Flexible LED Display Edge Protection via Viscoelastic Layer
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Solution Overview
Problem
Flexible LED display modules face issues such as cracking and damage due to bending, poor durability, and insufficient elasticity, particularly due to the susceptibility of connectors and plating layers to bending and oxidation, and the low bonding strength between viscoelastic films and the flexible circuit board.
Innovation Solution
A flexible LED display module design where the flexible circuit board is bent with edge portions hidden under the main portion, featuring a viscoelastic layer covering all exposed areas except for LEDs and controller units, and dummy pads limiting curvature to protect circuits, allowing for bezel-less displays with improved bonding strength and protection from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the flexible circuit board is bent to hide edge portions under the main portion, then the display achieves a bezel-less appearance, but the connectors and plating layers are susceptible to cracking and damage due to bending
Solution Approach 1:
The patent applies beforehand cushioning by introducing a protective layer that covers the flexible circuit board in the bending region. This protective layer is positioned in advance to prevent direct contact between external forces and the vulnerable connectors and plating layers, thereby cushioning them against cracking and damage while enabling the bezel-less display shape.
2Adaptability or versatility
If connectors are used to connect LED board and control board, then the display functionality is achieved, but the connectors cause cracks in the connection portion when bent
Solution Approach 1:
The patent applies taking out by removing the traditional rigid connectors from the flexible circuit board structure. Instead of using separate connector components that create stress concentration points, the electrical connections are integrated directly into the flexible circuit board through printed circuit patterns, thereby eliminating the crack-prone connector regions while maintaining display functionality.
3Reliability
If plating layers are exposed on the flexible circuit board, then electrical connectivity is achieved, but the plating layers are easily oxidized and crack due to bending susceptibility
Solution Approach 1:
The patent applies composite materials by creating a multi-layer protective structure that combines the flexible circuit board with an additional protective layer. This composite structure allows the plating layers to remain exposed for electrical connectivity while the protective layer shields them from oxidation and mechanical stress during bending, preventing cracking.
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 design prevents cracking and damage during bending, enhances bonding strength between viscoelastic films and the flexible circuit board, and facilitates the creation of bezel-less displays with improved durability and flexibility.
Implementation Method 1
A flexible LED display module according to one embodiment of the present invention includes a flexible circuit board, a plurality of LEDs mounted on the flexible circuit board, wherein the flexible circuit board is bent such that edge portions of the flexible circuit board mounted with controller units are hidden under a main portion of the flexible circuit board mounted with LEDs
Data Source
AI summary
Disclosed is an LED display panel including inner LED display modules and outer LED display modules. Each of the inner LED display modules and the outer LED display modules includes a first flexible circuit board and a second flexible circuit board arrayed in a row in the lengthwise direction and on which LEDs are arrayed, and an upper viscoelastic film and a lower viscoelastic film bonded to each other through the first flexible circuit board and the second flexible circuit board. Each of the first flexible circuit board and the second flexible circuit board includes a folded edge portion and an unfolded edge portion opposite to the folded edge portion. A controller unit is disposed under the folded edge portion to control the LEDs. The folded edge portion of the first flexible circuit board faces the folded edge portion of the second flexible circuit board in each of the inner LED display modules.