Patent ID: 12205927

DETAILED DESCRIPTION

For clearer descriptions of the principles, technical solutions, and advantages of the present disclosure, the embodiments of the present disclosure are hereinafter described in detail with reference to the accompanying drawings.

In related arts, in an LED display device formed by splicing a plurality of LED array substrates, the border of each LED array substrate is relatively wide, such that a seam visible to the human eyes is formed in the LED display device, thereby affecting a display effect of the LED display device. An embodiment of the present disclosure provides an array substrate, which solves the problem of wide seams formed in the splicing of the LED display device at least by reducing the border width of each LED array substrate.

FIG.1is a schematic structural diagram of an array substrate according to an embodiment of the present disclosure. As shown inFIG.1, the array substrate0includes a base substrate01, an organic material layer02, a lead structure03, an LED layer04and a control circuit05.

The base substrate01includes a first side X1 and a second side X2 opposite to each other, and a third side X3 adjacent to the first side X1 and the second side X2.

The organic material layer02includes a first planar portion021, a bending portion022, and a second planar portion023which are connected in sequence. The first planar portion021is disposed on the first side X1 of the base substrate01, the second planar portion023is disposed on the second side X2 of the base substrate01, and the bending portion022is disposed on the third side X3.

The lead structure03includes a first lead portion031, a bent lead portion032, and a second lead portion033which are connected in sequence. The first lead portion031is disposed on a side of the first planar portion021distal from the base substrate01, the bent lead portion032is disposed on a side of the bending portion022distal from the base substrate01, and the second lead portion033is disposed on a side of the second planar portion023distal from the base substrate01.

The LED layer04is disposed on a side of the first lead portion031distal from the base substrate01, and is connected to the first lead portion031.

The control circuit05is disposed on the second side X2 of the base substrate01and is connected to the second lead portion033, and the control circuit05is configured to control the LED layer04to emit light.

In summary, in the array substrate provided by the present embodiment of the present disclosure, the organic material layer and the lead structure are both bent to the second side of the base substrate, such that the lead structure is bound with the control circuit on the other side (the second side) of the base substrate where the LED layer is disposed, instead of a side (the first side) where the LED layer is disposed. This avoids the problem of a relatively wide border of the array substrate caused by binding the lead structure with the control circuit on the side (the first side) where the LED layer is disposed. When a plurality of display substrates is spliced, a width of a seam between every two adjacent display substrates can be effectively reduced.

In some embodiments, a material of the base substrate01includes a rigid material (such as glass, and the like), or a flexible material with a certain strength (such as polyethylene terephthalate (PET)), or metal, and the like. In the embodiments of the present disclosure, when the base substrate01is made of a rigid material, the base substrate01is a rigid substrate.

FIG.2is a schematic structural diagram of a base substrate according to an embodiment of the present disclosure. As shown inFIG.2, based onFIG.1, the base substrate01includes the third side X3 adjacent to the first side X1 and the second side X2. A connection portion between the surface of the second side X2 and the surface of the third side X3 may include a chamfered structure011. In the presence of the chamfered structure011, when the organic material layer02is bent from the first side X1 to the second side X2, the probability that the organic material layer02is damaged by a right angle of base substrate01can be reduced, thereby protecting the organic material layer02.

The organic material layer02may be made of any flexible material, such as polyimide (PI), and the like. A thickness of the organic material layer02may be within [5 micrometers, 10 micrometers], or within other ranges (such as [2 micrometers, 11 micrometers]). The lead structure03may be made of any electrically conductive material, such as copper or iron, and the like.

It should be noted that, in any of the array substrates according to the embodiments of the present disclosure, the organic material layer02may include a first planar portion021, m bending portions022, and m second planar portions023. When the base substrate01is in a shape of a polygon, m≥1.FIG.1is a schematic diagram of an embodiment with m=2; m>2, the m bending portions022are respectively disposed on different third sides X3 of the base substrate01; and the m second planar portions023are all disposed on the second side X2 of the base substrate01. The entire surface of the first planar portion021is on the first side X1 of the base substrate01, and the first planar portion021is connected to an ithsecond planar portion023through an ithbending portion022to form an integrated structure, 1≤i≤m.

The lead structure03includes n first lead portions031, n bent lead portions032, and n second lead portions033. The jthfirst lead portion031is connected to a jthlead portion031through a jthsecond lead portion033, and 1≤j≤n. Then first lead portions031are all disposed on the first planar portion021. The n bent lead portions032may all be disposed on the same bending portion022, or may be grouped, and a plurality of bent lead portions032in each group which are the same or different in quantity are respectively disposed on a plurality of bending portions022. The n second lead portions031may all be disposed on the same second planar portion023, or may be grouped, and a plurality of second lead portions031in each group which are the same or different in quantity are respectively disposed on a plurality of second planar portions023.

The n first lead portions031include all or part of a set of signal lines such as power lines, drive lines, data lines, and fan-out lines. The lead structure03is configured to connect each LED in the LED layer and a control circuit, such that an electrical signal in the control circuit can be transmitted to each LED with high quality, making the LED emit light. In some embodiments, the first lead portion further includes a connecting electrode that directly contacts and is electrically connected to each LED.

