Floating Display Mounting Structure for LED Panel Alignment
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Solution Overview
Problem
Existing display mounting systems for electronic billboards face challenges in aligning LED panels accurately across multiple axes, accommodating thermal expansion differences between mounting structures and LED panels, and allowing for installation inaccuracies, particularly under varying sunlight exposure conditions.
Innovation Solution
A modular display mounting system featuring a structural extrusion attached to a building or billboard frame, with LED panels clamping onto a floating or sliding mounting extrusion that allows for free movement in the X-axis, and a framing system comprising interlocking extrusion profiles that include a structural member with a receiving recess and a mounting member with alignment holes for precise positioning and thermal compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If LED panels are rigidly fixed to the mounting structure, then alignment precision is improved, but thermal expansion stress increases
Solution Approach 1:
The mounting system transitions from a rigid fixed connection to a dynamic floating connection that permits controlled movement. The mounting extrusion floats within the receiving recess, allowing the LED panel to move independently in response to thermal expansion while maintaining alignment through gravity and friction forces.
Solution Approach 2:
The system changes the physical state of the connection from rigid to semi-flexible by introducing a floating mounting mechanism. This allows the mounting extrusion to shift position within the receiving recess, accommodating dimensional changes due to thermal expansion while preserving alignment precision.
2Stability of the object's composition
If the mounting structure is rigidly attached to the building frame, then structural stability is improved, but installation accuracy tolerance decreases
Solution Approach 1:
The mounting extrusion is designed to float within the receiving recess rather than being rigidly fixed, creating a dynamic adjustment mechanism. This allows the mounting extrusion to self-align and accommodate installation inaccuracies while the structural extrusion maintains its rigid connection to the building frame for overall stability.
3Stability of the object's composition
If LED panels are tightly clamped to prevent movement, then alignment stability is improved, but thermal expansion accommodation decreases
Solution Approach 1:
The system employs a floating mounting mechanism where the mounting extrusion can move within the receiving recess. Gravity and friction provide sufficient holding force for alignment stability, while the unused portion of the recess allows thermal expansion accommodation through controlled movement.
4Adaptability or versatility
If the mounting system allows free movement, then thermal expansion accommodation is improved, but alignment precision deteriorates
Solution Approach 1:
The system changes the degree of freedom from complete freedom to controlled movement. The mounting extrusion floats within the receiving recess with movement permitted in certain directions while gravity and friction maintain alignment precision in critical axes.
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 system ensures accurate alignment of LED panels across all axes, accommodates thermal expansion differences, and simplifies the installation process by allowing for movement and adjustment, reducing stress on the panels due to temperature variations and installation inaccuracies.
Implementation Method 1
accommodating thermal expansion differences between mounting structures and LED panels
Data Source
AI summary
A modular display support structure is described, the modular display support structure comprising: a substantially vertical structural member including at least one mounting flange, and a receiving recess, the recess extending parallel with, and for a substantial portion of, a longitudinal axis of the structural member; and a mounting member including an interface flange to mate with the receiving recess, and an attachment flange; wherein the attachment flange includes a plurality of attachment apertures for each of a plurality of display panels. A system and method are also described.