DISPLAY TILE WITH INCREASED DISPLAY AREA

Abstract

A display tile having a frame whose compliance is increased in a well determined region to accommodate the different thermal expansions of the frame and one or more substrates to which the frame is fastened. The display tile has also regions of increased compliance that will deform to allow different parts of the frame to be brought into contact and glued to the lateral sides of two superimposed substrates when at least one lateral side of one of the substrates is not coplanar with the corresponding lateral side of the other substrate.

Claims

1-43. (canceled)

44. A frame for a display tile comprising one piece or being split into two or more frame elements or strips, the frame comprising a first material with a first coefficient of thermal expansion, the frame being adapted to be fastened to a substrate by means of a heat activated adhesive tape, wherein the substrate forms part of the display tile, the substrate comprising a second material with a second coefficient of thermal expansion; the one piece frame or each frame element or strip wherein it is divided into three parts: a first part to be glued by means of the heat activated adhesive tape to a lateral side of the substrate, a third part to serve as fastening interface to a support structure and a second part positioned between the first and third part to isolate the third part from strain in the first part.

45. The frame for a display tile according to claim 44, wherein at least one opening extends from an edge of the frame and extends across the first part and the second part of the frame.

46. The frame for a display tile according to claim 44, wherein grooves are formed in the first part and/or the second part of the frame and/or are formed on both sides of the frame.

47. The frame for a display tile according to claim 46, wherein the depth of the grooves is at least 50% of the thickness of the frame.

48. A frame for a display tile comprising one piece or being split into two or more frame elements or strips, the frame being adapted to be fastened to a first substrate and a second substrate by means of an adhesive tape, wherein the first substrate and the second substrate form part of the display tile; the one piece frame or each frame element or strip wherein it is divided into 3 parts: a first part to be glued by means of a heat activated adhesive tape to a lateral side of the first substrate, a third part to be glued by means of the heat activated adhesive tape to a lateral side of the second substrate and a second part positioned between the first and third part, the second part having a higher compliance than the first and third part thereby allowing the first and third part to be positioned in different planes.

49. The frame for a display tile according to claim 48, wherein grooves are formed in the second part of the frame, the grooves being substantially parallel to the first and second substrates, and/or grooves are formed on both sides of the frame.

50. The frame for a display tile according to claim 49, wherein the depth of the grooves is at least 50% of the thickness of the frame.

51. A display tile comprising a frame, the frame being of one piece or being split into two or more frame elements or strips, the frame being made of a first material with a first coefficient of thermal expansion and the frame being adapted to be fastened to a substrate by means of a heat activated adhesive tape, wherein the substrate forms part of the display tile, the substrate being made of a second material with a second coefficient of thermal expansion; the one piece frame or each frame element or strip wherein it is divided into three parts: a first part to be glued by means of the heat activated adhesive tape to a lateral side of the substrate, a third part to serve as fastening interface to a support structure and a second part positioned between the first and third part to isolate the third part from strain in the first part.

52. The display tile according to claim 51, wherein at least one opening extends from an edge of the frame and extends across the first part and the second part of the frame.

53. The display tile according to claim 51, wherein grooves are formed in the first part and/or the second part of the frame and/or grooves are formed on both sides of the frame.

54. The display tile according to claim 53, wherein the depth of the grooves is at least 50% of the thickness of the frame.

55. A display tile comprising a frame, the frame being of one piece or being split into two or more frame elements or strips, and the frame being adapted to be fastened to a first substrate and a second substrate by means of an adhesive tape, wherein the first substrate and the second substrate form part of the display tile; the one piece frame or each frame element or strip wherein it is divided into 3 parts: a first part to be glued by means of a heat activated adhesive tape to a lateral side of the first substrate, a third part to be glued by means of the heat activated adhesive tape to a lateral side of the second substrate and a second part positioned between the first and third part, the second part having a higher compliance than the first and third part thereby allowing the first and third part to be positioned in different planes.

56. The display tile according to claim 55, wherein grooves are formed in the second part of the frame, the grooves being substantially parallel to the first and second substrates, and/or grooves are formed on both sides of the frame.

57. The display tile according to claim 56, wherein the depth of the grooves is at least 50% of the thickness of the frame.