In addition, the surface of one bending portion022distal from the base substrate01is conformal with the surface of the one or more bent lead portions032, which are disposed on the bending portion022, distal from the base substrate01. At least two surfaces being conformal means that extension directions and undulations of the at least two surfaces are the same or similar.

In an exemplary embodiment,FIGS.3,4,5, and6show schematic diagrams of different types of partial structures of the organic material layer02.FIGS.3,4,5, and6only show the first planar portion021and the bending portion022of the organic material layer02, without the second planar portion023. In addition, the positions of the bending portion022relative to the first planar portion021inFIGS.3,4,5, and6may be matched with the shape of the base substrate. m=1 is taken as an example inFIG.3, m=2 is taken as an example inFIG.4, m=3 is taken as an example inFIG.5, and m=4 is taken as an example inFIG.6. In some embodiments, when the plane where the base substrate is disposed is in the shape of a pentagon, the first planar portion021is also in a shape of a pentagon, and m=5 at this time; or, when the plane where the base substrate is disposed is in the shape of a hexagon, the first planar portion021is also in the shape of a hexagon, and m=6 at this time, and so on. In addition, when m=1, the bending portion022may not be disposed on the right side of the first planar portion021as that shown inFIG.3, for example, the bending portion022may be disposed on any side of the first planar portion021except the right side. When m=2, two bending portions022may not be disposed on the left and right sides of the first planar portion021as those shown inFIG.4, for example, one of the two bending portions022may be disposed on the top side of the first planar portion021, and the other may be disposed on the right side of the first planar portion021, and the like. When m=3, three bending portions022may not be disposed on the left, right and top sides of the first planar part021as those shown inFIG.5, for example, the three bending portions022may be disposed on the left, right and bottom sides of the first planar part021respectively. In the present embodiment of the present disclosure, the first planar portion021of the organic material layer is rectangular as an example. The first planar portion021may not be rectangular, but instead circular, elliptical, a triangular or the like. The expanded schematic diagram of the organic material layer02inFIG.1may refer toFIG.4.

In some embodiments, in order to increase the surface tension of the bent lead portion and reduce the risk of breakage of the bending lead portion during the bending process, a recessed region may be provided on the surface of the bent lead portion032in the embodiments of the present disclosure. In an exemplary embodiment, the embodiment of the present disclosure is described by taking the surface of the bent lead portion032distal from the base substrate01having a recessed region as an example. It is also possible that the surface of the bent lead portion032proximal to the base substrate01has a recessed region, or both the surfaces of the bend lead portion032proximal to and distal from the base substrate01have recessed regions, which is not be limited in the embodiments of the present disclosure.

In an exemplary embodiment, for any of the array substrates according to the embodiments of the present disclosure,FIG.7shows an expanded schematic diagram of the bent lead portion and the bending portion. As shown inFIG.7, a first recessed region0321may be provided on the surface of the bent lead portion032distal from the base substrate by forming a groove and/or a protrusion on the surface of the bent lead portion032distal from the base substrate. The region in the surface of the bent lead portion032distal from the base substrate except the first recessed region0321is a first protruded region0322. With respect to a position where the first recessed region0321of the bent lead portion032is disposed, a minimum distance between the surface of the bent lead portion032distal from the base substrate and the surface of the bent lead portion032proximal to the base substrate is Y1; and with respect to a position where the first protruded region0322of the bent lead portion032is disposed, a distance between the surface of the bent lead portion032distal from the base substrate and the surface of the bent lead portion032proximal to the base substrate is Y2, and Y1<Y2. In the embodiments of the present disclosure, the recessed region (such as the abovementioned first recessed region) in the bent lead portion032may be formed by means of forming a groove on the bent lead portion. The groove may be formed by means of exposure and dry etching processes.

In another exemplary embodiment, for any of the array substrates according to the embodiments of the present disclosure,FIG.8shows another expanded schematic diagram of the bent lead portion and the bending portion. As shown inFIG.8, a second recessed region0221may be provided on the surface of the bending portion022distal from the base substrate by methods of forming a groove and/or a protrusion on the surface of the bending portion022distal from the base substrate. The region in the surface of the bending portion022distal from the base substrate except the second recessed region0221is a second protruded region0222. In the presence of the second recessed region0221on the bending portion022, the surface of the bent lead portion032distal from the base substrate has the first recessed region0321. The region in the surface of the bent lead portion032distal from the base substrate except the first recessed region0321is the first protruded region0322.

With respect to a position where the first recessed region0321of the bent lead portion032is disposed, a minimum distance between the surface of the bent lead portion032distal from the base substrate and the surface of the bent lead portion032proximal to the base substrate is Y1; and with respect to a position where the first protruded region0322of the bent lead portion032is disposed, a distance between the surface of the bent lead portion032distal from the base substrate and the surface of the bent lead portion032proximal to the base substrate is Y2, and Y1=Y2. With respect to a position where the second recessed region0221of the bending portion022is disposed, a minimum distance between the surface of the bending portion022distal from the base substrate and the surface of the bending portion022proximal to the base substrate is Y3; and with respect to a position where the second protruded region0222of the bending portion022is disposed, a distance between the surface of the bending portion022distal from the base substrate and the surface of the bending portion022proximal to the base substrate is Y4, and Y3<Y4.

