JPH10105082A - Production of led display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To effectively use excess LED elements without abandoning them by mounting the LED elements of different luminance while uniformly distributing them for each block consisting of the unit area of a panel substrate. SOLUTION: On the assumption that one entire panel is divided into blocks B of lateral 4 rows × longitudinal 8 columns and each block respectively includes 4×4=16 pieces (dots) of LED elements 2, the LED elements 2 are successively mounted one by one from the dot (1) of the No.1 block to the dot (1) of the No.32 block. When the LED elements are completely mounted to the No.32 block, processing is returned to the No.1 block B again and this time, the LED element 2 is mounted at the dot (2) of the No.1 block B. Afterwards, similar mounting work is repeated. In this case, since the LED elements 2 are taken from different taping reels, even when there is difference in the luminance among the elements, the low luminance LED elements 2 are mounted while being distributed over the entire panel.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an LED display device, and more particularly to a method for manufacturing an LED dot matrix panel in which a plurality of LED elements are arranged in a matrix and an arbitrary character or graphic is displayed.

[0002]

2. Description of the Related Art An LED dot matrix panel in which a plurality of LED elements are arranged in a matrix on a panel substrate is composed of, for example, 16 × 16 dots / one character. It is composed of a total of 512 dots.

Here, each L attached to the panel substrate is
The ED elements are taped for each luminance rank, and wound on a reel. Although the number of taped reels to be stored varies, for example, when the above-described dot matrix panel of 2 characters / 1 panel (512 dots) is manufactured using 2500 reels / reel, the following calculation is established.

2500 (pieces) ÷ 512 (dots) = 4 (panels)... 452 (remainder) That is, when one reel is used, the number of panels that can be manufactured is four, and 452 LED elements are left over. become. Therefore, in order to manufacture a fifth panel using the surplus LED elements, it was necessary to splice the taped LED elements on another reel.

[0005]

By the way, even if the LED elements taped on the reel are within the same rank satisfying the standard, they are 10 m in comparison with the center value of the luminance variation.
An acceptable range of about cd / taping reel is usually accepted.

Accordingly, when another reel is spliced to manufacture the fifth panel as described above, the difference in brightness level (bright and dark) becomes clear at the seam of the reel, and the display quality is increased. Sometimes had problems. This will be described in detail below.

First, LE for panel 1 according to the conventional example
As shown by arrows in FIG. 8, the mounting order of the D elements 2 is, for example, such that the D elements 2 are sequentially mounted upward from the lower left, moved to the next row, and then sequentially mounted downward. If this mounting is performed under the above conditions, up to four panels per reel,
As shown in FIG. 9, a panel having uniform luminance emission can be provided. However, since the fifth panel can be mounted only halfway through the panel, LED elements are supplied from another reel to the rest of the panel. I had to.

Here, as described above, the brightness level of the LED element may be slightly shifted between different reels. For example, FIG. 10 shows an example of the relationship between the number of LED elements sequentially mounted on a panel substrate and the luminance thereof. Taping reel (NO.
While the luminance level of the LED element of (1) is about 18 mcd, the taping reel (NO.
The luminance level of the LED element of 2) is about 12 mcd.
The brightness level of both taping reels is the same rank (10 to 10).
20 mcd) and within the same standard, but in practice
There is a difference in luminance of mcd.

In other words, since the LED elements of the same taping reel are used up to the fourth unit, the deviation of the brightness is extremely small, but the LED elements of another taping reel must be used in the middle of the five units. Therefore, since the luminance of this separate reel is shifted by about 6 mcd, the luminance of the LED elements to be mounted thereafter will be all shifted as compared with the luminance of the previous element.

Therefore, as shown in FIG. 11, the brightness level difference becomes clear at the seam of the reel, that is, at the point of time when the LED element 2 is switched (P section). Actually, such a blockwise luminance difference within one panel is not acceptable as a product because the display quality is impaired, and after all, the remaining LED elements (452) of the reels corresponding to four panels are used. They had to be discarded, which was a major factor in cost increase.

The brightness difference between the panels is determined by the LED for each panel (16 × 16 or 16 × 32 dots).
By adjusting the element drive circuit, the luminance level can be relatively easily adjusted.

In view of the above problems, the present invention does not produce a block-wise luminance difference even when a plurality of taping reels having different center values of the luminance variation of the LED elements are used. It is an object of the present invention to provide a manufacturing method that can use a less than excess LED element without waste without discarding it.

[0013]

To achieve the above object, a first aspect of the present invention is a method for manufacturing an LED display device in which a plurality of LED elements are mounted in a matrix on a panel substrate. The LED elements are uniformly distributed and mounted on each block constituting a unit area of the panel substrate.

