Method of constructing and sealing tiled, flat-panel displays

Abstract

The present invention features methods and apparatuses for sealing tiled, flat-panel displays (FPDs). Tile edges corresponding with the display's perimeter edges are designed with a wide seal. Interior edges, however, have narrow seals in order to maintain the desired, constant, pixel pitch across tile boundaries. In some cases, this invention applies specifically to arrays of tiles 2×2 or less, and, in other cases, to N×M arrays, where N and M are any integer numbers. The tiles are enclosed with top and bottom glass plates, which are sealed with an adhesive bond to the tiles on the outside perimeter of the tiled display. Vertical seams (where tiles meet at the perimeter of the FPD) are sealed with a small amount of polymer. The seal may be constructed between a cover plate and a back plate, sandwiching the tiles. The AMLCD edges may be coated with either a non-permeable material or a polymer having an extremely low permeability (for example, Parylene™). Alternatively, the edge sealing of individual tiles can be achieved by using a metallized film adhesive that is bonded to the tile edges. A low-temperature, sintered Solgel can be used to achieve extremely narrow, yet mechanically strong, seals for individual tiles. Still another enhancement employs a metallurgical seal outside a narrow, polymer seal.