In the embodiments of the present disclosure, the second recessed region may be formed by methods of forming a groove on the bending portion. The groove may be formed by methods of exposure and dry etching processes.

In some embodiments, the shape of any of the aforementioned recessed regions may be any shape, such as V-shape, U-shape, or trapezoid, which is not limited in the embodiments of the present disclosure.

In some embodiments, in any of the array substrates according to the embodiments of the present disclosure, the LED layer may include a plurality of LEDs. The LEDs may be ordinary LEDs or miniature LEDs. The miniature LED has a size smaller than the ordinary LED. In an exemplary embodiment, the minimum size of the miniature LED can reach a micron level. The miniature LEDs in the embodiments of the present invention may include: micro light emitting diodes (micro LEDs) or mini light emitting diodes (mini-LEDs). The LEDs in the LED layer may be fixed on a flexible substrate provided with connecting electrodes by methods of any method (such as reflow soldering or eutectic soldering).

In an exemplary embodiment, for any of the array substrates according to the embodiments of the present disclosure,FIG.9shows a schematic diagram of a plurality of LEDs41in an LED layer04. As shown inFIG.9, these LEDs041are all disposed on a side of the first lead portion031distal from the base substrate01. The length of any LED041in an extension direction D of the base substrate01may be expressed as 2a. A distance between centers of any two LEDs041in the plurality of LEDs041may be expressed as P. A distance between the bending portion022(not shown inFIG.9, please refer toFIG.1) and the LED041proximal to the bending portion022among the plurality of LEDs041may be expressed as b. The array substrate may satisfy at least one of the conditions: b≥0.6a and b<P/2. For example, the array substrate satisfies b≥0.6a or b<P/2, or b≥0.6a and b<P/2. After testing and verification, when b≥0.6a, a luminous effect of the LEDs041is better, and accordingly, a display effect of the LED layer04is better. When b<P/2, a splicing effect between the array substrates is better, and accordingly, a display effect of a display device formed by splicing a plurality of array substrates is better.

In some embodiments, the array substrate according to the present embodiment of the present disclosure may further include: a black adhesive (represented by06inFIG.1). The black adhesive is filled among the plurality of LEDs to improve the contrast of the respective LEDs. The black adhesive can also slightly cover a side of each LED distal from the base substrate, and at least part of light emitted by the LED can transmit through the black adhesive, which is not limited in the embodiments of the present disclosure.

In some embodiments, the control circuit provided by the present embodiment of the present disclosure may be any type of control circuit. The following will take eight types of control circuits as examples for description.

(1)FIG.10is an expanded schematic diagram of a partial structure inFIG.1according to an embodiment of the present disclosure. With reference toFIG.1andFIG.2, a control circuit05includes a flexible printed circuit (FPC)051and a printed circuit board (PCB)052. The FPC051is disposed on a side of a lead structure (such as the second lead portion033in the lead structure) distal from the base substrate01, and is connected to the second lead portion033and the PCB052. The PCB052may be disposed on either side of the FPC051. In the present embodiment of the present disclosure, for example, the PCB052and the second lead portion033are disposed on the same side of the FPC051.

(2)FIG.11is an expanded schematic diagram of a partial structure in an array substrate according to an embodiment of the present disclosure. As shown inFIG.11, based onFIG.10, the control circuit05includes a FPC051, but does not include a PCB052. The FPC051is disposed on the side of the second lead portion033distal from the base substrate01and is connected to the second lead portion033.

(3)FIG.12is an expanded schematic diagram of a partial structure in another array substrate according to an embodiment of the present disclosure. As shown inFIG.12, based onFIG.10, the control circuit05includes not only a FPC051and a PCB052, but also a chip053. The FPC051is disposed on the side of the second lead portion033distal from the base substrate01, and is connected to the second lead portion033and the PCB052; and the PCB052may be disposed on either side of the FPC051, for example, in the present embodiment of the present disclosure, the PCB052and the second lead portion033are disposed on the same side of the FPC051. The chip053is disposed on the side of the second lead portion033distal from the base substrate01and is connected to the second lead portion033. The chip053and the FPC051are disposed on the same layer.

(4)FIG.13is an expanded schematic diagram of a partial structure in another array substrate according to an embodiment of the present disclosure. As shown inFIG.13, based onFIG.12, the control circuit05may not include the PCB052.

(5)FIG.14is an expanded schematic diagram of a partial structure in another array substrate according to an embodiment of the present disclosure. As shown inFIG.14, based onFIG.10, the control circuit05includes not only a FPC051and a PCB052, but also a chip053. The FPC051is disposed on the side of the second lead portion033distal from the base substrate01. The PCB052may be disposed on either side of the FPC051. In the present embodiment of the present disclosure, for example, the PCB052and the second lead portion033are disposed on the same side of the FPC051. The chip053is disposed on a side of the FPC051distal from the base substrate01, and the FPC051is connected to the second lead portion033, the PCB052, and the chip053. When the chip053is disposed on the FPC051, the chip053and the FPC051may be collectively referred to as chip on film (COF).

(6)FIG.15is an expanded schematic diagram of a partial structure in another array substrate according to an embodiment of the present disclosure. As shown inFIG.15, based onFIG.14, the control circuit05may not include the PCB052.

