Video Display Panel Alignment Mount for Tolerance Stack-Up Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current systems for mounting and aligning modular video display panels in mosaicked video walls face challenges due to tolerance stack-up, leading to complexity and difficulty in achieving a uniform and accurate continuous display surface, especially at low pixel pitches.
Innovation Solution
The proposed solution involves a video display panel alignment mount with a body member having opposed support and display sides, where the support and display contact surfaces are separated by a fixed depth dimension, and the use of corner and side mounts that provide both structural and electrical connections, reducing tolerance stack-up by controlling the distance between the panel and the support structure to a single known dimension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple connecting surfaces and components are used to mount display panels, then the panels can be securely attached to the support structure, but tolerance stack-up occurs leading to difficulty in achieving a uniform display surface
Solution Approach 1:
The patent extracts and eliminates the intermediate LED module housing and heatsink components from the mounting path. By directly mounting the LED PCB to the support structure, it removes two connecting surfaces (A and B) from the tolerance stack-up chain, keeping only the critical display surface C. This extraction of non-essential components resolves the contradiction by maintaining secure attachment while eliminating the sources of tolerance accumulation.
Solution Approach 2:
The patent merges the mounting function and electrical connection function into a single integrated support structure. The support structure simultaneously provides mechanical attachment and electrical connectivity to the LED PCB, eliminating the need for separate wiring harnesses and connectors. This merging reduces the number of interface surfaces and eliminates additional tolerance sources, achieving both secure attachment and uniform display surface.
2Adaptability or versatility
If numerous components and connection interfaces are used, then the display panel array can be assembled with various functions, but the assembly complexity increases
Solution Approach 1:
The support structure is designed as a multi-functional universal component that simultaneously provides mechanical support, electrical connection, and thermal management capabilities. By integrating multiple functions into a single component, the patent reduces assembly complexity while maintaining adaptability and versatility of the display panel array system.
Solution Approach 2:
The patent combines multiple separate components (mounting structure, wiring harness, connectors, heatsink) into a single integrated support structure. This merging eliminates the need for multiple assembly steps and reduces the overall system complexity while preserving all necessary functional capabilities through intelligent integration.
3Reliability
If separate wiring harnesses and electrical connectors are used, then electrical connections can be established, but the panels must be in a specific rotational orientation increasing assembly difficulty
Solution Approach 1:
The patent merges the electrical connection function directly into the support structure, eliminating separate wiring harnesses and connectors. The support structure provides integrated electrical contacts that automatically align with corresponding contacts on the LED PCB, ensuring reliable electrical connection while eliminating the need for specific rotational orientation during assembly.
Solution Approach 2:
The integrated support structure with built-in electrical contacts performs the electrical connection function automatically when the LED PCB is mounted. The system self-aligns and establishes electrical connections without requiring manual wiring or specific panel orientation, thereby improving ease of operation while maintaining connection reliability.
Data Source
AI summary
Systems, devices and methods for mounting and aligning video display panels in a video display wall formed of an array of video display panels are disclosed. Disclosed embodiments provide a simplified mounting arrangement with reduced tolerances and tolerance stack up, while also permitting simple removal of individual video display panels for repair or replacement without necessitating removal or movement of video display panels adjacent the panel to be removed.