58. A method of fabricating a frame for a display tile, the frame being of one piece or being split into two or more frame elements or strips, the frame being made of a first material with a first coefficient of thermal expansion, the method comprising: fastening the one piece frame or each frame element or strip to a substrate made of a second material with a second coefficient of thermal expansion by means of a heat activated adhesive tape, wherein the substrate forms part of the display tile; fabricating the one piece frame or each frame element or strip in three parts: gluing a first part by means of the heat activated adhesive tape to a lateral side of the substrate, fastening a third part to a support structure and positioning a second part between the first and third part to isolate the third part from strain in the first part.

59. A method of fabricating a frame for a display tile, said frame being of one piece or being split into two or more frame elements or strips, the method comprising: fastening the one piece frame or each frame element or strip to a first substrate and a second substrate forming part of the display tile, by means of an adhesive tape; fabricating the one piece frame or each frame element or strip in 3 parts: gluing a first part by means of a heat activated adhesive tape to a lateral side of the first substrate, gluing a third part by means of the heat activated adhesive tape to a lateral side of the second substrate, and positioning a second part between the first and third part, the second part having a higher compliance than the first and third part thereby allowing the first and third part to be positioned in different planes.

60. A display comprising: at least one display tile, the at least one display tile having a frame, the frame being of one piece or being split into two or more frame elements or strips, the frame being made of a first material with a first coefficient of thermal expansion and being adapted to be fastened to a substrate by means of a heat activated adhesive tape, wherein the substrate forms part of the display tile, the substrate being made of a second material with a second coefficient of thermal expansion; the one piece frame or each frame element or strip wherein it is divided into three parts: a first part to be glued by means of the heat activated adhesive tape to a lateral side of the substrate, a third part to serve as fastening interface to a support structure and a second part positioned between the first and third part to isolate the third part from strain in the first part.

61. The display according to claim 60, wherein at least one opening extends from an edge of the frame and extends across the first part and the second part of the frame.

62. The display according to claim 60, wherein grooves are formed in the first part and/or the second part of the frame and/or grooves are formed on both sides of the frame.

63. The display according to claim 62, wherein the depth of the grooves is at least 50% of the thickness of the frame.

64. A display comprising: a display tile, a frame being of one piece or being split into two or more frame elements or strips, the frame being adapted to be fastened to a first substrate and a second substrate by means of an adhesive tape, wherein the first substrate and the second substrate form part of the display tile; the one piece frame or each frame element or strip wherein it is divided into 3 parts: a first part to be glued by means of a heat activated adhesive tape to a lateral side of the first substrate, a third part to be glued by means of the heat activated adhesive tape to a lateral side of the second substrate and a second part positioned between the first and third part, the second part having a higher compliance than the first and third part thereby allowing the first and third part to be positioned in different planes.

65. The display according to claim 64, wherein grooves are formed in the second part of the frame, the grooves being substantially parallel to the first and second substrates and/or grooves are formed on both sides of the frame.

66. The display according to claim 65, wherein the depth of the grooves is at least 50% of the thickness of the frame.

67. The display according to claim 64, wherein the third part forms an interface with a backlight element or a support structure.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0039] FIG. 1 shows a schematic representation of a tiled display.

[0040] FIG. 2A shows an exploded view of a display tile, its frame and a backlight structure.

[0041] FIG. 2B shows an example of profile for a non-planar frame element.

[0042] FIGS. 3A, 3B and 3C show how the substrate and the frame are fastened together by means of a heat activated adhesive tape in accordance with an embodiment of the present invention.

[0043] FIGS. 4A and 4B show the deformation of the frame and the substrate during and after heat activation of the adhesive tape of an embodiment of the present invention.

[0044] FIG. 5 shows a first adaptation of the frame to prevent deformation of the substrate caused by strain in the region of the frame that is glued to the substrate in accordance with an embodiment of the present invention.

[0045] FIG. 6 shows a second adaptation of the frame in accordance with an embodiment of the present invention.

[0046] FIGS. 7A and 7B illustrate the deformations of the second part of the frame.

[0047] FIG. 8 illustrates how first and second adaptation of the frame can be combined in accordance with an embodiment of the present invention.

[0048] FIGS. 9A to D illustrate a first and second substrate fastened to a frame in accordance with an embodiment of the present invention.