(7)FIG.16is an expanded schematic diagram of a partial structure in another array substrate according to an embodiment of the present disclosure. As shown inFIG.16, based onFIG.10, the control circuit05includes a connector054. The connector054is disposed on the side of the second lead portion033distal from the base substrate01, and is connected to the second lead portion033and the PCB052. The PCB052may be disposed on either side of the connector054. In the present embodiment of the present disclosure, for example, the PCB052and the second lead portion033are disposed on the same side of the connector054.

(8)FIG.17is an expanded schematic diagram of a partial structure in another array substrate according to an embodiment of the present disclosure. As shown inFIG.17, based onFIG.10, the control circuit05includes a terminal (such as a lead)055. The terminal055is disposed on the side of the second lead portion033distal from the base substrate01, and is connected to the second lead portion033and the PCB052. The PCB052may be disposed on either side of the terminal055. In the present embodiment of the present disclosure, for example, the PCB052and the second lead portion033are disposed on the same side of the terminal055.

In some embodiments, regardless of the manner by which the control circuit05is implemented, the array substrate according to the embodiment of the present disclosure may further include: an adhesive disposed between the base substrate01and the control circuit05(see an adhesive07inFIG.1). In the presence of the adhesive, the control circuit05can be effectively fixed on the base substrate01, thereby ensuring the stability of the array substrate01. The adhesive may be rubber. In an exemplary embodiment, when the control circuit05includes a PCB, the adhesive may be configured to adhere the PCB with the base substrate01. When the control circuit05does not include a PCB, the adhesive may be configured to adhere FPC with the base substrate.

Further, as shown inFIG.1, the array substrate provided by the embodiment of the present disclosure may further include a first spacer structure08disposed between the base substrate01and the bending portion022. The first spacer structure08can support the bending portion022to prevent the bending portion022from breaking.

In some embodiments, the first spacer structure08may be made of any material, such as a material with adhesion or a material without adhesion. When the first spacer structure08is adhesive, the first spacer structure08can not only support the bending portion022, but also fix the bending portion022with the base substrate01, so as to improve the stability of the array substrate.

In some embodiments, in the array substrate according to the embodiment of the present disclosure, the surface of the first spacer structure distal from the base substrate may include an arc face. The arc face can improve a supporting effect of the first spacer structure on the bending portion. In an exemplary embodiment, the first spacer structure is diversified in shape. Four shapes of the first spacer structures will be described below as examples.

(1)FIG.18is a schematic diagram of a first spacer structure according to an embodiment of the present disclosure (a wire structure is not shown inFIG.18). As shown inFIG.18, the surface of the first spacer structure08distal from the base substrate01is a semicircular arc face. In addition, in an arrangement direction Z1 of the base substrate01and the first spacer structure08, a maximum length Z2 of the first spacer structure08is greater than the radius R of the semicircular arc face.

(2)FIG.19is a schematic diagram of another first spacer structure according to an embodiment of the present disclosure (a wire structure is not shown inFIG.19). As shown inFIG.19, based onFIG.18, the array substrate further includes a second spacer structure09disposed between a base substrate01and a second planar portion022, and the second spacer structure09is connected to the first spacer structure08. At this time, a contact area between the base substrate01and an entire body formed by the first spacer structure08and the second spacer structure09is relatively large, such that the array substrate has better stability and is easier to be assembled. In some embodiments, a side of the first spacer structure08proximal to the second spacer structure09is disposed on an extension plane of the third side X3, and a side of the second spacer structure09proximal to the first spacer structure08is disposed on the extension plane of the third side X3. It can be understood that when a connection portion between the second side X2 and the third side X3 includes a chamfered structure, the side of the first spacer structure08proximal to the second spacer structure09and the side of the second spacer structure09proximal to the first spacer structure08are both disposed on an extension plane of a plane where a main region except the chamfered structure of the third side X3 is disposed. The first spacer structure08and the second spacer structure09may be of an integral structure.

It should be noted that an extension length of the second spacer structure09is not limited in the embodiments of the present disclosure. In an exemplary embodiment, when a structure (such as an adhesive07inFIG.1) needs to be provided on the second side of the base substrate, the second spacer structure09may extend to a position where this structure is disposed, and may be disposed between the base substrate and this structure; or, the second spacer structure09may also extend through the position where this structure is disposed, and may be disposed between the base substrate and this structure; or, the second spacer structure09may not extend to the position where this structure is disposed, and in this case, the second spacer structure09and this structure are arranged side by side on the second side of the base substrate.

(3)FIG.20is a schematic diagram of another first spacer structure according to an embodiment of the present disclosure (a wire structure is not shown inFIG.20). As shown inFIG.20, the surface of the first spacer structure08distal from the base substrate01includes a first arc face, a plane and a second arc face which are connected in sequence, wherein a radius R1 of the first arc face is equal to a radius R2 of the second arc face.

(4)FIG.21is a schematic diagram of another first spacer structure according to an embodiment of the present disclosure (a wire structure is not shown inFIG.21). As shown inFIG.21, based onFIG.20, the array substrate further includes a second spacer structure09. For details about the second spacer structure09inFIG.21, reference may be made to the second spacer structure09inFIG.19, which are not repeated in the embodiment of the present disclosure.

