Composite Display Modules Edge Sealing Gap Reduction
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Solution Overview
Problem
The current inability to manufacture large-size display modules in one piece due to cutting tolerance and edge sealing requirements results in significant inactive gaps when smaller modules are assembled, leading to undesirable visible dead space, particularly problematic for applications like price rails where continuous active image areas are desired.
Innovation Solution
The development of composite display modules where multiple single display modules are mounted closely on a single back support structure, edge-sealed or with overlapping ends, and optionally featuring an optical compensation window to minimize visible dead space, with designs accommodating both one and two-dimensional configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple smaller display modules are assembled together to create a large-size display, then the desired large display area is achieved, but significant inactive gaps appear between modules due to cutting tolerance and edge sealing requirements
Solution Approach 1:
The invention divides the large display into multiple smaller display modules that can be manufactured separately and then assembled together. Each module is kept small enough to be manufactured without excessive gaps, yet large enough to provide sufficient display area when combined. The segmentation allows optimization of each module's size to minimize gaps while achieving the desired total display area.
Solution Approach 2:
The invention merges multiple smaller display modules into a single composite display system by mounting them on a common back support structure. The modules are positioned edge-to-edge with minimal gaps, and the entire assembly is edge-sealed to protect the integrity of all modules. This combining approach achieves large display area while minimizing the visual impact of individual module gaps.
2Reliability
If edge sealing is applied to protect module integrity, then reliability is improved, but the inactive gap width increases
Solution Approach 1:
Instead of sealing each module individually (which would require wide gaps), the invention combines multiple modules on a shared back support structure and applies a single edge seal around the entire composite display perimeter. This approach maintains module integrity through the seal while minimizing gaps between modules, as the seal protects the assembly as a whole rather than requiring separation between individually sealed modules.
3Manufacturing precision
If cutting tolerance is reduced to minimize gaps, then manufacturing precision is improved, but the difficulty and cost of manufacturing increase
Solution Approach 1:
The invention segments the display into modules of optimized size that balance manufacturing ease with gap minimization. Rather than attempting to manufacture one extremely large module with tight tolerances (which would be difficult and expensive), or many tiny modules (which would create excessive gaps), the segmentation approach finds an optimal module size that is easy to manufacture while minimizing gaps when assembled.
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 approach significantly reduces visible dead space between display modules, enabling longer active image sections with minimal discontinuity, making it suitable for applications like price rails where continuous displays are essential.
Implementation Method 1
the display panel comprises display cells filled with an electrophoretic fluid
Data Source
AI summary
The present invention provides composite display modules which have reduced visible dead space between display modules. This is of particular interest for the price rail, where it is desirable to achieve a long (about 3-4 ft) section of an active module. The present invention is directed to a composite display module comprising: (a) more than one single display module, wherein said single display modules are not edge-sealed and they are mounted on a single back support structure and are kept tightly close to each other right up to their edges; and (b) said composite display module is edge sealed.