According to a second aspect of the present invention, there is provided a method of manufacturing an LED display device in which a plurality of taping reels each having a plurality of LED elements taped thereon are used to sequentially mount the LED elements on a panel substrate. The LED elements peeled off from the plurality of taping reels are united to the panel substrate so as to suppress the partial brightness of the panel substrate due to the luminance difference between the LED elements and to make the entire panel substrate have uniform luminance. It is characterized by being uniformly distributed and mounted for each block constituting the area.

[0015] Claim 3 is based on claim 1 or 2,
Each of the blocks includes a plurality of and the same number of LED element mounting sections, and one LED element is mounted on the LED mounting section of the block, and then moved to another adjacent block to mount the LED elements. A first step of mounting one LED element on each of all the blocks forming the entire panel substrate, and a first step of repeating the first step for each of the LED mounting portions; And a second step of mounting the LED elements on all of the LED mounting sections.

A fourth aspect of the present invention relates to the first or second aspect,
The order in which the LED elements are mounted is such that each block is moved vertically or horizontally by one block each time one LED element is mounted, and the moving distance of each block is LE.
The distance is set such that the mounting speed of the surface mounter for the D element does not decrease.

As described above, the LED element mounting method according to the present invention uniformly arranges the LED elements one by one over the entire panel substrate. Therefore, even if the method is switched to the taping reel on which the low-luminance LED elements are mounted, This L
Since the ED elements are scattered over the entire panel, the brightness is made uniform when the entire panel substrate is viewed. For this reason, according to the conventional mounting method, the remaining LE of the taping reel that has been discarded due to light and darkness is generated.
The D element can also be used effectively, which can contribute to cost reduction.

Further, since the moving distance in one block unit is set to a distance at which the mounting speed of the surface mounter of the LED element does not decrease, the time for mounting the LED is minimized. It can contribute to the efficiency of the manufacturing process.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing an LED dot matrix panel according to one embodiment of the present invention will be described with reference to FIGS. FIGS. 1A and 1B are top views for explaining the order of mounting the LED elements according to the present embodiment, and FIG. 2 is a top view showing the actual mounting order.

For comparison with the prior art, FIGS. 8 to 11 show the number of mounted LED elements per panel substrate, the number of LED elements per tape reel, and the difference in luminance between different tape reels. Conditions. Also, the same symbols are given to the same functional parts.

The feature of this embodiment lies in the order in which the LED elements 2 are mounted on the panel substrate 1. In order to determine this order, here, as shown in FIG. It is assumed that the block is divided into 32 blocks B of 8 rows × 8 columns. Here, it is assumed that each block B includes 4 × 4 16 (dot) LED elements 2. That is, 16 blocks / block × 32 blocks = 512
The mounting order of the pieces will be described below.

First, starting from the dot of the block of No. 1 in FIG.
The D elements 2 are sequentially mounted one by one. FIG. 2 shows this mounting order.

When the mounting up to the number 32 is completed,
Returning to the block B of No. 1 again, the LED element 2 is attached to the dot of the block B of No. 1 this time. Less than,
The same mounting operation is repeated until the LED elements 2 are mounted on all the dots of each block B. This mounting order is summarized in Table 1.

[0024]

[Table 1]

FIG. 3 shows the order of mounting all 512 LED elements according to the contents of Table 1 above. The number of each dot in the figure indicates the mounting order.

Each LE when mounted in the above order
FIG. 4 shows the brightness of the D element. As shown in FIG.
Even when there is a difference in luminance between the elements by taking the ED elements 2 from different taping reels, L
Since the ED elements 2 are mounted in a distributed manner over the entire panel, a block-like luminance difference (brightness / darkness) does not occur.

The fact that the luminance is made uniform will be described with reference to FIGS. 5 and 6. FIG. First, in FIG. 5 showing a case where an LED element is mounted by a conventional mounting method, a block having a unit area having the highest luminance in one panel is referred to as a block No.
Block No. 1 as the block having the unit area with the lowest luminance. Take number 17. Next, when the light quantity of each block is obtained, the block No. For one, 18 mcd
× 16 dots = 288 mcd. On the other hand, block N
o. For 17, 17 mcd × 16 dots = 192
mcd. Therefore, the light amount of the brightest part is 1.5 of the darkest part.
It has twice the luminance, and a clear luminance difference occurs as schematically shown in FIG.

On the other hand, in FIG. 6 corresponding to the present embodiment, similarly, the block having the highest luminance in one panel has the block No. 1 as the block with the lowest luminance. Take number 17. Next, when the light quantity of each block is obtained, the block No. 1 is 18 mcd × 15 dots + 12 mcd × 1 dot =
282 mcd. On the other hand, the block No. As for 17, it is 18 mcd × 14 dots + 12 mcd × 2 dots = 276 mcd. Therefore, even the light amount of the brightest part is about 1.02 times that of the darkest part (282 mcd / 276 mcd =
1.02), and the difference in luminance between the two blocks can be extremely small.

