WO2019094287A1

WO2019094287A1 - Sub-displays with alignment structures and tiled displays fabricated from the sub-displays

Info

Publication number: WO2019094287A1
Application number: PCT/US2018/058892
Authority: WO
Inventors: Alexander Lee CUNO; Kuan-Ting Kuo; Po Ki Yuen
Original assignee: Corning Incorporated
Priority date: 2017-11-09
Filing date: 2018-11-02
Publication date: 2019-05-16
Also published as: JP7254795B2; TW201923724A; TWI821212B; JP2021503099A; CN111448658A; CN111448658B; KR20200071770A

Abstract

A sub-display for a tiled display includes a backplane, an array of light sources, and a plurality of press fit interlocking structures. The backplane includes a first surface and a second surface opposite to the first surface. The array of light sources is coupled to the first surface of the backplane. The plurality of press fit interlocking structures are coupled to the second surface of the backplane. Each of the plurality of press fit interlocking structures is configured to engage a corresponding press fit interlocking structure of a base plate to align and secure the sub-display to the base plate.

Description

SUB-DISPLAYS WITH ALIGNMENT STRUCTURES AND TILED DISPLAYS FABRICATED FROM THE SUB-DISPLAYS

[0001] This application claims the benefit of priority under 35 U.S.C. § 120 of U.S.

Application Serial No. 62/583,738 filed on November 9, 2017, the content of which is relied upon and incorporated herein by reference in its entirety.

BACKGROUND

Field

[0002] The present disclosure relates generally to tiled displays. More particularly, it relates to tiled displays comprising multiple sub-displays including alignment structures.

Technical Background

[0003] Large-area displays may not be practical to manufacture on a single large-area substrate. For example, the size of the display may be larger than what existing processing equipment can handle and/or the yield of large display sizes may be much lower than the yield of smaller display sizes. In these cases, manufacturing a display by tiling multiple smaller sub-displays is advantageous. The tiling of smaller sub- displays to create larger displays may apply to display technologies including light emitting diode (LED), microLED, organic light emitting diode (OLED), and liquid crystal display (LCD). A common problem of tiled displays is the alignment of the sub-displays of the tiled display.

[0004] MicroLEDs are small (e.g., typically less than Ι ΟΟμιη by Ι ΟΟμιη) light emitting components. They are inorganic semiconductor components producing high luminance up to 50 million nits. Therefore, microLEDs are particularly suitable for high resolution and large tiled displays. However, sub-displays of a tiled microLED display should be precisely aligned to prevent visible seams between the sub-displays. Accordingly, sub-displays and tiled displays fabricated from the sub-displays that can be precisely aligned are disclosed herein. SUMMARY

[0005] Some embodiments of the present disclosure relate to a sub-display for a tiled display. The sub-display includes a backplane, an array of light sources, and a plurality of press fit interlocking structures. The backplane includes a first surface and a second surface opposite to the first surface. The array of light sources is coupled to the first surface of the backplane. The plurality of press fit interlocking structures are coupled to the second surface of the backplane. Each of the plurality of press fit interlocking structures is configured to engage a corresponding press fit interlocking structure of a base plate to align and secure the sub-display to the base plate.

[0006] Yet other embodiments of the present disclosure relate to a sub-display for a tiled display. The sub-display includes a backplane, an array of light sources, and a plurality of press fit interlocking structures. The backplane includes a first surface, a second surface opposite to the first surface, and a sidewall extending between the first surface and the second surface. The array of light sources is coupled to the first surface of the backplane. A plurality of press fit interlocking structures is coupled to the sidewall of the backplane. Each of the plurality of press fit interlocking structures is configured to engage a corresponding press fit interlocking structure of a further sub-display to align and secure the sub-display to the further sub-display.

[0007] Yet other embodiments of the present disclosure relate to a sub-display for a tiled display. The sub-display includes a backplane, an array of light sources, and a plurality of magnets. The backplane includes a first surface and a second surface opposite to the first surface. The array of light sources is coupled to the first surface of the backplane. The plurality of magnets is coupled to the second surface of the backplane. Each of the plurality of magnets is configured to engage a respective magnet of a base plate to align and secure the sub-display to the base plate.

[0008] Yet other embodiments of the present disclosure relate to a sub-display for a tiled display. The sub-display includes a backplane, an array of light sources, and a plurality of magnets. The backplane includes a first surface, a second surface opposite to the first surface, and sidewalk extending between the first surface and the second surface. The array of light sources is coupled to the first surface of the backplane. The plurality of magnets is coupled to the sidewalk of the backplane. Each of the plurality of magnets is configured to engage a respective magnet of a further sub-display to align and secure the sub-display to the further sub-display

[0009] Yet other embodiments of the present disclosure relate to a tiled display The tiled display includes a base plate, a first sub-display, and a second sub-display The base plate includes a plurality of first press fit interlocking structures in a first area and a plurality of second press fit interlocking structures in a second area. The first sub- display includes a plurality of third press fit interlocking structures engaged with the plurality of first press fit interlocking structures such that the first sub-display is aligned with and secured to the first area of the base plate. The second sub-display includes a plurality of fourth press fit interlocking structures engaged with the plurality of second press fit interlocking structures such that the second sub-display is aligned with and secured to the second area of the base plate.

