Illuminator, illuminator fabricating method, and illuminator repairing method
View Patent ↗An illuminator includes a substrate, an interlayer, a plurality of connecting pads, a plurality of LEDs, and a plurality of adhesive blocks. The interlayer is on the substrate. The connecting pads are on a side of the interlayer away from the substrate. Each LEDs is on a corresponding connecting pad. Each adhesive blocks bonds one LED to one connecting pad. The interlayer defines a plurality of grooves, each of the grooves corresponds to a connecting pad, each grooves includes an opening through a surface of the interlayer facing the top side of the illuminator. The opening is configured and arranged so that the corresponding adhesive block, in a molten form, flows through the opening into the corresponding groove of the plurality of grooves. A method of fabricating the illuminator and a method of repairing the illuminator are further disclosed.
1 . An illuminator comprising, from a bottom side to a top side in a following order: a substrate; an interlayer; a plurality of connecting pads; a plurality of adhesive blocks; and a plurality of light emitting diodes (LEDs), wherein:
each of the plurality of LEDs is on a corresponding connecting pad of the plurality of connecting pads,
each of the plurality of adhesive blocks bonds a corresponding LED of the plurality of LEDs to the corresponding connecting pad, and is partially covered by the corresponding LED,
the interlayer defines a plurality of grooves each positioned to the corresponding connecting pad, each of the plurality of grooves comprises an opening through a surface of the interlayer facing the top side of the illuminator, and a position of the opening is configured and arranged so that the corresponding adhesive block, in a molten form, flows through the opening into the corresponding groove of the plurality of grooves, and each of the plurality of grooves is configured to receive substantially an entire amount of the corresponding adhesive block in the molten form to release the corresponding LED from the corresponding connecting pad.
2 . The illuminator of claim 1 , wherein the corresponding adhesive block at least partially covers the opening.
3 . The illuminator of claim 1 , wherein the interlayer comprises at least one conductive layer and at least one insulating layer, each of the at least one insulating layer corresponds to one of the at least one conductive layer; the at least one conductive layer forms conductive traces electrically connected to the plurality of connecting pads.
4 . The illuminator of claim 3 , wherein the interlayer comprises a conductive layer and an insulating layer; the conductive layer is on the substrate, and the insulating layer is on a side of the conductive layer facing the top side of the illuminator.
5 . The illuminator of claim 3 , wherein the interlayer comprises at least two conductive layers and at least two insulating layers; and the at least two conductive layers and the at least two insulating layers are alternately arranged.
6 . The illuminator of claim 5 , wherein each of the plurality of grooves comprises a connecting hole and a chamber; the chamber extends through a surface of the conductive layer on the substrate facing away from the connecting pads; the connecting hole extends through the interlayer and communicates with the chamber; the connecting hole defines the opening.
7 . The illuminator of claim 1 , further comprising a protective layer on a side of the interlayer facing the top side of the illuminator; the protective layer covers at least a portion of each of the plurality of adhesive blocks which is not covered by the plurality of LEDs.
8 . The illuminator of claim 1 , wherein the illuminator is a backlight of a liquid crystal display, a display panel of a self-luminous display, or a lighting device.
9 . The illuminator of claim 1 , wherein the plurality of grooves extends through the interlayer to expose the substrate to the plurality of adhesive blocks.
10 . The illuminator of claim 9 , wherein the substrate is made of a transparent material.
11 . The illuminator of claim 6 , wherein a volume of the chamber is equal to or greater than a volume of the corresponding adhesive block; the corresponding adhesive block in the molten form is accommodated in the chamber.
12 . The illuminator of claim 1 , wherein an orthographic projection of a profile of the opening on the substrate is tangent to or spaced apart from an orthographic projection of the corresponding connecting pad on the substrate.
13 . The illuminator of claim 1 , wherein the interlayer further comprises a planarization layer, and the planarization layer is an outermost layer of the interlayer facing the top side of the illuminator.
14 . An illuminator comprising, from a bottom side to a top side in a following order:
a substrate;
an interlayer on the substrate and comprising at least one conductive layer and at least one insulating layer;
a plurality of connecting pads on a side of the interlayer away from the substrate;
a plurality of adhesive blocks; and
a plurality of light emitting diodes (LEDs);
wherein each of the plurality of LEDs is bonded to a corresponding connecting pad of the plurality of connecting pads by a corresponding adhesive block of the plurality of adhesive blocks;
the interlayer defines a plurality of grooves each positioned to the corresponding connecting pad and comprising a connecting hole and a chamber; the connecting hole extends through the interlayer to form an opening through a surface of the interlayer facing the top side of the illuminator and communicates with the chamber; the chamber extends into the at least one conductive layer toward the substrate; and the connecting hole and the chamber are collectively configured such that, the corresponding adhesive block, in a molten form, flows through the connecting hole into the chamber to release the corresponding LED from the corresponding connecting pad.
15 . The illuminator of claim 14 , wherein the corresponding adhesive block at least partially covers the opening.
16 . The illuminator of claim 14 , wherein the interlayer comprises at least two conductive layers and at least two insulating layers; and the at least two conductive layers and the at least two insulating layers are alternately arranged.
17 . The illuminator of claim 14 , further comprising a protective layer on a side of the interlayer facing the top side of the illuminator; the protective layer covers at least a portion of each of the plurality of adhesive blocks which is not covered by the plurality of LEDs, surfaces of the plurality of connecting pads which is not covered by the plurality of adhesive blocks and side surfaces of the plurality of LEDs.
18 . The illuminator of claim 14 , wherein the substrate is made of a transparent material.
19 . The illuminator of claim 14 , wherein an orthographic projection of a profile of the opening on the substrate is tangent to or spaced apart from an orthographic projection of the corresponding connecting pad on the substrate.
20 . The illuminator of claim 14 , wherein the interlayer further comprises a planarization layer, and the planarization layer is an outermost layer of the interlayer facing the top side of the illuminator.