[0049] FIG. 10 illustrates the problem to fasten first and second substrate to a frame when the first and second substrates have different lateral dimensions and/or are misaligned.

[0050] FIGS. 11 and 11A show an adaptation of the frame to allow deformation (i.e. compliance) of the frames and to allow the frame to be glued to first and second substrate even when at least one lateral side of one of the substrate is not coplanar with the corresponding lateral side of the other substrate in accordance with an embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

[0051] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims.

[0052] Embodiments of the present relate to a design of a display tile T that has one, or some or all of the following advantages: [0053] keeps its form and flatness, [0054] has only negligible thermal expansion regardless of its environment (high humidity, temperature fluctuations . . . ) and/or [0055] will stay aligned with adjacent display tiles when used in a tiled display.

[0056] The invention is also related to tiled displays where the width of the seam will be as small or smaller than the spacing between adjacent pixels on a display tile.

[0057] To that end, with reference to FIGS. 2, 3, 5, 9 and 11 a stable transparent substrate 1 like for example glass is used. The substrate 1 is either part of a rear projection screen or a glass plate in a liquid crystal panel. The glass is for instance soda lime glass. Any suitable transparent material or other types of glass are possible. The coefficient of thermal expansion of the material used for the carrier substrate is advantageously lower than 9.5.Math.10.sup.−6 K.sup.−1. The substrate 1 has a first side or entry face that is substantially planar. The entry face is the face or side of the substrate 1 through which the light projected by a projector or a backlight enters. The substrate 1 has a second side or exit face that is substantially planar. The exit face is the face or side of the substrate 1 through which the light exits towards a viewer. The first side and second side of the substrate 1 are substantially parallel. When a line or surface, in particular a plane, is said to be perpendicular to the substrate, it means that the line or surface is perpendicular to the first and second sides of the substrate 1.

[0058] The substrate 1 is usually a parallelepiped with a first surface, a second surface parallel to the first surface and lateral sides 1A, 1B, 1C and 1D as shown in FIG. 2A.

[0059] A display (whether it is a rear projection display or an emissive display like a liquid crystal display or LCD), can be a fixed format display. The substrate 1 is associated with other layers. For instance the substrate 1 can support an optical element such as a Fresnel lens and/or a diffuser layer. The substrate 1 can also be part of an LCD panel. In that case, the substrate 1 is but one component of a liquid crystal panel: thin film transistors can be formed on the substrate 1; a the first glass substrate 1 and second glass substrate parallel to the first delimit a space to enclose a layer of liquid crystals, additional layers like e.g. colour filters can be formed on the second surface etc. . . . . In the description of the invention below, only the first substrate 1 will be explicitly mentioned. The display could also be a plasma display.

[0060] To avoid a non-display area along the perimeter of the substrate 1, the substrate is fastened to a frame 2 by mean of an adhesive film 3 distributed along the lateral sides 1A, 1B, 1C and 1D of the substrate as shown in FIGS. 3B, 3C, 9C, 9D, 10, 11. Avoiding a non-display area is useful both in e.g. a single panel LCD and a tiled display panel.

[0061] The frame 2 is advantageously made of metal. This allows reducing the thickness of the frame without compromising on the solidity of the assembly. The frame can be e.g. an aluminium ribbon cut in a sheet with a thickness between 0.1 mm and 1 mm. For instance, the thickness of the frame is 0.2 mm.

[0062] An example of adhesive film 3 is given in the utility model DE202009015262U1 “Latent reaktive, hitzeaktivierbare Klebmasse and damit hergestellte Klebemittel” which is incorporated herein by reference. Heat activation of the heat activated adhesive film can be done e.g. by near infrared heating or hot air (as provided by e.g. a heat gun).

[0063] Heat activated adhesive films not being fluid like glue; it is easier to control the thickness of the adhesive film 3 that will contribute to the seam between adjacent tiles.

[0064] Heat activated adhesive films are also easy to apply and cause no risk of glue penetration between layers associated with the substrate 1 or glue spilling onto one the first and/or second side of the substrate 1. This is very important because glue penetration would cause visual artefacts.

