Adjustable Display Tile for Tiled LED Displays
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Solution Overview
Problem
Existing tiled display systems face issues with LED misalignment due to tolerances in the position of LEDs relative to their boards, leading to visual artefacts, and current adjustment methods are impractical and uneconomical for precise alignment.
Innovation Solution
A method and apparatus that adjust the distance between the LEDs on a board and the carrier board using an adjusting means with a spacer and glue, allowing precise alignment without requiring custom-machined components, ensuring the LEDs are in the same plane across the display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reference pins are used to align the LED board with the carrier board, then the LED board alignment is improved, but the LED position accuracy deteriorates due to tolerances in LED mounting
Solution Approach 1:
The patent introduces an intermediary adjusting means between the LED board and carrier board that compensates for cumulative tolerances. This adjusting means acts as a mediator that absorbs positioning errors from both the LED board mounting and LED soldering processes, ensuring precise LED alignment across the tiled display without requiring perfect precision at each individual step.
2Manufacturing precision
If clips and receptacles are used to align adjacent display tiles, then the tile alignment is improved, but the z-coordinate alignment of LEDs deteriorates
Solution Approach 1:
The patent addresses the z-coordinate alignment issue by introducing adjusting means that operates in the vertical dimension (z-axis) between the LED board and carrier board. This allows independent adjustment of LED height position separate from the horizontal tile alignment provided by clips and receptacles, enabling precise control of LED z-positions to eliminate visual artifacts.
3Ease of operation
If washers are used to adjust the distance between LED board and carrier board, then the distance adjustment is improved, but the manufacturing complexity and cost deteriorate
Solution Approach 1:
The patent employs dynamic adjusting means that can be modified or repositioned to achieve the required LED-to-carrier-board distance. Rather than requiring custom-machined washers for each specific distance requirement, the adjusting means provides a flexible, adjustable mechanism that adapts to different spacing needs, simplifying manufacturing while maintaining ease of operation.
4Manufacturing precision
If LED boards are perfectly aligned with carrier boards, then the alignment precision is improved, but visual artifacts persist due to LED position tolerances
Solution Approach 1:
The adjusting means serves as a compensatory intermediary that absorbs the cumulative effect of tolerances from LED mounting and LED soldering processes. By introducing this intermediate adjustment layer, the system achieves precise LED positioning and eliminates visual artifacts even when individual components are manufactured within standard tolerance ranges, without requiring perfect precision at each step.
Data Source
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AI summary
The invention relates to a display tile comprising a display board (1) and a carrier board (3) fastened together by the intermediary of a spacer (7) and an adjusting means positioned between the spacer (7) and the carrier board (3) whereby the adjusting means engage in an opening in the carrier board (3). The invention further relates to methods to adjust the distance between the top of a LED (2) on a first surface (11) of a LED board on a display tile and the back surface (32) of the carrier board of the display tile.