[00010] Yet other embodiments of the present disclosure relate to a method for fabricating a display. The method includes attaching a first sub-display comprising a first plurality of first press fit interlocking structures to a base plate comprising a plurality of second press fit interlocking structures such that the first plurality of first press fit interlocking structures engage with a first portion of the plurality of second press fit interlocking structures to secure and align the first sub-display with the base plate. The method includes attaching a second sub-display comprising a second plurality of first press fit interlocking structures to the base plate such that the second plurality of first press fit interlocking structures engage with a second portion of the plurality of second press fit interlocking structures to secure and align the second sub- display with the base plate.

[00011] The tiled displays disclosed herein provide precise alignment of sub-displays to a base plate and/or to each other. The tiled displays may be assembled and disassembled as needed. The press fit interlocking structures enable self-alignment of the sub-displays to the base plate and/or to each other.

[00012] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[00013] It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments described herein, and together with the description serve to explain the principles and operations of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[00014] FIGS. 1 A-1B schematically depict one example of a sub-display;

[00015] FIG. 2 schematically depicts one example of a base plate;

[00016] FIG. 3 depicts one example of the assembly of a tiled display;

[00017] FIGS. 4A-4B schematically depict another example of a sub-display;

[00018] FIG. 5 schematically depicts another example of a base plate;

[00019] FIG. 6 depicts another example of the assembly of a tiled display;

[00020] FIG. 7 depicts one example of a safety feature of a sub-display;

[00021] FIG. 8 depicts one example of a safety feature of a base plate;

[00022] FIG. 9 depicts one example of a safety feature of a sub-display coupled to a safety feature of a base plate;

[00023] FIG. 10 depicts one example of a locked safety feature of a sub-display and a base plate;

[00024] FIGS. 11A-11B depict one example of press fit interlocking structures of a sub- display;

[00025] FIG. 12 depicts one example of press fit interlocking structures of a base plate;

[00026] FIG. 13 depicts another example of the assembly of a tiled display;

[00027] FIGS. 14A-14B depict one example of a pair of press fit interlocking structures;

[00028] FIGS. 15A-15B depict examples of the pair of press fit interlocking structures of

FIGS. 14A-14B engaged with each other;

[00029] FIG. 16 depicts an internal view of the engaged press fit interlocking structures of FIGS. 15A-15B;

[00030] FIG. 17 depicts other examples of press fit interlocking structures; and

[00031] FIG. 18 a flow diagram illustrating one example of a method for fabricating a display. DETAILED DESCRIPTION

[00032] Reference will now be made in detail to embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[00033] Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[00034] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom, vertical, horizontal - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[00035] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order, nor that with any apparatus, specific orientations be required. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or that any apparatus claim does not actually recite an order or orientation to individual components, or it is not otherwise specifically stated in the claims or description that the steps are to be limited to a specific order, or that a specific order or orientation to components of an apparatus is not recited, it is in no way intended that an order or orientation be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps, operational flow, order of components, or orientation of components; plain meaning derived from grammatical organization or punctuation, and; the number or type of embodiments described in the specification.

[00036] As used herein, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, reference to "a" component includes aspects having two or more such components, unless the context clearly indicates otherwise.

[00037] As used herein, the term "press fit" includes any coupling in which elements couple when one or more contacting portions of the elements are pushed together. In some embodiments, a press fit includes a friction fit, in which two elements are held together at least in part by friction between mating surfaces. In other embodiments, a press fit includes an interference fit, in which the coupled elements interfere with one another (e.g., a solid or hollow shaft that is slightly larger than a hole into which it is inserted such as male and female luers). In other embodiments, a press fit may include resilient engagement (e.g., a pin inserted into a hole in an elastomeric sleeve whose inner diameter is less than the diameter of the pin).

[00038] As used herein, the term "stud" includes any projection on a surface of an element. A stud may be solid or hollow and may, for example, include a bump, a protuberance, a boss, or a pin. A stud may have any suitable shape including, for example, round, square, rectangular, trapezoidal, oval, or any combination thereof. In some embodiments, a stud may be formed within physical tolerances that allow one or more studs on a surface to be coupled to another element.

[00039] Referring now to FIGS. 1A-1B, an exemplary sub-display 100 is schematically depicted. FIG. 1A is a top view of sub-display 100 and FIG. IB is a bottom view of sub-display 100. Sub-display 100 includes a backplane 102, an array of light sources 108, a plurality of press fit interlocking structures 110, a plurality of magnets 1 12, and a shaft 1 14. Backplane 102 includes a first surface 104 (FIG. 1A) and a second surface 106 (FIG. IB) opposite to the first surface 104. Each light source 108 is coupled to the first surface 104 of the backplane 102. Light sources 108 may be arranged in an array including any suitable numbers of rows and columns. Each light source 108 may include a light emitting diode (LED), a micro LED, an organic light emitting diode (OLED), or another suitable light source. Each light source 108 is electrically coupled to circuitry (not shown) for controlling the operation of each light source.

[00040] Each press fit interlocking structure 110 is coupled to the second surface 106 of the backplane 102. In this example, four press fit interlocking structures 1 10 are coupled to backplane 102 and each press fit interlocking structure 110 is arranged proximate to a corner of backplane 102. In other examples, another suitable number of press fit interlocking structures 110 may be coupled to backplane 102 and each press fit interlocking structure 110 may be arranged at any suitable location on backplane 102. Press fit interlocking structures 110 may for example, be arranged in a pattern including a series of rows, columns, or a combination thereof. Each press fit interlocking structure 110 is configured to engage a corresponding press fit interlocking structure of a base plate as will be described below to align and secure the sub-display to the base plate.

