Flexible Pixel Element Hermetic Sealing for Outdoor Displays
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Solution Overview
Problem
Existing electronic display devices and signage struggle with conforming to irregular shapes and surfaces, as they rely on rectangular-grid video components, which are inefficient, costly, and prone to failure, with signal distribution limitations that restrict size and increase vulnerability to environmental conditions.
Innovation Solution
The use of discreet flexible pixel elements connected in series to form flexible pixel strings, with on-board light-emitting elements and drivers, and a display controller for efficient signal distribution, allowing for direct view, large-scale, dynamic electronic displays and signage that can conform to irregular shapes and surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional enclosures are used to protect electronic components, then protection from environmental factors is improved, but device complexity and cost increase
Solution Approach 1:
The display system is divided into discrete flexible pixel elements that can be independently sealed and protected. Each pixel element is a separate module that can be individually protected, rather than requiring a single complex enclosure for the entire display system.
Solution Approach 2:
A flexible protective coating or encapsulation layer is applied to the pixel elements and electronic components. This thin flexible barrier provides environmental protection without requiring rigid complex enclosures, allowing the components to be protected while maintaining flexibility and reducing overall device complexity.
2Reliability
If conventional enclosures are used to protect electronic components, then protection from environmental factors is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the display into discrete pixel elements, each element can be manufactured and sealed independently using standardized processes. This modular approach reduces manufacturing complexity and cost compared to creating custom complex enclosures for each application.
Solution Approach 2:
The flexible protective coating provides environmental protection at a lower cost than rigid enclosures. The coating can be applied through conventional coating processes rather than requiring complex enclosure fabrication and assembly, significantly reducing manufacturing costs.
3Adaptability or versatility
If discrete flexible pixel elements are used, then adaptability to irregular surfaces is improved, but vulnerability to environmental damage increases
Solution Approach 1:
The flexible protective coating conforms to the irregular shapes of the pixel elements and provides environmental protection. The flexibility of the coating allows it to follow the contours of mounted surfaces while maintaining continuous protection against environmental factors.
Solution Approach 2:
The protective coating creates a barrier that isolates the electronic components from the external environment, effectively creating a protected micro-environment around each pixel element. This barrier prevents moisture, oxygen, and other environmental factors from reaching the vulnerable electronics.
4Reliability
If hermetic sealing is implemented, then protection from environmental factors is improved, but manufacturing process complexity increases
Solution Approach 1:
The flexible protective coating provides hermetic sealing through a single-layer barrier rather than requiring multi-component sealing assemblies. This approach achieves hermetic protection through material properties rather than complex mechanical sealing structures, simplifying the fabrication process.
Solution Approach 2:
The protective coating is applied in a manner that allows it to self-seal or self-configure around the pixel elements. The coating process itself creates the hermetic barrier without requiring additional sealing steps or complex assembly operations, reducing fabrication process complexity.
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 solution enables efficient, economical production of large-scale, dynamic electronic displays and signage that can conform to irregular shapes, reducing the need for multiple driver PCBs and cables, enhancing reliability by minimizing failure points and allowing for easier replacement of components, while maintaining advanced graphical capabilities.
Implementation Method 1
In a preferred embodiment of the present invention, said on-board light-emitting elements or pixels of said discreet flexible pixel element comprise a plurality of red, green and blue LED light-emitting pixel elements
Data Source
AI summary
Discrete flexible pixel elements are hermetically sealed from the environment and comprise unitary, self-contained replaceable modules which enable efficient, economical production of large scale, free-form electronic displays, signs and lighting effects for outdoor use. The method and means for producing hermetically sealed discrete flexible pixel elements include encapsulation means, exterior casement means, and cable connector means.