Laser Welded Sheet Metal Chassis for Display Alignment
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Solution Overview
Problem
Current methods for manufacturing support chassis for electronic displays, such as die casting, are costly, inflexible, and prone to imperfections that can distort images due to non-planar surfaces and alignment issues, especially when multiple chassis are combined.
Innovation Solution
The use of shaped sheet metal pieces joined by laser welding to form a support chassis, ensuring planar surfaces and precise alignment for seamless integration of display modules, reducing manufacturing costs and improving image clarity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If die casting is used to manufacture support chassis, then manufacturing cost is reduced, but manufacturing precision and surface planarity deteriorate
Solution Approach 1:
The chassis is divided into multiple sheet metal components that are separately formed and then joined together. This segmentation allows each component to be precisely formed with planar surfaces using sheet metal fabrication techniques, while the overall chassis structure maintains cost-effectiveness through the use of standard metal forming processes.
Solution Approach 2:
The patent replaces traditional mechanical joining methods (such as welding or fastening) with laser welding technology. This substitution provides superior precision and surface planarity compared to conventional joining methods, while maintaining manufacturing efficiency and cost-effectiveness through automated laser welding processes.
2Productivity
If die casting is used to manufacture support chassis, then manufacturing speed is improved, but manufacturing precision and alignment deteriorate
Solution Approach 1:
The sheet metal components are pre-formed with precise geometries and mounting features before assembly. This preliminary action ensures that alignment is built into each component during fabrication, eliminating alignment issues that would arise during final assembly while maintaining high manufacturing speed through efficient sheet metal forming processes.
Solution Approach 2:
Laser welding technology is used to join components with high precision and consistency. This automated joining method provides superior alignment control compared to manual or conventional mechanical joining methods, ensuring that multiple chassis assemble perfectly together while maintaining rapid production throughput.
3Device complexity
If traditional joining methods are used for sheet metal components, then device complexity is reduced, but manufacturing precision and surface quality deteriorate
Solution Approach 1:
The patent employs laser welding technology to join sheet metal components, replacing traditional mechanical joining methods. This substitution significantly improves surface quality and manufacturing precision by creating clean, precise welds without the distortion or surface imperfections associated with conventional welding or fastening methods.
Solution Approach 2:
The patent utilizes controlled laser parameters (power, speed, focal position) to optimize the welding process. By carefully adjusting these parameters, the process achieves high-precision joining with excellent surface quality while maintaining a relatively simple overall manufacturing process that can be automated.
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 approach results in a cost-effective, flexible, and high-precision support chassis that maintains planarity and alignment, ensuring uniform pixel spacing and image quality across multiple display modules.
Implementation Method 1
one or more components that make up the support chassis are formed from shaped pieces of sheet metal that are joined together with a laser welding method
Data Source
AI summary
An electronic display comprises a support system comprising a plurality of support chassis, each support chassis comprising a plurality of chassis components each formed from one or more pieces of sheet metal, wherein the plurality of chassis components are welded together with a plurality of laser weld joints to form the support chassis having a front wall with a planar or substantially planar front mounting face, and a plurality of planar or substantially planar side walls, wherein the planar or substantially planar mounting faces of the plurality of support chassis are aligned to collectively form a front mounting surface, and a plurality of display modules mounted to the front mounting face, wherein each display module comprises an array of light-emitting element pixels, wherein the plurality of display modules collectively form a display surface.