[00041] Each magnet 112 is coupled to the second surface 106 of the backplane 102. In this example, four magnets 1 12 are coupled to backplane 102. Each magnet 112 is arranged proximate a corresponding sidewall of backplane 102 and substantially centered along the corresponding sidewall. In other examples, another suitable number of magnets 112 may be coupled to backplane 102 and each magnet 112 may be arranged at any suitable location on backplane 102. Magnets 1 12 may, for example, be arranged in a pattern including a series of rows, columns, or a combination thereof. Each magnet 112 is configured to engage a respective magnet of a base plate as will be described below to align and secure the sub-display to the base plate. In certain exemplary embodiments, at least one magnet 112 or at least a portion of the plurality of magnets 112 is electrically coupled to the array of light sources 108.

[00042] Shaft 114 is coupled to the second surface 106 of the backplane 102. In this example, shaft 114 is substantially centered on backplane 102. In other examples, sub-display 100 may include multiple shafts 114 arranged at other suitable locations on backplane 102. Shaft 114 is used to align and secure sub-display 100 to a base plate as will be described below.

[00043] FIG. 2 schematically depicts an exemplary base plate 120. Base plate 120 includes a plurality of areas 122i to 1224 defined in FIG. 2 by the edges of base plate 120 and the dashed lines. Each area 122i to 1224 is configured to receive a sub- display 100 as previously described and illustrated with reference to FIGS. 1A-1B. Each area 122i to 1224 includes a plurality of press fit interlocking structures 124, a plurality of magnets 126, and a through hole 130.

[00044] Each press fit interlocking structure 124 is coupled to the top surface of the base plate 120 (i.e., the surface of the base plate that receives the sub-displays). In this example, four press fit interlocking structures 124 are coupled to base plate 120 for each area 122i to 1224 and each press fit interlocking structure 124 is arranged proximate to a corner of each area 122i to 1224. In other examples, another suitable number of press fit interlocking structures 124 may be coupled to base plate 120 for each area 122i to 1224 and each press fit interlocking structure 124 may be arranged at any suitable location of each area 1221 to 1224. Press fit interlocking structures 124 may, for example, be arranged in a pattern including a series of rows, columns, or a combination thereof within each area 122i to 122₄. In any case, each press fit interlocking structure 124 is configured to engage a corresponding press fit interlocking structure 110 of a sub-display 100 (FIG. IB).

[00045] Each magnet 126 is coupled to the top surface of the base plate 120. In this example, four magnets 126 are coupled to base plate 120 for each area 1221 to 1224. Each magnet 126 is arranged proximate a corresponding edge of each area 1221 to 1224 and substantially centered along the corresponding edge. In other examples, another suitable number of magnets 126 may be coupled to base plate 120 and each magnet 126 may be arranged at any suitable location of each area 1221 to 1224. Magnets 126 may, for example, be arranged in a pattern including a series of rows, columns, or a combination thereof within each area 122 i to 1224. In any case, each magnet 126 is configured to engage a respective magnet 112 of a sub-display 100 (FIG. I B). In certain exemplary embodiments, at least one magnet 126 of each area 122i to 1224 is electrically coupled to at least one magnet of another area 122 i to 1224 via a signal path 128. Magnets 126 may be used to pass electrical signals and/or power to magnets 1 12 of a sub-display 100, which in turn may pass the electrical signals and/or power to the array of light sources 108.

[00046] Each through hole 130 extends through base plate 102 within an area 122 1 to 1224. In this example, each through hole 130 is substantially centered within each area 122i to 1224. In other examples, base plate 120 may include multiple through holes 130 arranged at other suitable locations within each area 1221 to 1224. In any case, each through hole 130 is configured to receive a shaft 1 14 of a sub-display 100 (FIG. IB).

[00047] FIG. 3 depicts one example of the assembly of a tiled display 140. Tiled display 140 includes a base plate 120 as previously described and illustrated with reference to FIG. 2 and a plurality of sub-displays 1001 to IOO4, where each sub-display 1001 to I OO4 is a sub-display 100 as previously described and illustrated with reference to FIGS. 1A-1 B. FIG. 3 illustrates sub-displays lOOi to I OO3 attached to base plate 120 and sub-display l OC prior to attachment to base plate 120. While tiled display 140 includes four sub-displays 1001 to I OO4 and a base plate 120 including a corresponding four areas 122i to 1224 for receiving the sub-displays, in other examples tiled display 140 may include any suitable number of sub-displays arranged in any suitable number of rows and columns and a base plate including a corresponding number of areas for receiving the sub-displays.

[00048] Each area 122i to 1224 of base plate 120 receives a sub-display 1001 to I OO4, respectively. Accordingly, press fit interlocking structures 124 of each area 1221 to 1224 of base plate 120 engage the corresponding press fit interlocking structures 110 of each sub-display l OOi to I OO4, respectively. In addition, magnets 126 of each area 122i to I224 of base plate 120 engage the corresponding magnets 112 of each sub- display lOOi to I OO4, respectively. The engagement of the press fit interlocking structures and the engagement of the magnets of base plate 120 and each sub-display lOOi to I OO4 ensures the alignment of each sub-display 1001 to I OO4 with base plate 120 and the alignment of sub-displays 1001 to IOO4 with each other. Further, the engaged press fit interlocking structures and the engaged magnets of base plate 120 and each sub-display l OOi to IOO4 may, for example, be disengaged to disassemble tiled display 140 and/or to replace a sub-display 100.

