TracXon B.V., Netherlands
The purpose of this project is to design, develop and produce an ultra-thin high-resolution (p2 or p3) display for automotive interior applications. Being a display, each RGD LED needs to driven individually, which makes the backplane extremely complex, unlike a passive matrix display.
Given the very high density of smart RGB LEDs, as well as the driving scheme, a high density backplane is required. The customer requirement of low-cost foil as a substrate added to the complexity. The customer requires this display to be eventually part of a larger transparent PET foil containing other functionalities, albeit distributed over a larger area.
TracXon has taken up this challenge to create a fully printed backplane with double-sided circuitry requiring the creation of 4k VIAs to connect both the sides, as well as the assembly of >4k smart RGB LEDs of 1 mm x 1 mm size. We have successfully created the first prototype, which is very likely an industry-first in terms of the complexity of this hybrid printed electronics device.
Functionality
- The display size is 160 mm x 120 mm.
- Part of the circuitry (backplane) is printed on Side-B of the foil and the conductive ink is cured in a convection oven.
- More than 4k VIA holes are drilled using laser from Side-A, stopping on the circuitry on Side-B. Hence, they are BLIND VIAs.
- Subsequently, the second layer of the circuitry is printed on Side-A. While printing, VIA filling is also realized, based on a very tight and optimized process window. Thus, in a single print step, circuit structures as well as 4k VIA interconnections are realized. The conductive ink is then oven cured.
- After the curing step, conductive adhesive dots are dispensed on the circuitry, after which >4k smart RGB LEDs are bonded and the adhesive is cured.
- After testing the display functionality, a transparent elastomeric foil is laminated on the display to protect it.
- External hardware driver that is programmable is used to drive the display.
Benefits of the project
- Ultra-thin RGB LED display of high resolution.
- This display can be part of a larger foil containing other functionalities. In other words, a number of such local display clusters can be produced on a larger foil substrate, which makes it suitable for integration in glass (automotive glass, building glass, etc.).
- Additive manufacturing technologies used, thereby eliminating the need for wasteful chemical etching and high temperature vaccum processes.
- Can be easily upscaled and produced in Europe at high volumes using fully automated R2R processes.
Target Industry
- Digital signage and advertising
- Display for smart home applications
- Display for automotive applications
Organic & Printed Components
- Conductive path
- Interconnection
- Printed VIA interconnections
Classical Components
- Smart LEDs (RGB)
- Driving hardware is Arduino-based