(5)FIG.22is a schematic diagram of another first spacer structure according to an embodiment of the present disclosure (a wire structure is not shown inFIG.22). As shown inFIG.22, the surface of the first spacer structure08distal from the base substrate01includes n first arc faces, a plane, and n second arc faces, which are connected in sequence, n>1. The radii of the n first arc faces are different from each other, and the radius of an ithfirst arc face is equal to the radius of an (n−i+1)thsecond arc face, 1≤i≤n. InFIG.22, n=2 is taken as an example. In this case, the first spacer structure08has two first arc faces and two second arc faces, wherein the radius R11 of a 1stfirst arc face is equal to the radius R22 of a 2ndsecond arc face, and the radius R12 of the 2ndfirst arc face is equal to the radius R21 of the 1stsecond arc face.

(6)FIG.23is a schematic diagram of yet another first spacer structure according to an embodiment of the present disclosure (a wire structure is not shown inFIG.23). As shown inFIG.23, when n=3, the first spacer structure08has three first arc faces and two second arc faces, wherein the radius R11 of the 1stfirst arc face is equal to the radius R23 of a 3rdsecond arc face, the radius R12 of the 2ndfirst arc face is equal to the radius R22 of the 2ndsecond arc face, and the radius R13 of the 3rdfirst arc face is equal to the radius R21 of the 1stsecond arc face.

(7)FIG.24is a schematic diagram of yet another first spacer structure according to an embodiment of the present disclosure (a wire structure is not shown inFIG.24). As shown inFIG.24, based onFIG.22, the array substrate further includes a second spacer structure09. The second spacer structure09inFIG.24may refer to the second spacer structure09inFIG.19, and the details are not repeated in the embodiment of the present disclosure.

(8)FIG.25is a schematic diagram of another first spacer structure according to an embodiment of the present disclosure (a wire structure is not shown inFIG.25). As shown inFIG.25, based onFIG.23, the array substrate further includes a second spacer structure09. The second spacer structure09inFIG.25may refer to the second spacer structure09inFIG.19, and the details are not repeated in the embodiment of the present disclosure.

Further,FIG.26is a schematic structural diagram of another array substrate according to an embodiment of the present disclosure. As shown inFIG.26, based onFIG.1, the array substrate further includes a binding substrate10disposed between the base substrate01and the second planar portion023. In some embodiments, the base substrate01may be made of the same material as the binding substrate10, and a thickness of the base substrate01is the same as a thickness of the binding substrate10. The base substrate01may be configured to support the second planar portion023. It should be noted that the array substrate shown inFIG.26may include the abovementioned spacer structures (such as the first spacer structure021and the second spacer structure023), or may not include a spacer structure. The spacer structure is not shown inFIG.26.

In some embodiments, the array substrate further includes a light reflecting layer disposed between the base substrate and the first planar portion. In an exemplary embodiment,FIG.27is a schematic structural diagram of another array substrate according to an embodiment of the present disclosure. As shown inFIG.27, based onFIG.1, the array substrate further includes a light reflecting layer11. In some embodiments, a distance between the light reflecting layer11and the bending portion022is greater than 0.

In some embodiments,FIG.28is a schematic structural diagram of another array substrate according to an embodiment of the present disclosure. As shown inFIG.28, based onFIG.26, the array substrate further includes a light reflecting layer11. The light reflecting layer11includes a first light reflecting portion111disposed between the base substrate01and the first planar portion021, and a second light reflecting portion112disposed between the binding substrate10and the second planar portion023. In some embodiments, a distance between the first light reflecting portion111and the bending portion022is greater than 0, and a distance between the second light reflecting portion112and the bending portion022is also greater than 0.

In summary, in the array substrates according to the embodiments of the present disclosure, the organic material layer and the lead structure are both bent to the second side of the base substrate, such that the lead structure is bound with the control circuit on the other side (the second side) of the side (the first side) where the LED layer is disposed. This avoids the problem of a relatively wide border of the array substrate caused by binding the lead structure with the control circuit on the side (the first side) where the LED layer is disposed. When a plurality of display substrates are spliced, a seam between every two adjacent display substrates can be effectively reduced.

An embodiment of the present disclosure provides a display device. The display device may include any of the array substrates according to the embodiments of the present disclosure. In some embodiments, the display device may further include cover plates which are in one-to-one correspondence to the array substrates according to the embodiment of the present disclosure, and each cover plate is disposed on a side of an LED layer in the corresponding array substrate distal from a base substrate.

In an exemplary embodiment, the display device may be any product or component having a display function, such as electronic paper, a mobile phone, a tablet computer, a television, a display, a laptop computer, a digital photo frame, or a navigator.

In some embodiments,FIG.29is a schematic structural diagram of a display device according to an embodiment of the present disclosure. The display device20may include a plurality of array substrates0which is spliced with each other. Because a border of the array substrate according to the embodiments of the present disclosure is relatively narrow, a border of the array substrate0according to the present embodiment of the present disclosure is relatively narrow. In the display device20including a plurality of array substrates0that is spliced, a seam between every two adjacent array substrates is relatively narrow. It may be understood that in any two adjacent array substrates0among the plurality of array substrates0arranged in a first direction (as shown in a vertical direction inFIG.29), a distance between two closest LEDs in the first direction is Q1, and a distance between two LEDs arranged in the first direction in each array substrate0is P1, and P1=Q1. In any two adjacent array substrates0among the plurality of array substrates0arranged in a second direction (as shown in a horizontal direction inFIG.29), a distance between two closest LEDs in the second direction is Q2, and a distance between two LEDs arranged in the second direction in each array substrate0is P2, and P2=Q2. As such, when the display device20displays an image, it is difficult for a viewer to notice the existence of borders of adjacent array substrates, that is, it is also difficult or impossible to see seams caused by the splicing of the array substrates.