[00049] The shaft 114 of each sub-display l OOi to I OO4 is received by the through hole 130 of each area 122i to 1224 of base plate 120, respectively. In certain exemplary embodiments, shaft 1 14 and through hole 130 provide a coarse alignment of each sub- display l OOi to IOO4 with each area 122i to 1224 of base plate 120, and press fit interlocking structures 110, 124 and magnets 1 12, 126 provide a fine alignment of each sub-display lOOi to I OO4 with each area 1221 to 1224 of base plate 120. Shaft 114 of each sub-display 1001 to I OO4 may, for example, be removed from a corresponding through hole 130 to disassemble tiled display 140 and/or to replace a sub -display 100.

[00050] FIGS. 4A-4B schematically depict another example of a sub-display 200. FIG.

4A is a top perspective view of sub-display 200 and FIG. 4B is a bottom view of sub- display 200. Sub-display 200 includes a backplane 202, an array of light sources 208, a plurality of press fit interlocking structures 210, a plurality of magnets 2121 and 2122, and a shaft 214. Backplane 202 includes a first surface 204 (FIG. 4A) and a second surface 206 (FIG. 4B) opposite to the first surface 204. Backplane 202 also includes a plurality of sidewalls 2051 to 2054 extending between the first surface 204 and the second surface 206. Each light source 208 is coupled to the first surface 204 of the backplane 202. Light sources 208 may be arranged in an array including any suitable numbers of rows and columns. Each light source 208 may include a LED, a microLED, an OLED, or another suitable light source. Each light source 208 is electrically coupled to circuitry (not shown) for controlling the operation of each light source.

[00051] Each press fit interlocking structure 210 is coupled to a sidewall 2051 or 2053 of the backplane 202. In other examples, press fit interlocking structures 210 may also be coupled to sidewalls 2052 and/or 2054 in place of or in addition to sidewalls 2051 and/or 2053. In this example, two press fit interlocking structures 210 are coupled to sidewall 2051 and two press fit interlocking structures 210 are coupled to sidewall 2053. Each press fit interlocking structure 210 is arranged proximate to a corner of backplane 202. In other examples, another suitable number of press fit interlocking structures 210 may be coupled to each sidewall 2051 and 2053 and each press fit interlocking structure 210 may be arranged at any suitable location on each sidewall 2051 and 2053. Each press fit interlocking structure 210 is configured to engage a corresponding press fit interlocking structure 210 of an adjacent sub-display 200 to align and secure each sub-display 200 to an adjacent sub-display 200.

[00052] Each magnet 212i is coupled to a sidewall 2051 or 2053 of the backplane 202. In other examples, magnets 212i may also be coupled to sidewalls 2052 and/or 2054 in place of or in addition to sidewalls 2051 and/or 2053. In this example, one magnet 212i is coupled to sidewall 205i and one magnet 212i is coupled to sidewall 2053. Each magnet 212i is substantially centered along the corresponding sidewall. In other examples, another suitable number of magnets 2121 may be coupled to each sidewall 205i and 2053 and each magnet 2121 may be arranged at any suitable location on each sidewall 205i and 2053. Each magnet 2121 is configured to engage a respective magnet 2121 of an adjacent sub-display 200 to align and secure the sub -display to an adjacent sub-display 200. In certain exemplary embodiments, at least one magnet 212i or at least a portion of the plurality of magnets 212i is electrically coupled to the array of light sources 208.

[00053] Each magnet 2122 is coupled to the second surface 206 of the backplane 202. In this example, four magnets 2122 are coupled to backplane 202. Each magnet 2122 is arranged proximate a corresponding sidewall of backplane 202 and substantially centered along the corresponding sidewall. In other examples, another suitable number of magnets 2122 may be coupled to backplane 202 and each magnet 2122 may be arranged at any suitable location on backplane 202. Magnets 2122 may, for example, be arranged in a pattern including a series of rows, columns, or a combination thereof. Each magnet 2122 is configured to engage a respective magnet of a base plate as will be described below to align and secure each sub-display 200 to the base plate. In certain exemplary embodiments, at least one magnet 2122 or at least a portion of the plurality of magnets 2122 is electrically coupled to the array of light sources 208.

[00054] Shaft 214 is coupled to the second surface 206 of the backplane 202. In this example, shaft 214 is substantially centered on backplane 202. In other examples, sub-display 200 may include multiple shafts 214 arranged at other suitable locations on backplane 202. Shaft 214 is used to align and secure sub-display 200 to a base plate as will be described below.

[00055] FIG. 5 schematically depicts another example of a base plate 220. Base plate 220 includes a plurality of areas 2221 to 2224 defined in FIG. 5 by the edges of base plate 220 and the dashed lines. Each area 2221 to 2224 is configured to receive a sub- display 200 as previously described and illustrated with reference to FIGS. 4A-4B. Each area 222i to 2224 includes a plurality of magnets 226 and a through hole 230.

