CN104465485B - 一种制备小间距led全彩显示阵列的方法 - Google Patents
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Abstract
本发明公开了一种制备小间距LED全彩显示阵列的方法,包括:在透明面板正面的四周边缘制备金属电极,所述金属电极包括行金属电极和列金属电极;将正装LED芯片直接固晶到透明面板正面的中间区域,排成阵列;通过打金线方式连接每行芯片的P电极,并与透明面板边缘的行金属电极相连;通过打金线方式连接每列芯片的N电极,与透明面板边缘的列金属电极相连;在透明面板正面进行封胶保护,形成封装胶,并在封装胶表面制作反射镜。本发明由于不需要电绝缘层,因此小间距LED全彩显示阵列的成品率增加,坏点(不亮芯片)减少;制备小间距LED全彩显示阵列的工艺步骤大大简化,提高了生产效率,降低了成本。
Description
技术领域
本发明涉及光电器件技术领域,尤其涉及一种制作小间距LED全彩显示阵列的方法。
背景技术
LED显示屏是八十年代后期在全球迅速发展起来的新型信息显示媒体,它利用LED发光二极管构成的点阵模块或像素单元组成大面积显示屏幕,LED显示屏以可靠性高、亮度高、使用寿命长、环境适应能力强、耐冲击、性能稳定等特点,将成为平板显示领域的主流产品。
随着LED芯片制造、集成封装、显示控制和工艺技术的不断进步,高清LED显示产品将引领LED显示的发展趋势。LED小点间距显示产品具有亮度高、整体无拼缝、寿命长、高效节能、响应时间短、大视角等优势,预计高清LED显示产品将在未来爆发式增长。
实现高清显示的关键技术是缩小显示屏的发光像素,目前比较好的方法如图1所示,在面板上制备行控制线和列数据线,行线列线都是金属线条,行列金属线条之间用绝缘层进行电隔离,在行列金属线条的交叉处,通过光刻工艺露出后序压焊芯片电极的位置,在此阵列上通过倒装焊工艺将红、绿、蓝芯片固晶在行控制线和列数据线的交叉位置,最后通过控制和驱动引向面板四周的行控制线和列数据线,在面板的正面显示全彩图像。
由于行控制线和列数据均为金属线条,它们之间的电绝缘非常重要,在它们的交叉处压焊芯片后,由于机械压力容易使电绝缘层受损,发生短路现象,使该处的芯片无法点亮。此外,整个面板的制备过程工艺步骤较多,需要经过如下工艺步骤:制备列数据线→制备电绝缘层→制备行控制线→passivation保护→植金球→倒装焊红、绿、蓝芯片→封胶保护,面板的制备工艺复杂,成本高。蓝、绿倒装芯片的制备成本较高,是蓝、绿正装芯片的2倍。
发明内容
(一)要解决的技术问题
鉴于上述技术问题,本发明提供了一种制备小间距LED全彩显示阵列的方法,以简化小间距LED显示阵列工艺步骤、降低成本、提高可靠性。
(二)技术方案
本发明提供了一种制备小间距LED全彩显示阵列的方法。该方法包括:在透明面板正面的四周边缘制备金属电极,所述金属电极包括行金属电极和列金属电极;
步骤2、将正装LED芯片直接固晶到透明面板正面的中间区域,排成阵列;
步骤3、通过打金线方式连接每行芯片的P电极,并与透明面板边缘的行金属电极相连;通过打金线方式连接每列芯片的N电极,与透明面板边缘的列金属电极相连;
步骤4、在透明面板正面进行封胶保护,形成封装胶,并在封装胶表面制作反射镜。
(三)有益效果
从上述技术方案可以看出,本发明制备小间距LED全彩显示阵列的方法具有以下有益效果:
(1)由于不需要电绝缘层,因此小间距LED全彩显示阵列的成品率增加,坏点(不亮芯片)减少;
(2)制备小间距LED全彩显示阵列的工艺步骤大大简化,提高了生产效率,降低了成本;
(3)蓝、绿芯片的制造成本大大降低。
附图说明
图1是现有技术制备的小间距全彩LED显示阵列示意图;
图2是根据本发明制备的小间距全彩LED显示阵列示意图;
[主要元件]:
1-显示面板;2-列数据线;3-电绝缘层;
4-行控制线;5-倒装LED红光芯片;
6-倒装LED绿光芯片;7-倒装LED蓝光芯片;
8-RGB芯片组;9-透明显示面板;10-行金属电极
11-列金属电极 12-正装LED红光芯片;13-正装LED绿光芯片;
14-正装LED蓝光芯片;15-金线;16-厚封胶层;17-反射镜。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚明白,以下结合具体实施例,并参照附图,对本发明作进一步的详细说明。
在本发明的一个示例性实施例中,提供了一种制备小间距全彩LED显示阵列的方法。请参阅图2所示,本实施例包括如下步骤:
步骤1:在透明面板9正面沉积金属薄膜,然后通过光刻和刻蚀工艺将金属薄膜制备成金属电极,此金属电极位于透明面板四周边缘。此金属电极分为行金属电极10和列金属电极11两部分,行金属电极10位于透明面板的左右两侧或上下两侧,通过金线15与LED阵列中的行控制线相连接。列金属电极11位于透明面板的上下两侧或左右两侧(与行金属电极10垂直),通过金线15与LED阵列中的列数据线相连接。最终,透明面板9四周的金属电极与LED显示阵列的驱动和控制电路相连。
