Curved LED Module Assembly for Smooth Spherical Displays
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Solution Overview
Problem
Current spherical or near-spherical LED display screens are not smooth enough for aesthetic purposes, necessitating the development of a more refined and uniform spherical LED display system.
Innovation Solution
The design involves removable LED modules with a curved substrate and support, including a heat sink and insulating cover, connected to a skeleton using magnets, allowing for flexible and curved formation of a spherical shape, with the substrate's dimensions defined by a specific formula to achieve a smoother globe-like appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional LED display modules are used to form a spherical display, then the display can be constructed, but the surface is not smooth enough for aesthetic purposes
Solution Approach 1:
The spherical LED display is divided into multiple removable LED modules, each with a curved substrate. This segmentation allows each module to be precisely manufactured with controlled curvature, and when assembled together, they form a smooth spherical surface. The substrate itself is curved rather than flat, which is key to achieving the smooth spherical appearance when modules are joined.
Solution Approach 2:
The substrate of each LED module is designed with a curved shape rather than a flat surface. This curvature is essential for achieving the smooth spherical appearance of the overall display. The curved substrate allows LED components to be mounted on a pre-formed curve, and when multiple such modules are assembled, they create a uniformly smooth spherical surface.
2Shape
If LEDs are mounted on a curved substrate to form a smooth sphere, then aesthetic appearance is improved, but heat dissipation becomes more challenging
Solution Approach 1:
The display is segmented into multiple independent modules, each with its own heat sink. This allows heat to be dissipated locally at each module rather than requiring a complex global heat management system for the entire sphere. Each module can be optimized for heat dissipation independently.
Solution Approach 2:
A heat sink is introduced as an intermediary component between the LED light-emitting components and the curved substrate. The heat sink captures and dissipates heat generated by the LEDs, preventing it from accumulating in the curved substrate or skeleton structure. This intermediary element solves the heat dissipation problem while maintaining the curved aesthetic appearance.
3Stability of the object's composition
If a rigid spherical structure is used to maintain shape, then structural stability is achieved, but adaptability and ease of assembly are reduced
Solution Approach 1:
The spherical display is divided into multiple independent, removable modules that can be assembled in different configurations. Each module is a self-contained unit with its own substrate, LED components, and mounting features. This segmentation allows the display to be assembled, disassembled, and reconfigured easily while maintaining structural stability when assembled.
Solution Approach 2:
The module mounting system uses magnets rather than permanent mechanical fasteners, allowing modules to be easily attached and detached. This dynamic mounting approach provides flexibility for assembly and reconfiguration while maintaining stable operation once assembled. The magnetic connection is strong enough to hold the structure together but allows for easy changes.
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 solution enables the creation of a smooth and aesthetically pleasing spherical LED display system by ensuring uniform curvature and effective heat dissipation, enhancing the visual appeal and functionality of LED displays.
Implementation Method 1
The substrate may comprise a heat sink for dissipating heat
Implementation Method 2
The support is attached to a skeleton by the magnet
Data Source
AI summary
The patent application discloses an LED module. The LED module is removably connected to a source of constant current. The LED module may comprise a substrate and an electrical circuit. The substrate may have a parallel top and bottom side, a curved side connected to both ends of the top and bottom sides to form a quadrilateral shape. The electrical circuit is mounted and molded on the substrate. The electrical circuit may comprise an LED.