[00056] Each magnet 226 is coupled to the top surface of the base plate 220. In this example, four magnets 226 are coupled to base plate 220 for each area 2221 to 2224. Each magnet 226 is arranged proximate a corresponding edge of each area 2221 to 2224 and substantially centered along the corresponding edge. In other examples, another suitable number of magnets 226 may be coupled to base plate 220 and each magnet 226 may be arranged at any suitable location of each area 2221 to 2224. Magnets 226 may, for example, be arranged in a pattern including a series of rows, columns, or a combination thereof within each area 2221 to 2224. In any case, each magnet 226 is configured to engage a respective magnet 2122 of a sub-display 200 (FIG. 4B). In certain exemplary embodiments, at least one magnet 226 of each area 222i to 2224 is electrically coupled to at least one magnet of another area 2221 to 2224 via a signal path 228. Magnets 226 may be used to pass electrical signals and/or power to magnets 2122 of a sub-display 200, which in turn may pass the electrical signals and/or power to the array of light sources 208. [00057] Each through hole 230 extends through base plate 220 within an area 222 1 to 2224. In this example, each through hole 230 is substantially centered within each area 2221 to 2224. In other examples, base plate 220 may include multiple through holes 230 arranged at other suitable locations within each area 222 i to 2224. In any case, each through hole 230 is configured to receive a shaft 214 of a sub-display 200 (FIG. 4B).

[00058] FIG. 6 depicts another example of the assembly of a tiled display 240. Tiled display 240 includes a base plate 220 as previously described and illustrated with reference to FIG. 5 and a plurality of sub-displays 200i to 2004, where each sub- display 200i to 2ΟΟ4 is a sub-display 200 as previously described and illustrated with reference to FIGS. 4A-4B. FIG. 6 illustrates sub-displays 2001 to 2ΟΟ3 attached to base plate 220 and sub-display 2ΟΟ4 prior to attachment to base plate 220. While tiled display 240 includes four sub-displays 2001 to 2ΟΟ4 and a base plate 220 including a corresponding four areas 2221 to 2224 for receiving the sub-displays, in other examples tiled display 240 may include any suitable number of sub-displays arranged in any suitable number of rows and columns and a base plate including a corresponding number of areas for receiving the sub-displays.

[00059] Each area 222i to 2224 of base plate 220 receives a sub-display 200 i to 2ΟΟ4, respectively. Accordingly, magnets 226 of each area 222i to 2224 of base plate 220 engage the corresponding magnets 2122 of each sub-display 2001 to 2ΟΟ4, respectively. In addition, press fit interlocking structures 210 of sub-display 200i engage the corresponding press fit interlocking structures 210 of adjacent sub-display 2ΟΟ2, and press fit interlocking structures 210 of sub-display 2ΟΟ3 engage the corresponding press fit interlocking structures 210 of adjacent sub-display 2ΟΟ₄. Magnet 212i of sub-display 200i engages the corresponding magnet 212₁ of adjacent sub-display 2ΟΟ2, and magnet 212i of sub-display 2ΟΟ3 engages the corresponding magnet 212i of adjacent sub-display 2ΟΟ4. The engagement of the press fit interlocking structures 210 and the engagement of the magnets 2121 of sub-displays 200i to 2ΟΟ4 ensures the alignment of sub-displays 2001 to 2ΟΟ4 with each other. The engagement of the magnets 2122, 226 of sub-displays 2001 to 2ΟΟ4 and base plate 220 ensures the alignment of each sub-display 2001 to 2ΟΟ4 with base plate 220. Further, the engaged press fit interlocking structures and the engaged magnets of base plate 120 and each sub-display 2001 to 2ΟΟ4 may, for example, be disengaged to disassemble tiled display 240 and/or to replace a sub-display

[00060] The shaft 214 of each sub-display 2001 to 2ΟΟ4 is received by the through hole 230 of each area 222i to 2224 of base plate 220, respectively In certain exemplary embodiments, shaft 214 and through hole 230 provide a coarse alignment of each sub- display 2001 to 2ΟΟ4 with each area 222i to 2224 of base plate 220, and press fit interlocking structures 210 and magnets 2121 , 2122, 226 provide a fine alignment of each sub-display 200i to 2ΟΟ4 with each area 222i to 2224 of base plate 220 and with each other. Shaft 214 of each sub-display 200i to 2ΟΟ4 may, for example, be removed from a corresponding through hole 230 to disassemble tiled display 240 and/or to replace a sub-display.

[00061] FIG. 7 depicts an exemplary safety feature 300 of a sub-display. Safety feature 300 includes a shaft 304 coupled to a backplane 302 of a sub-display, such as sub- display 100 of FIGS. 1A-1B or sub-display 200 of FIGS. 4A-4B. In certain exemplary embodiments, shaft 304 is used for shaft 114 of sub-display 100 or shaft 214 of sub-display 200. A first end of shaft 304 is coupled to the bottom (i.e., second) surface of backplane 302. A second end of shaft 304 opposite to the first end includes a through hole 306.

[00062] FIG. 8 depicts an exemplary safety feature 320 of a base plate. Safety feature 320 includes a hollow shaft 324 coupled to the bottom surface of a base plate 322, such as base plate 120 of FIG. 2 or base plate 220 of FIG. 5. Base plate 322 and hollow shaft 324 define a through hole 326. In certain exemplary embodiments, through hole 326 is used for each through hole 130 of base plate 120 or each through hole 230 of base plate 220.