In some embodiments, the display device20may also include a frame support (not shown inFIG.29) on a non-display side of the plurality of array substrates0. The plurality of array substrates0in the display device20may be fixed on the frame support (for example, the second side of the base substrate in the array substrate is connected to a support) by a mechanical force, an adhesive force, a magnetic force, or the like, such that the plurality of array substrates0is spliced to form the display device20.

In some embodiments, an LED layer in each array substrate includes a plurality of LEDs disposed on a first planar portion, wherein a distance between centers of any two LEDs in the plurality of LEDs is P; and in any two adjacent array substrates in the display device, a distance between centers of two closest LEDs is Q, and P=Q. In some embodiments, the distance between any two adjacent array substrates in the display device is greater than or equal to 0.

In an exemplary embodiment,FIGS.30,31,32,33, and34are schematic diagrams of spliced positions of any two array substrates in five kinds of display devices according to embodiments of the present disclosure. InFIGS.30,31,32, and33, the distance between adjacent array substrates being greater than 0 is taken as an example; and inFIG.34, the distance between adjacent array substrates being equal to 0 is taken as an example. For details about a spacer structure inFIG.30, a spacer structure inFIG.31, a spacer structure inFIG.32, a space structure inFIG.33, and a spacer structure inFIG.34, reference may be made toFIG.18,FIG.21,FIG.24,FIG.25, andFIG.19respectively.

It should be noted that when the distance between adjacent array substrates in the display device is greater than 0, it is less difficult to splice a plurality of array substrates. The smaller the length of the first spacer structure in the array substrate in an arrangement direction of the base substrate and the first spacer structure is, the larger the distance between adjacent array substrates in the display device is, and the less difficult to splice a plurality of array substrates is. Therefore, in the embodiments of the present disclosure, the distance between adjacent array substrates and the abovementioned length of the first spacer structure can be set reasonably according to the difficulty of splicing the array substrates.

An embodiment of the present disclosure provides a method for manufacturing an array substrate. The method is applicable to manufacturing any of the array substrates according to embodiments of the present disclosure. As shown inFIG.35, the method may include the following steps:

Step3501: An initial structure is formed, wherein the initial structure includes a base substrate, an organic material layer, a lead structure, an LED layer, and a control circuit; the base substrate includes a first side and a second side opposite to each other, and a third side adjacent to the first side and the second side; wherein the organic material layer, the lead structure, and the LED layer are all disposed on the first side of the base substrate, and are sequentially arranged in a direction away from the base substrate, and the control circuit and the LED layer are disposed on the same layer; an orthographic projection of the organic material layer on a plane where the base substrate is disposed is partially overlapped with an orthographic projection of the base substrate on the plane where the base substrate is disposed; and a side of the organic material layer distal from the base substrate is covered by the lead structure, and the lead structure is connected to the LED layer and the control circuit.

Step3502: The control circuit is moved from the first side of the base substrate to the second side of the base substrate by bending the organic material layer and the lead structure, wherein the bent organic material layer includes a first planar portion, a bending portion and a second planar portion which are connected in sequence; the first planar portion is disposed on the first side of the base substrate, the second planar portion is disposed on the second side of the base substrate, and the bending portion is disposed on the third side; the bent lead structure includes a first lead portion, a bent lead portion, and a second lead portion which are connected in sequence, wherein the first lead portion is disposed on a side of the first planar portion distal from the base substrate and is connected to the LED layer, the bent lead portion is disposed on a side of the bending portion distal from the base substrate, and the second lead portion is disposed on a side of the second planar portion distal from the base substrate and is connected to the control circuit.

The method for manufacturing the array substrate according to the embodiments of the present disclosure is relatively easy to implement, and therefore, can facilitate mass production.

FIG.36is a flowchart of a method for manufacturing another array substrate according to an embodiment of the present disclosure. The method is used for manufacturing the array substrate shown inFIG.1. As shown inFIG.36, the method may include the following steps.

Step3601: An initial substrate, an organic material layer, a lead structure and an LED layer which are sequentially laminated are formed.

As shown inFIG.37, a plane U2 paralleled to the initial substrate U1 is the plane where the initial substrate U1 is disposed. An orthographic projection of the organic material layer02on the plane U2 is within an orthographic projection of the initial substrate U1 on the plane U2. The lead structure03covers a side of the organic material layer02distal from the initial substrate U1, and is connected to the LED layer04.

In step3601, the organic material layer, the lead structure, and the LED layer may be sequentially formed on the initial substrate.

Further, in3601, a flexible film layer (the flexible film layer may partially cover a basic substrate) and a lead layer may be sequentially formed on the basic substrate first. Then, the basic substrate formed with the flexible film layer and the lead layer is cut into a plurality of substrate units. Each of the substrate units includes an initial substrate obtained by cutting the basic substrate, an organic material layer obtained by cutting the flexible film layer, and a lead structure obtained by cutting the lead layer. Finally, a plurality of LEDs is formed on the lead structure of each substrate unit by means of a mass transfer technology, thereby forming the LED layer on each of the substrate unit.