As described above, according to the mounting method of the LED element according to the present embodiment, the L taken from a plurality of taping reels is used.
Even if an ED element is used, block-like brightness of a panel does not occur in one panel. Therefore, in the past, the number of LED elements that had been discarded because they were insufficient in number to be mounted on one panel can be effectively utilized. It can contribute to cost reduction.

By the way, in the LED element mounting process, it is needless to say that the faster the mounting speed of all the LED elements to the entire panel substrate, the shorter the manufacturing process time is. Therefore, in the above embodiment, each block is divided in consideration of not only the mounting order but also the mounting speed. This will be described with reference to FIG. FIG.
Is obtained by adding the distance between the respective elements to the drawing of FIG.

In other words, the mounting speed of the surface mount automatic mounter for mounting the LED elements decreases as the distance between the elements increases. In the surface mount automatic mounter employed in this embodiment, it is possible to mount the device without reducing the speed as long as the distance between the elements is within 20 mm. If this includes, for example, the 32nd to 33rd movement in FIG. 7, the movement in the horizontal direction (X direction) is 1
Although it is 2 mm, the movement in the vertical direction (Y direction) is 60 mm, and the mounting speed is reduced.

In this embodiment, after the first LED element is mounted, the horizontal (X direction) movement distance for mounting after mounting the second LED element is also the vertical direction such as 14th to 15th. The moving distance in the (Y direction) is 16 mm,
Since the distance is within mm, mounting in the shortest time is possible.

[0033]

As described above, the LE according to the present invention is used.
According to the mounting method of the D element, even if an LED element taken from a plurality of taping reels is used, the brightness of the block does not occur in one panel. LEDs were discarded due to insufficient number
Elements can also be used effectively, contributing to cost reduction.

Further, the LED element can be mounted in the shortest mounting time.

[Brief description of the drawings]

FIGS. 1A and 1B are top views of a panel substrate for explaining a mounting order of LED elements according to an embodiment of the present invention.

FIG. 2 is a top view of a panel substrate for explaining an order of mounting LED elements in block units according to an embodiment of the present invention.

FIG. 3 is a top view of the panel substrate for explaining the order of mounting all LED elements on the panel substrate according to one embodiment of the present invention.

FIG. 4 is a top view of the panel substrate for showing the effect of the present invention.

FIG. 5 is a top view for explaining a light emitting state of a panel substrate by a conventional mounting method for comparison with the present invention.

FIG. 6 is a top view illustrating a light emitting state of a panel substrate according to one embodiment of the present invention.

FIG. 7 is a top view of a panel substrate for explaining a mounting speed of an LED element according to an embodiment of the present invention.

FIG. 8 is a top view of a panel substrate for explaining a mounting order of LED elements according to a conventional example.

FIG. 9 is a top view for explaining a light emitting state of a panel substrate according to a conventional example.

FIG. 10 is a characteristic diagram showing a relationship between the number of mounted LED elements and luminance.

FIG. 11 is a top view for explaining another light emitting state of the panel substrate according to the conventional example.

[Explanation of symbols]

 1 Panel board 2 LED element B block

Claims (4)

[Claims] 1. A method of manufacturing an LED display device in which a plurality of LED elements are mounted in a matrix on a panel substrate, wherein the LED elements having different luminances are uniformly distributed for each block constituting a unit area of the panel substrate. A method for manufacturing an LED display device, comprising: 2. The method according to claim 1, wherein a plurality of taping reels on which a plurality of LED elements are taped are used to form the LED on a panel substrate.
In a method of manufacturing an LED display device in which ED elements are sequentially mounted, a partial brightness of the panel substrate due to a difference in brightness of LED elements between a plurality of taping reels is suppressed, and the entire panel substrate has uniform brightness. As described above, a method for manufacturing an LED display device, wherein the LED elements peeled off from the plurality of taping reels are uniformly distributed and mounted for each block constituting a unit area of the panel substrate. 3. Each of the blocks includes a plurality of and the same number of LED element mounting portions, and one LED element is mounted on the LED mounting portion of the block, and then moved to another adjacent block. The process of mounting one LED element is repeated, and the first step of mounting one LED element at a time on all blocks constituting the entire panel substrate is performed.
And a second step of repeating the first step for each of the LED mounting sections to mount LED elements on all the LED mounting sections of the panel substrate. 1
Or the method of manufacturing an LED display device according to any one of 2. 4. The mounting order of the LED elements is such that each block is moved vertically or horizontally by one block each time one LED element is mounted, and the moving distance of each block is the LED element. 2. The distance set so that the mounting speed of the surface mounter does not decrease.
Or the method of manufacturing an LED display device according to any one of 2.