[00063] FIG. 9 depicts an exemplary embodiment of a safety feature 300 of a sub-display coupled to a safety feature 320 of a base plate. Shaft 304 of safety feature 300 of FIG. 7 is inserted into through hole 326 of safety feature 320 of FIG. 8 such that the bottom (i.e. second) surface of backplane 302 contacts the top surface of base plate 322. Shaft 304 extends through hollow shaft 324 such that a portion of shaft 304 extends past the bottom of hollow shaft 324. As depicted in FIG. 10, a removable locking pin 308 is inserted into through hole 306. Removable locking pin 308 extends through shaft 304 and is sized to prevent passage of the locking pin through hollow shaft 324 when engaged with shaft 304 to secure the sub-display to the base plate. With removable locking pin 308 inserted in through hole 306, accidental disassembly of the sub-display from the base plate is prevented. Removable locking pin 308 may, for example, be removed from through hole 306 to disassemble the sub-display from the base plate. In certain exemplary embodiments, removable locking pin 308 is coupled to base plate 322 via a cable (not shown) to secure the locking pin to base plate 322 when the locking pin is not inserted in through hole 306.

[00064] FIGS. 11A-11B depict exemplary press fit interlocking structures 410 of a sub- display 400. FIG. 11A is a top view of sub-display 400 and FIG. 1 IB is a bottom view of sub-display 400. Sub-display 400 includes a backplane 402, an array of light sources (not shown), and a plurality of press fit interlocking structures 410. Backplane 402 includes a first surface 404 (FIG. 11 A) and a second surface 406 (FIG. 1 IB) opposite to the first surface 404.

[00065] Each press fit interlocking structure 410 is coupled to the second surface 406 of the backplane 402. In this example, four press fit interlocking structures 410 are coupled to backplane 402 and each press fit interlocking structure 410 is arranged proximate to a corner of backplane 402. In other examples, another suitable number of press fit interlocking structures 410 may be coupled to backplane 402 and each press fit interlocking structure 410 may be arranged at any suitable location on backplane 402. Press fit interlocking structures 410 may, for example, be arranged in a pattern including a series of rows, columns, or a combination thereof. Each press fit interlocking structure 410 is configured to engage a corresponding press fit interlocking structure of a base plate as will be described below to align and secure the sub-display to the base plate. In this example, each press fit interlocking structure 410 is a stud, such as a pin, bump, male luer, or the like. Backplane 402 may include a glass substrate and these studs may be created, for example, by a laser process on the glass substrate.

[00066] FIG. 12 depicts exemplary press fit interlocking structures 424 of a base plate 420. Base plate 420 includes a plurality of areas 4221 and 4222 defined in FIG. 12 by the edges of base plate 420 and the dashed line. Each area 4221 and 4222 is configured to receive a sub-display 400 as previously described and illustrated with reference to FIGS. 11 A-l IB. Each area 422i and 4222 includes a plurality of press fit interlocking structures 424.

[00067] Each press fit interlocking structure 424 extends into the top surface of the base plate 420. In this example, four press fit interlocking structures 424 extend into base plate 420 for each area 4221 and 4222 and each press fit interlocking structure 424 is arranged proximate to a corner of each area 4221 and 4222. In other examples, another suitable number of press fit interlocking structures 424 may extend into base plate 420 for each area 4221 and 4222 and each press fit interlocking structure 424 may be arranged at any suitable location of each area 4221 and 4222. Press fit interlocking structures 424 may, for example, be arranged in a pattern including a series of rows, columns, or a combination thereof within each area 4221 and 4222. In any case, each press fit interlocking structure 424 is configured to engage a corresponding press fit interlocking structure 410 of a sub-display 400 (FIGS. 11A- 11B). In this example, each press fit interlocking structure 424 includes a coupling recess, such as a hole, a cavity, a female luer, or the like.

[00068] FIG. 13 depicts one example of the assembly of a tiled display 440. Tiled display 440 includes a base plate 420 as previously described and illustrated with reference to FIG. 12 and a plurality of sub-displays 4001 and 4002, where each sub- display 400i and 4002 is a sub-display 400 as previously described and illustrated with reference to FIGS. 11A-11B. FIG. 13 illustrates sub-displays 4001 and 4002 just prior to attachment to base plate 420. While tiled display 440 includes two sub-displays 400i and 4002 and a base plate 420 including a corresponding two areas 4221 and 4222 for receiving the sub-displays, in other examples tiled display 440 may include any suitable number of sub-displays arranged in any suitable number of rows and columns and a base plate including a corresponding number of areas for receiving the sub- displays.

[00069] Each area 422i and 4222 of base plate 420 receives a sub-display 4001 and 4002, respectively. Accordingly, press fit interlocking structures 424 of each area 4221 and 4222 of base plate 420 engage the corresponding press fit interlocking structures 410 of each sub-display 4001 and 4002, respectively. The engagement of the press fit interlocking structures of base plate 420 and each sub-display 4001 and 4002 ensures the alignment of each sub-display 4001 and 4002 with base plate 420 and the alignment of sub-displays 4001 and 4002 with each other. Further, the engaged press fit interlocking structures of base plate 420 and each sub-display 4001 and 4002 may, for example, be disengaged to disassemble tiled display 440 and/or to replace a sub- display.

[00070] FIGS. 14A-14B depict an exemplary pair of press fit interlocking structures.