In some embodiments, when step3601is finished, black adhesive may be applied to a side of the LED layer distal from the initial substrate. The black adhesive can improve a display effect of the LED layer, protect the LED layer, and increase the soldering strength of the LED layer.

Step3602: A control circuit is connected to the lead structure on a side of the lead structure distal from the initial substrate.

The structure obtained by connecting the control circuit05and the lead structure03may be as shown inFIG.38. In the present embodiment of the present disclosure, the control circuit05includes a FPC051and a PCB052, and the lead structure03is connected to the FPC051; a connection is taking example, as the FPC051is connected to the PCB052and the FPC051is connected to the PCB052. The connection portion between FPC051and PCB052is taken as example.

Step3603: A partial region is removed from the initial substrate to obtain an initial structure including the base substrate, the organic material layer, the lead structure, the LED layer, and the control circuit.

An orthographic projection of the partial region on the plane where the initial substrate is disposed is outside an orthographic projection of the LED layer on the plane where the initial substrate is disposed. In an exemplary embodiment, after the partial region of the initial substrate is removed, the initial substrate can be changed to the base substrate01as shown inFIG.39. The organic material layer02, the lead structure03, and the LED layer04are all disposed on a first side X1 of the base substrate01, and are sequentially arranged in a direction away from the base substrate01. The control circuit05and the LED layer04are disposed on the same layer. A plane U3 paralleled to the base substrate01is the plane where the base substrate01is disposed. An orthographic projection of the organic material layer02on the plane U3 is partially overlapped with an orthographic projection of the base substrate01on the plane U3. The lead structure covers a side of the organic material layer02distal from the base substrate01, and is connected to the LED layer04and the control circuit05.

Step3604: The control circuit is moved from the first side of the base substrate to a second side of the base substrate by bending the organic material layer and the lead structure.

As shown inFIG.1, the second side X2 is opposite to the first side X1. The bent organic material layer02includes a first planar portion021, a bending portion022and a second planar portion023which are connected in sequence. The first planar portion021is disposed on the first side X1 of the base substrate01. The bending portion022is bent from the first side X1 to the second side X2 of the base substrate022. The second planar portion023is disposed on the second side X2 of the base substrate01. The bent lead structure03includes a first lead portion031, a bent lead portion032, and a second lead portion033which are connected in sequence, wherein the first lead portion031is disposed on a side of the first planar portion021distal from the base substrate01and is connected to the LED layer04, the bent lead portion032is disposed on a side of the bending portion022distal from the base substrate01, and the second lead portion033is disposed on a side of the second planar portion023distal from the base substrate01and is connected to the control circuit05.

In some embodiments, step3603may be performed in multiple ways. The embodiments of the present disclosure are described by taking the following two implementations as examples.

(1) In step3603, as shown inFIG.40, laser may be irradiated to a region U4 to be separated of the initial substrate U1 from a side of the initial substrate U1 distal from the organic material layer02, such that the region U4 to be separated is separated from the organic material layer02. The partial region U5 to be removed may be disposed in the region U4 to be separated and is smaller than the region U4 to be separated. Then, as shown inFIG.41, the edge of the partial region U5 on the initial substrate U1 may be cut. Finally, as shown inFIG.42, the partial region U5 is peeled off.

In some embodiments, if the prepared base substrate has a chamfered structure proximal to the bending portion, the chamfered structure may be formed in the process of cutting the edge of the partial region U5 on the initial substrate U1.

(2) Further, in step3603, prior to forming the organic material layer on the initial substrate, as shown inFIG.43, a light reflecting layer11may be formed on the initial substrate U1. An orthographic projection of the light reflecting layer11on a plane U2 where the initial substrate is disposed is outside an orthographic projection of the partial region U5 on the plane U2 where the initial substrate is disposed. In some embodiments, the orthographic projection of the light reflecting layer11on the plane U2 where the initial substrate is disposed may be spaced apart from the orthographic projection of the partial region U5 on the plane U2 where the initial substrate is disposed.

In step3603, as shown inFIG.44, laser may be irradiated to the initial substrate U1 from a side of the initial substrate U1 distal from the light reflecting layer11, such that a region irradiated with the laser in the initial substrate U1 (including the abovementioned partial region U5) is separated from the organic material layer02. Because the light reflecting layer11can reflect the laser (for example, the reflectivity of the laser may be greater than 80%, or 90%, or the like), and prevent the laser from transmitting through, a region covered by the light reflecting layer11in the initial substrate U1 is not separated from the organic material layer02. Then, as shown inFIG.45, the edge of the partial region U5 on the initial substrate U1 may be cut. Finally, as shown inFIG.46, the partial region U5 is peeled off.

In practice, the initial structure formed in step3603further includes a light reflecting layer disposed between the base substrate and the organic material layer.

It can be seen that in the second implementation, during the irradiation with laser, since the light reflecting layer can effectively define the region irradiated by the laser in the organic material layer, there is no need to set laser emitted by a laser irradiating device, and the accuracy of laser irradiation can be made less than 1 micron.