[0065] The frame 2 is not necessarily of one piece. It can for instance be split into e.g. 2 or more frame strips (2A, 2B, 2C and 2D) as illustrated on FIG. 2A. As illustrated on FIG. 2A, several frame strips can be glued to a lateral side of the substrate 1 (e.g. 1B). The frame strips need not be planar as illustrated by FIG. 2B that shows an example of profile for a non-planar frame strip 2B. The frame strips (2A, 2B, 2C and 2D) are used as mechanical interface between the substrate 1 and a backlight structure B (in the case of e.g. a liquid crystal display) or a support structure B (in the case of e.g. a rear projection display). Fastening of the frame 2 to the structure B can be done e.g. by means of screws like screw S and nuts like nut N.

[0066] A strip, e.g. 2A, is pressed against the heat activated adhesive tape 3 applied to one of the lateral sides, e.g. 1A, of the substrate 1 as illustrated on FIGS. 3A and 3B. Heat and pressure are applied to the frame strip with help of e.g. a bonding head 4 as illustrated on FIG. 3C. The use of a bonding head allows application of heat and pressure in a well delimited region of the frame strip (the shaded area on FIG. 3A).

[0067] When heat is applied to activate the adhesive tape 3, the frame strip heats and expands. Heating and expansion will be highest right under the bonding head. Even if the frame strip is made of a metal like e.g. aluminum, the temperature will vary across the width W of the frame strip from a higher temperature T+ to a lower temperature T−. As a result, the frame strip will not expand uniformly as illustrated on FIG. 4A. At the same time, the dimensions of the glass substrate 1, and in particular the length of the lateral side (1A, 1B, 1C or 1D) being glued to the frame strip (2A, 2B, 2C or 2D), will change as well but to a lesser extent than the frame strip.

[0068] As it cools down, the frame strip 2A will return to its initial length, inducing deformations of the substrate as illustrated on FIG. 4B where the substrate 1 buckles under compressive stress by one or more of the frame strips. The impact of such deformations on the seam between adjacent tiles causes variations of the seam width along a seam and from seam to seam that will make the seam between tiles more perceptible to a viewer than would otherwise be the case. In some cases, the contraction can cause failure of the adhesive tape.

[0069] To solve this problem, the shape of the metallic frame strip is modified as illustrated on FIG. 5 in accordance with one embodiment of the present invention.

[0070] The frame strip 2 is divided in three parts: a first part 21, a second part 22 and a third part 23. A first part 21 will be glued to a lateral side of the substrate 1.

[0071] A second part 22 acts as a strain relief structure between the first part 21 and the third part 23. The second part 22 is preferably more compliant than the other two parts, 21 and 23.

[0072] At least some strain relief is assured by one or more openings or slits 5 in the frame strip. An opening 5 extends from the edge of the frame strip and extends across the first and second part of the frame strip.

[0073] The opening 5 can be shaped as a rectangle but other geometries are possible. For instance, the corners of the opening can be rounded as illustrated on FIG. 5.

[0074] Strain relief can also be assured by grooves 6 etched or stamped in the first and/or second part of the frame strip as illustrated on FIG. 6.

[0075] The grooves 6 are formed, e.g. by etching on both sides of the frame strip 2 giving a corrugated aspect to the region where they are formed.

[0076] The depth of the grooves is ideally more than 50% of the thickness (x) of the frame strip.

[0077] The grooves 6 are preferably substantially perpendicular to the substrate 1. In other words, the angle made by a groove 6 and the substrate 1 is preferably 90.0 degrees of angle +/−0.1 degree of angle. Alternatively, the angle made by a groove 6 and the substrate 1 is preferably 90.0 degrees of angle +/−0.5 degree of angle. Alternatively, the angle made by a groove 6 and the substrate 1 is preferably 90.0 degrees of angle +/−1.0 degree of angle. Alternatively, the angle made by a groove 6 and the substrate 1 is preferably 90.0 degrees of angle +/−5.0 degree of angle. Alternatively, the angle made by a groove 6 and the substrate 1 is less than 90.0 degrees of angle but more than 45.0 degrees of angle.

[0078] It is also possible to combine openings 5 and grooves 6 to further improve the isolation of the third part 23 of the frame strip from strain in the first part 21 of the frame strip. Openings 5 and grooves or corrugations 6 can be combined in different manners. An example of how openings 5 and grooves or corrugation 6 can be combined is illustrated on FIG. 8. In this example, the grooves 6 are etched right under the openings 5.

