Hexagonal LED Matrix Units for Arc Display Splicing
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Solution Overview
Problem
Traditional LED arc displays face issues with discontinuities and unsmooth visual experiences due to assembly tolerances and gaps between adjacent quadrilateral LED matrix units, leading to noticeable splicing tolerance and break gaps.
Innovation Solution
The design incorporates modularized LED arc displays with non-quadrilateral LED matrix units featuring a hexagonal outer contour, including protrusion and recess portions for alignment, and adjustable components for precise assembly, allowing for smoother curvature and reduced gaps between units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If quadrilateral LED matrix units are assembled to form large-area arc display, then the display area is increased, but assembly tolerance and gaps cause discontinuities and unsmooth visual experience
Solution Approach 1:
The patent applies curvature by designing the LED matrix units with non-quadrilateral (e.g., hexagonal, pentagonal) outer contours instead of traditional rectangular shapes. This curved/polygonal geometry allows the units to fit together in an arc configuration where the outer edges form continuous smooth curves, eliminating the discontinuities and gaps that occur when assembling rectangular units into an arc display.
2Area of stationary object
If multiple LED matrix units are assembled together, then the display size is increased, but gaps and breaks between units become noticeable
Solution Approach 1:
The non-quadrilateral outer contour design with rounded edges creates a curved appearance that masks the individual unit boundaries. When assembled, the rounded corners and edges of adjacent units blend together to form a continuous smooth contour, making the gaps and breaks between units imperceptible to the human eye.
Solution Approach 2:
The patent applies different geometric properties to different parts of the LED matrix unit. The outer contour features rounded edges and curved segments specifically designed to mask gaps, while the inner display area maintains standard LED matrix characteristics. This localized application of curved geometry at the boundaries solves the contour smoothness problem without affecting the overall display functionality.
3Shape
If non-quadrilateral LED matrix units are used, then visual smoothness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the LED matrix unit into distinct functional areas: the inner display region with standard LED components and the outer contour region with rounded edges. This segmentation allows the manufacturing process to use standard techniques for the display area while applying specialized curved edge processing only to the boundaries, thereby reducing overall manufacturing complexity compared to creating entirely non-standard units.
Data Source
AI summary
An LED arc display includes at least one LED matrix array module. Each LED matrix array module is composed of a plurality of LED matrix units arranged regularly. Each LED matrix unit includes a display surface, and the display surface has an outer contour. The outer contour is a non-quadrilateral. Therefore, a non-smooth visual experience caused by assembly tolerances of the plurality of LED matrix units can be improved by using non-quadrilateral outer contours of each LED matrix unit.