In some embodiments, if the prepared base substrate has a chamfered structure proximal to the bending portion, the chamfered structure may be formed in the process of cutting the edge of the partial region U5 on the initial substrate U1.

(3) Further, in step3603, prior to forming the organic material layer on the initial substrate, as shown inFIG.47, a dissociating layer12may be formed on the initial substrate U1. An orthographic projection of the partial region U5 to be removed from the initial substrate U1 on the plane U2 where the initial substrate is disposed is within an orthographic projection of the dissociating layer12on the plane U2 where the initial substrate is disposed; and adhesion between the dissociating layer12and the organic material layer02is less than adhesion between the initial substrate U1 and the organic material layer02. In an exemplary embodiment, the dissociating layer12may be made of a polyimides material, or modified ultraviolet (UV) release adhesive or other materials. In some embodiments, the area of the orthographic projection of the partial region U5 on the plane U2 where the initial substrate is disposed may be smaller than the area of the orthographic projection of the dissociating layer12on the plane U2 where the initial substrate is disposed.

In step3603, as shown inFIG.48, the edge of the partial region U5 on the initial substrate U1 may be cut first. Next, as shown inFIG.49, the partial region U5 and a portion of the dissociating layer12that covers the partial region U5 are peeled off. Since the abovementioned partial region U5 removed from the initial substrate U1 is the same as the region in the initial substrate U1 that is separated from the organic material layer02, there is no need to move a cutting position outward in the process of cutting the partial region U5, which can further reduce the border width of the prepared array substrate (for example, reduce the border width by about 30 microns). In this case, the prepared array substrate may include a portion of the dissociating layer12that does not cover the partial region U5.

In some embodiments, if the prepared base substrate has a chamfered structure proximal to the bending portion, the chamfered structure may be formed in the process of cutting the edge of the partial region U5 on the initial substrate U1.

In some embodiments, if the prepared array substrate needs to include a binding substrate10as shown inFIG.26, after the partial region in the initial substrate is removed in step3603, both the base substrate and the binding substrate can be obtained. It can be seen that in the initial substrate, the base substrate and the binding substrate are respectively disposed on both sides of this partial region. The initial structure obtained in step3603may also include a binding substrate which is spaced apart from the base substrate. Two ends of the organic material layer are lapped on the base substrate and the binding substrate respectively.

In an exemplary embodiment, when the array substrate including the control circuit shown inFIG.10includes an auxiliary substrate10, the initial structure obtained in step3603may be as shown inFIG.50. When the array substrate including the control circuit shown inFIG.11includes an auxiliary substrate10, the initial structure obtained in step3603may be as shown inFIG.51. When the array substrate including the control circuit shown inFIG.12includes an auxiliary substrate10, the initial structure obtained in step3603may be as shown inFIG.52. When the array substrate including the control circuit shown inFIG.13includes an auxiliary substrate10, the initial structure obtained in step3603may be as shown inFIG.53. When the array substrate including the control circuit shown inFIG.14includes an auxiliary substrate10, the initial structure obtained in step3603may be as shown inFIG.54. When the array substrate including the control circuit shown inFIG.15includes an auxiliary substrate10, the initial structure obtained in step3603may be as shown inFIG.55. When the array substrate including the control circuit shown inFIG.16includes an auxiliary substrate10, the initial structure obtained in step3603may be as shown inFIG.56. When the array substrate including the control circuit shown inFIG.17includes an auxiliary substrate10, the initial structure obtained in step3603may be as shown inFIG.57.

In some embodiments, if the prepared array substrate needs to include a spacer structure (such as a first spacer structure, or a first spacer structure and a second spacer structure), before step3604, the spacer structure may be assembled on the side of the base substrate. In step3604, the organic material layer needs to bypass the spacer structure to be bent to the second side of the base substrate.

It should be noted that in the accompanying drawings, for clarity of the illustration, the dimension of the layers and regions may be scaled up. It may be understood that when an element or layer is described as being “above” another element or layer, the described element or layer may be directly on the other element or layer, or at least one intermediate layer may be arranged between the described element or layer and the other element or layer. In addition, it may be understood that when an element or layer is described as being “below” another element or layer, the described element or layer may be directly below the other element or layer, or at least one intermediate layer may be arranged between the described element or layer and the other element or layer. In addition, it may be further understood that when a layer or element is described as being arranged “between” two layers or elements, the described layer or element may be the only layer between the two layers or elements, or at least one intermediate layer or element may be arranged between the described element or layer and the two layers or elements. In the whole specification described above, like reference numerals denote like elements.

In the present disclosure, the terms “first” and “second” are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. The term “a plurality of” refers to two or more, unless specifically defined otherwise.

It should be noted that the method embodiments of the present disclosure may be cross referenced, which is not limited in the embodiments of the present disclosure. The sequence of the steps in the method embodiments of the present disclosure may be adjusted appropriately, and the steps may be deleted or added according to the situation. Within the technical scope disclosed in the present disclosure, any variations of the method easily derived by a person of ordinary skill in the art shall fall within the protection scope of the present disclosure, which is not repeated here.

Described above are merely optional embodiments of the present disclosure, and are not intended to limit the present disclosure. Within the spirit and principles of the present disclosure, any modifications, equivalent substitutions, improvements, and the like should fall within the protection scope of the present disclosure.