Carbon Fibre LED Display Substrate for Heat Dissipation and Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional LED display devices face issues with heavy weight, low strength, and poor heat dissipation, leading to deformation and reduced stability, especially due to the use of metal substrates which complicate assembly and transportation.
Innovation Solution
A carbon fibre-based supporting substrate is designed with a sandwich structure, incorporating thermal-conductive materials and reinforcing bosses, allowing for efficient heat dissipation and enhanced structural integrity, featuring a lightweight and high-strength construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metal aluminum sheet is used as a heat dissipation module and frame, then heat dissipation effect is improved, but weight increases and deformation occurs due to temperature changes
Solution Approach 1:
The patent uses a composite structure consisting of a lightweight substrate (aluminum alloy or magnesium alloy) combined with a carbon fiber reinforcement layer. This composite material provides both the heat dissipation capability of metal and the lightweight, high-strength properties of carbon fiber, resolving the contradiction between heat dissipation effectiveness and weight reduction.
Solution Approach 2:
The patent changes the material parameters by selecting specific aluminum alloy or magnesium alloy substrates with optimized thickness and thermal conductivity, and controlling the carbon fiber layer properties. This parameter optimization achieves the balance between heat dissipation performance and weight reduction.
2Temperature
If a metal aluminum sheet is used as a frame, then heat dissipation is improved, but strength and stability decrease due to deformation from temperature changes
Solution Approach 1:
The composite structure of metal substrate with carbon fiber reinforcement combines the thermal conductivity of metal with the dimensional stability and low thermal expansion of carbon fiber. This prevents frame deformation under temperature changes while maintaining heat dissipation capability.
Solution Approach 2:
The patent addresses thermal expansion issues by using carbon fiber material which has low thermal expansion characteristics, counteracting the thermal expansion of the metal substrate and maintaining frame stability under temperature variations.
3Temperature
If a box-shaped design with fan is used, then heat dissipation is addressed, but device complexity, volume, and noise increase
Solution Approach 1:
The patent extracts and eliminates the fan component from the heat dissipation system, relying instead on the inherent thermal conductivity of the metal substrate and the heat dissipation effect of the carbon fiber layer to conduct and radiate heat passively, thereby simplifying the overall structure.
Solution Approach 2:
The heat dissipation function is achieved through the self-service capability of the materials themselves - the aluminum alloy or magnesium alloy substrate conducts heat internally, and the carbon fiber layer provides external heat radiation, eliminating the need for active cooling components.
4Temperature
If a heavy metal substrate is used, then heat dissipation is improved, but ease of assembly and transportation deteriorates
Solution Approach 1:
The composite material structure combines lightweight metal substrates (aluminum alloy or magnesium alloy) with carbon fiber reinforcement, achieving both excellent heat conductivity and reduced weight, thereby improving ease of assembly and transportation.
Solution Approach 2:
The patent optimizes material parameters by selecting lightweight alloy compositions and controlling substrate thickness, achieving the right balance between thermal conductivity and weight for improved handling and assembly.
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
The carbon fibre substrate provides a lightweight, high-strength, and thermally conductive solution that improves stability and heat dissipation, facilitating easier assembly, transportation, and extending the lifespan of LED display devices.
Implementation Method 1
the carbon fibre substrate provides... a good thermal conductivity... The carbon fibre fabric... adding resin into the carbon fibre fabric to form the prepreg
Implementation Method 2
incorporating thermal-conductive materials... efficient heat dissipation
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Disclosed are a manufacturing method for a support substrate (14), and an LED display device. The support substrate (14) is made of a carbon fibre material. The manufacturing method for the support substrate (14) comprises the steps of: S1: preparing a carbon fibre prepreg fabric; S2: preparing a support substrate (14) sheet; S3: pre-forming; and S4: molding. The LED display device comprises at least one cellular LED display screen (1), and the cellular LED display screen (1) comprises a support substrate (14) manufactured using the abovementioned method. The cellular LED display screen (1) comprises an LED display module, the support substrate (14), a control plate and a back cover (16). The LED display module comprises a face guard (11), a lamp plate (12) and a backing plate (13). The support substrate (14) is arranged between the LED display module and the control plate in a sandwich manner; the back cover (16) is connected to the support substrate (14) through studs; and the adjacent cellular LED display screens (1) are assembled by connecting bases (142) and locating pins (143) arranged at the four corners of the support substrate (14). The LED display device is simple in structure, light and thin, has a strong bearing capacity, and is convenient to install and low in transportation costs.