FIG. 14A depicts a press fit interlocking structure 500 configured to engage with a press fit interlocking structure 520 depicted by FIG. 14B. In certain exemplary embodiments, press fit interlocking structures 500 and 520 may be used for press fit interlocking structures 110 of sub-display 100 (FIGS. 1A-1B), press fit interlocking structures 124 of base plate 120 (FIG. 2), and/or press fit interlocking structures 210 of sub-display 200 (FIGS. 4A^B). Press fit interlocking structure 500 includes a plurality of solid studs 510 (i.e., nine in this example) coupled to a surface 502. Corresponding press fit interlocking structure 520 includes a plurality of hollow studs 524 (i.e., four in this example) coupled to a surface 522.

[00071] FIG. 15A-15B depict examples of the pair of press fit interlocking structures of FIGS. 14A-14B engaged with each other. FIG. 15A depicts an exemplary embodiment in which press fit interlocking structure 520 is a press fit interlocking structure of a base plate and press fit interlocking structure 500 is a corresponding press fit interlocking structure of a backplane of a sub-display. Accordingly, studs 524 are coupled to the top surface of the base plate, and studs 510 are coupled to the bottom (i.e., second surface) of the backplane of the sub-display. FIG. 15B depicts an exemplary embodiment in which press fit interlocking structure 500 is a press fit interlocking structure of a base plate and press fit interlocking structure 520 is a corresponding press fit interlocking structure of a backplane of a sub-display. Accordingly, studs 510 are coupled to the top surface of the base plate, and studs 524 are coupled to the bottom (i.e., second surface) of the backplane of the sub-display. In other examples, press fit interlocking structure 500 may be a press fit interlocking structure of a sidewall of the backplane of a first sub-display and press fit interlocking structure 520 may be a corresponding press fit interlocking structure of a sidewall of the backplane of a second sub-display for aligning and securing the first and second sub -displays to each other.

[00072] FIG. 16 depicts an internal view of the engaged press fit interlocking structures of FIG. 15B. The four hollow studs 524 are pressed between the nine solid studs 510 to engage press fit interlocking structure 520 with press fit interlocking structure 500.

[00073] FIG. 17 depicts other examples of press fit interlocking structures. In this example, the four hollow studs 524 of press fit interlocking structure 520 are replaced with studs 530, 532, and 534. Studs 530 are hollow and octagonal in shape, studs 532 are solid and X-shaped, and studs 534 are solid and rectangular shaped. In other examples, the studs may have other suitable shapes, sizes, and/or configurations. Studs 530, 532, and 534 are configured to engage with studs 510 of press fit interlocking structure 500.

[00074] FIG. 18 a flow diagram illustrating an exemplary embodiment of a method 600 for fabricating a display. At 602, method 600 includes attaching a first sub-display comprising a first plurality of first press fit interlocking structures to a base plate comprising a plurality of second press fit interlocking structures such that the first plurality of first press fit interlocking structures engage with a first portion of the plurality of second press fit interlocking structures to secure and align the first sub- display with the base plate. At 604, method 600 includes attaching a second sub- display comprising a second plurality of first press fit interlocking structures to the base plate such that the second plurality of first press fit interlocking structures engage with a second portion of the plurality of second press fit interlocking structures to secure and align the second sub -display with the base plate.

[00075] In certain exemplary embodiments, the first sub-display comprises a first microLED sub-display, and the second sub-display comprises a second microLED sub-display. Attaching the first sub-display to the base plate may, for example, include engaging a first plurality of first magnets of the first sub-display with a first portion of a plurality of second magnets of the base plate. Likewise, attaching the second sub-display to the base plate may, for example, include engaging a second plurality of first magnets of the second sub-display with a second portion of the plurality of second magnets of the base plate. Method 600 may, for example, also include passing a shaft of each of the first sub-display and the second sub-display through a corresponding through hole of the base plate and securing the shaft of each of the first sub-display and the second sub-display within the corresponding through hole to prevent disengagement of each of the first sub-display and the second sub- display from the base plate.

[00076] It will be apparent to those skilled in the art that various modifications and variations can be made to embodiments of the present disclosure without departing from the spirit and scope of the disclosure. Thus it is intended that the present disclosure cover such modifications and variations provided they come within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. A sub-display for a tiled display, the sub-display comprising:

a backplane comprising a first surface and a second surface opposite to the first surface;

an array of light sources coupled to the first surface of the backplane; and a plurality of press fit interlocking structures coupled to the second surface of the backplane, each of the plurality of press fit interlocking structures configured to engage a corresponding press fit interlocking structure of a base plate to align and secure the sub-display to the base plate.

2. The sub-display of claim 1, further comprising:

a plurality of magnets coupled to the second surface of the backplane, each of the plurality of magnets configured to engage a respective magnet of the base plate.

3. The sub-display of claim 2, wherein at least a portion of the plurality of magnets are electrically coupled to the array of light sources.

4. The sub-display of claim 1, further comprising:

at least one magnet coupled to a sidewall of the backplane, the sidewall extending between the first surface and the second surface.

5. The sub-display of claim 4, wherein the at least one magnet is electrically coupled to the array of light sources.

6. The sub-display of claim 1, further comprising:

a shaft comprising a first end coupled to the second surface of the backplane and a second end opposite to the first end; and

a removable locking pin extending through the second end of the shaft, wherein the shaft is configured to pass through a hole in the base plate to secure the sub-display to the base plate.

