality of display panels (100A, 100B, 100C, 100D, 100E) with reference to the plurality of alignment marks (<NUM>) by matching the another portion of the plurality of alignment marks on the plurality of light emitting units to the portion of the plurality of alignment marks on the base; and
fixing the plurality of display panels by a fixing member (<NUM>),
wherein the alignment marks (<NUM>) are so arranged that the display panels (100A, 100B, 100C, 100D, 100E) are tiled to make all the same interpitches (P1, P2), and the interpitch (P1, P2) is a closest distance between two closest light emitting units (<NUM>) in any two adjacent display panels.