[0079] As mentioned earlier, the substrate 1 may be associated to other layers and/or substrates as is e.g. the case in a liquid crystal panel.

[0080] In that case, the different substrates and layer may have slightly different dimensions as illustrated on FIGS. 9A, B, C, e.g. FIG. 9D where substrate 1 is slightly smaller than substrate 7 resulting in a mismatch M between the lateral side of substrates 1 and 7. Alternatively, both substrates can have close to identical dimensions but they can be misaligned, resulting in their lateral sides not being coplanar.

[0081] When the dimensions of substrates 1 and 7 differ too much and/or when both substrates are misaligned, it can be difficult to glue them together to the frame 2 (the bond may be weaker than expected or even inexistent with one or both of the substrates). This is illustrated on FIG. 10 where a cross section of a frame strip 2A the heat activated layer 3 and substrates 1 and 7 are shown. As can be seen on FIG. 10, the mismatch M between the substrates lateral sides 1A and 7A makes bonding of the lateral sides 1A to the frame strip very difficult or impossible. Two adhesive tapes 3A and 3B can be used on the lateral sides 7A and 1A of substrates 7 and 1 respectively but this will not prevent that there will be no contact between the adhesive strip 3B and the frame element 2A.

[0082] A solution to that problem in accordance with an embodiment of the present invention is to increase the compliance (i.e. flexibility) of the frame element 2A in the region of the frame element that will correspond to the border between substrates 1 and 7. The compliance can, for instance, be increased by etching grooves 8 in the frame element as illustrated on FIG. 11, especially FIG. 11A. The depth of the grooves 8 is preferably more than 50% of the thickness of the frame element 2.

[0083] FIG. 11 shows frame strip 2, the heat activated adhesive layer 3A and substrates 1 and 7. A heat activated adhesive tape 3A and optionally 3B can be used on the lateral sides 7A and optionally sides 1A of substrates 7 and 1 respectively.

[0084] As shown in FIG. 11, frame 2 can be fastened to the first substrate 1 and the second substrate 7 by means of an adhesive tape 3A 3B, respectively. The frame 2 is divided into 3 parts: a first part 31 which can be optionally glued by means of a heat activated adhesive tape 3B to a lateral side of the first substrate 1, a third part 33 to be glued by means of the heat activated adhesive tape 3A to a lateral side of the second substrate 7 and a second part 32 positioned between the first 31 and third 33 part, the second part 32 having a higher compliance (i.e. better able to comply or adjust) than the first 31 and third 33 part thereby allowing the first 31 and third 33 part to be positioned in different planes.

[0085] The grooves 8 can be formed in the second part 32 of the frame 2, the grooves 8 being substantially parallel to the first 1 and second 7 substrates. The depth of the grooves 8 is preferably more than 50% of the thickness of the frame 2. The grooves 8 can be formed on both sides of the frame 2.

[0086] The frame 2 can be split into two or more frame elements or strips 31, 32, 33. A frame 2, e.g. 2A, 2B, 2C . . . that will accommodate both the thermal expansion during heat activation and the mismatch between the position of the lateral sides (e.g. 1A and 7A) of substrates 1 and 7 can be obtained by positioning the grooves 8 in the first part 31 of a frame 2, e.g. 2A, 2B, 2C . . . . The desired deformation of the frame 2 will be obtained with grooves 8 substantially parallel to the first and second substrate 1, 7 to which substrates the frame 2 is glued.

[0087] In other words, the angle made by a groove 8 and the first and second substrates 1 and 7 is preferably 0.0 degrees of angle +/−0.1 degree of angle. Alternatively, the angle made by a groove 8 and the first and second substrates 1 and 7 is preferably 0.0 degrees of angle +/−0.5 degree of angle. Alternatively, the angle made by a groove 8 and the first and second substrates 1 and 7 is preferably 0.0 degrees of angle +/−1.0 degree of angle. Alternatively, the angle made by a groove 8 and the first and second substrates 1 and 7 is preferably 0.0 degrees of angle +/−5.0 degree of angle. Alternatively, the angle made by a groove 8 and the first and second substrates 1 and 7 is larger than 0.0 degrees of angle but less than 45.0 degree of angle.