本步骤中,透明面板9必须是电绝缘材料,可以是玻璃、蓝宝石(Al2O3)或树脂材料。沉积薄膜工艺可以是电子束蒸发、热蒸发、溅射或电镀工艺等。金属薄膜为Au、Ag、Al、Pt、Cu,或是Ni、Ti、Cr与Au、Ag、Al、Pt、Cu形成的复合金属,金属薄膜的厚度为0.2~5um。刻蚀工艺可以是湿法腐蚀或干法刻蚀工艺。位于透明面板四周的金属电极为圆形、方形或长方形图形。金属电极的数量、大小和间距根据LED显示阵列的像素数和尺寸而定。通常直径为50~500um。所述正装LED芯片尺寸小于10mil
步骤2:通过固晶工艺将正装LED红光芯片12、正装LED绿光芯片13和正装LED蓝光芯片14压焊到透明面板9正面的中间区域。每组LED红、绿、蓝芯片成为一个RGB芯片组8,RGB芯片组8排布成周期分布的整齐阵列。RGB芯片组的周期即是LED全彩显示阵列的点间距,点间距越小,LED全彩显示阵列的分辨率越高。RGB芯片组8也可以全部由蓝光芯片组成,并通过在透明面板背面涂敷绿光和红光荧光粉,将蓝光转换成绿光和红光。
本步骤中,固晶工艺是这样完成的:在透明面板上点透明胶,拾取芯片,将芯片压焊到固晶胶上,最后加热使固晶胶与芯片粘结牢固。
步骤3:通过打金线工艺将LED阵列中每行芯片的P电极相连,最终连接到透明面板9左右边缘的行金属电极10上。通过打金线工艺将LED阵列中每列芯片的N电极相连,最终连接到透明面板上下边缘的列金属电极11上。LED显示阵列的驱动控制电路与透明面板四周的行列金属电极相连后,完成驱动和控制功能。
打金线工艺通过自动打线机完成,金线直径15~30um。
步骤4:对已经排满LED芯片的透明面板进行封胶保护。在封装胶16上淀积一层高反射率的金属或介质膜作为反射镜17,以便把从LED芯片正面发出的光反射回去,从透明面板的背面射出。
此步骤中,封装胶16为高支撑低吸收的绝缘胶,如硅胶、聚合物等。封装胶厚度5um以上。高反射率的金属可以是Ag、Al,或者薄层金属Ti、Cr、Ni与Ag、Al的复合金属膜层。金属厚度0.2~1um。高反射率的介质膜可以是SiO2与Ta2O5的多层复合高反膜或SiO2与TiO2的多层复合高反膜。沉积工艺可以是热蒸发、电子束蒸发、溅射等工艺。
步骤5:对全部由蓝光LED芯片组成的阵列,对准正面的每列管芯,在面板背面按列分别涂覆红色荧光粉、绿色荧光粉和不涂荧光粉,按周期重复。红色荧光粉激发蓝光LED发出红光,绿色荧光粉激发蓝光LED发出绿光,于是形成按列依次排布的红、绿、蓝LED管芯。
具体做法是:在透明面板背面放置mask模版,模版上有一列列镂空列线条,模版与透明面板正面的每列管芯对准,每隔两列管芯的距离有一条镂空列线。先在镂空列线中喷涂红色荧光粉,200度固化后再将mask模板平移到相邻的一列管芯对准,再对镂空列线中喷涂绿色荧光粉,200度固化绿色荧光粉。
以上所述的具体实施例,对本发明的目的、技术方案和有益效果进行了进一步详细说明,应理解的是,以上所述仅为本发明的具体实施例而已,并不用于限制本发明,凡在本发明的精神和原则之内,所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (8)
1.一种制作小间距LED全彩显示阵列的方法,其特征在于,包括:
步骤1、在透明玻璃面板正面的四周边缘制备金属电极,所述金属电极包括行金属电极和列金属电极;
步骤2、将正装LED芯片直接固晶到透明玻璃面板正面的中间区域,排成阵列;
步骤3、通过打金线方式连接每行芯片的P电极,并与透明玻璃面板边缘的行金属电极相连;通过打金线方式连接每列芯片的N电极,与透明玻璃面板边缘的列金属电极相连;
步骤4、在透明玻璃面板正面进行封胶保护,形成封装胶,并在封装胶表面制作反射镜,把从LED芯片正面发出的光反射回去,从透明玻璃面板的背面射出。
2.根据权利要求1所述方法,其特征在于,所述正装LED芯片包括正装LED红光芯片、正装LED绿光芯片和正装LED蓝光芯片,且相邻的正装LED红光芯片、正装LED绿光芯片和正装LED蓝光芯片形成一组RGB芯片组。
3.根据权利要求1所述方法,其特征在于,所述正装LED芯片全部由正装LED蓝光芯片组成。
4.根据权利要求3所述的方法,其特征在于,还包括:
对准每列正装LED蓝光芯片,在透明玻璃面板背面按列分别涂覆红色荧光粉、绿色荧光粉和不涂荧光粉,按周期重复。
5.根据权利要求1所述方法,其特征在于,所述正装LED芯片尺寸小于10mil。
6.根据权利要求1所述方法,其特征在于,所述封装胶为高支撑低吸收的绝缘胶,封装胶厚度在5um以上。
7.根据权利要求1所述方法,其特征在于,所述反射镜由高反射率的金属或介质膜形成。
8.根据权利要求7所述的方法,其特征在于,所述高反射率的金属可以是Ag、Al,或者薄层金属Ti、Cr、Ni与Ag、Al的复合金属膜层,金属厚度为0.2~1um;所述高反射率的介质膜可以是SiO2与Ta2O5的多层复合高反膜或SiO2与TiO2的多层复合高反膜。
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