Adhesive Spacer for Display Tile Flatness
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Solution Overview
Problem
Existing technologies for aligning display tiles in tiled displays face challenges in ensuring perfect alignment of LEDs with the carrier board, leading to visual artefacts due to variations in the z-coordinate and tolerances in LED positioning.
Innovation Solution
The use of an adhesive spacer between the display board and the carrier board, which adapts to differences in distance automatically, allows for precise alignment and adjustment of the LED position relative to the carrier board, facilitating automated manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment methods are used to align LEDs in the perpendicular direction, then the z-position alignment is improved, but the ease of manufacture and automation deteriorates
Solution Approach 1:
The patent replaces manual mechanical adjustment operations with an automated positioning system that uses programmable mechanisms (such as motorized actuators or precision translation stages) to adjust and lock the LED board position. This substitution maintains the precision of manual adjustment while enabling automation, allowing the alignment process to be controlled by software and integrated into automated assembly lines.
2Manufacturing precision
If multiple adjusting means are positioned in openings of the carrier board, then the alignment precision is improved, but the device complexity and manufacturing time increases
Solution Approach 1:
The patent designs the alignment fixture as a universal, multi-functional device that can perform multiple alignment operations. The same fixture with its adjustable positioning mechanism is used for both initial board alignment and subsequent LED position adjustment, eliminating the need for multiple specialized adjusting components. This universal tool reduces overall device complexity while maintaining high alignment precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures improved alignment of tiles, reduces visual artefacts, and allows for mass production by automating the process, maintaining a Z-direction difference below 3% of the pixel pitch.
Implementation Method 1
The display board and the carrier board are fastened together by the intermediary of a spacer positioned between the display board and the carrier board
Data Source
AI summary
A display tile includes a display board and a carrier board, the carrier board being for attachment to a frame or a bracket, the display board and the carrier board being fastened together by the intermediary of a spacer positioned between the display board and the carrier board. The spacer is glue or adhesive. The adhesive forms the spacer itself. The spacer can engage in an opening in the carrier board. The display board has image forming elements and the spacer is for setting a relative position of the tops of the image forming elements with respect to the carrier board.