7. The sub-display of claim 6, wherein the removable locking pin is a quick release locking pin.

8. The sub-display of claim 1 , wherein the plurality of press fit interlocking structures comprise studs.

9. The sub-display of claim 8, wherein the studs are hollow.

10. The sub-display of claim 8, wherein the studs comprise pins, bumps, or male luers.

11. The sub-display of claim 1, wherein a press fit interlocking structure of the plurality of press fit interlocking structures is arranged at each corner of the backplane.

12. The sub-display of claim 1, wherein a press fit interlocking structure of the plurality of press fit interlocking structures is arranged on a sidewall of the backplane, the sidewall of the backplane extending between the first surface and the second surface.

13. The sub-display of claim 1 , wherein the array of light sources comprises an array of microLEDs.

14. A sub-display for a tiled display, the sub-display comprising:

a backplane comprising a first surface, a second surface opposite to the first surface, and a sidewall extending between the first surface and the second surface; an array of light sources coupled to the first surface of the backplane; and a plurality of press fit interlocking structures coupled to the sidewall of the backplane, each of the plurality of press fit interlocking structures configured to engage a corresponding press fit interlocking structure of a further sub-display to align and secure the sub-display to the further sub-display.

15. The sub-display of claim 14, further comprising:

at least one magnet coupled to the sidewall of the backplane.

16. The sub-display of claim 15, wherein the at least one magnet is electrically coupled to the array of light sources.

17. A sub-display for a tiled display, the sub-display comprising:

an array of light sources coupled to the first surface of the backplane; and a plurality of magnets coupled to the second surface of the backplane, each of the plurality of magnets configured to engage a respective magnet of a base plate to align and secure the sub-display to the base plate.

18. The sub-display of claim 17, wherein at least a portion of the plurality of magnets are electrically coupled to the array of light sources.

19. The sub-display of claim 17, further comprising:

20. A sub-display for a tiled display, the sub-display comprising:

a backplane comprising a first surface, a second surface opposite to the first surface, and sidewalls extending between the first surface and the second surface; an array of light sources coupled to the first surface of the backplane; and a plurality of magnets coupled to the sidewalls of the backplane, each of the plurality of magnets configured to engage a respective magnet of a further sub- display to align and secure the sub-display to the further sub-display.

21. The sub-display of claim 20, wherein at least one magnet of the plurality of magnets is electrically coupled to the array of light sources.

22. A tiled display comprising:

a base plate comprising a plurality of first press fit interlocking structures in a first area and a plurality of second press fit interlocking structures in a second area; a first sub-display comprising a plurality of third press fit interlocking structures engaged with the plurality of first press fit interlocking structures such that the first sub-display is aligned with and secured to the first area of the base plate; and a second sub-display comprising a plurality of fourth press fit interlocking structures engaged with the plurality of second press fit interlocking structures such that the second sub-display is aligned with and secured to the second area of the base plate.

23. The tiled display of claim 22, wherein the base plate comprises a plurality of first magnets in the first area and a plurality of second magnets in the second area,

the first sub-display comprises a plurality of third magnets engaged with the plurality of first magnets, and

the second sub-display comprises a plurality of fourth magnets engaged with the plurality of second magnets.

24. The tiled display of claim 23, wherein at least one of the plurality of first magnets is electrically coupled to at least one of the plurality of second magnets.

25. The tiled display of claim 22, wherein the base plate comprises a first through hole in the first area and a second through hole in the second area, the first sub-display comprises a first shaft extending through the first through hole and a first locking pin securing the first shaft within the first through hole, and

the second sub-display comprises a second shaft extending through the second through hole and a second locking pin securing the second shaft within the second through hole.

26. The tiled display of claim 22, wherein the plurality of first press fit interlocking structures and the plurality of second press fit interlocking structures comprise holes, cavities, or female luers, and

the plurality of third press fit interlocking structures and the plurality of fourth press fit interlocking structures comprise pins, bumps, or male luers engaged with the holes, cavities, or female luers.

27. The tiled display of claim 22, wherein each of the first sub-display and the second sub-display comprises a micro LED sub-display.

28. A method for fabricating a display, the method comprising:

attaching a first sub-display comprising a first plurality of first press fit interlocking structures to a base plate comprising a plurality of second press fit interlocking structures such that the first plurality of first press fit interlocking structures engage with a first portion of the plurality of second press fit interlocking structures to secure and align the first sub-display with the base plate; and

attaching a second sub-display comprising a second plurality of first press fit interlocking structures to the base plate such that the second plurality of first press fit interlocking structures engage with a second portion of the plurality of second press fit interlocking structures to secure and align the second sub-display with the base plate.

29. The method of claim 28, further comprising:

passing a shaft of each of the first sub-display and the second sub-display through a corresponding through hole of the base plate; and

securing the shaft of each of the first sub-display and the second sub-display within the corresponding through hole to prevent disengagement of each of the first sub-display and the second sub-display from the base plate.

30. The method of claim 28, wherein attaching the first sub-display to the base plate comprises engaging a first plurality of first magnets of the first sub- display with a first portion of a plurality of second magnets of the base plate, and

attaching the second sub-display to the base plate comprises engaging a second plurality of first magnets of the second sub-display with a second portion of the plurality of second magnets of the base plate.

31. The method of claim 28, wherein the first sub-display comprises a first microLED sub-display, and

the second sub-display comprises a second microLED sub-display.