LED Display Module Segmentation for Assembly Precision
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Solution Overview
Problem
The mass transfer of light emitting diodes (LEDs) during assembly is a time-consuming process prone to misalignment and can cause deformation or warping of circuit boards due to uneven stress, hindering their commercial application as display light sources.
Innovation Solution
The LED display device incorporates a system board with a drive power circuit, first and second gate circuits, and daughterboards with LEDs, transistor switches, and a substrate, where the transistor switches cooperatively control current flows and receive timing signals to facilitate efficient assembly and reduce misalignment, using a matrix configuration to minimize parasitic capacitance and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mass transfer of LEDs is performed during assembly, then LEDs can be installed on circuit boards, but the process becomes time-consuming and prone to misalignment
Solution Approach 1:
The invention divides the LED display into multiple independently controllable modules (first and second light emitting modules). Each module can be assembled and tested separately before final integration, significantly reducing the overall assembly time and complexity while maintaining precise alignment through modular design
Solution Approach 2:
The patent implements preliminary testing and validation of each light emitting module before final assembly. The first and second gate circuits are configured to independently control and test each module, allowing defects to be identified and corrected early in the manufacturing process, thereby reducing rework time and improving overall assembly efficiency
2Ease of manufacture
If mass transfer of LEDs is performed during assembly, then LEDs can be installed on circuit boards, but misalignment problems occur
Solution Approach 1:
By segmenting the LED display into discrete modules with defined physical boundaries and connection interfaces, the invention ensures that each module maintains precise internal alignment during separate assembly. The modular structure prevents cumulative alignment errors that would occur in continuous mass transfer processes
Solution Approach 2:
The patent employs independent gate circuits that can selectively activate and test individual modules at different stages of assembly. This parameter control allows verification of alignment and positioning before final integration, ensuring manufacturing precision without requiring perfect alignment throughout the entire assembly process
3Length of moving object
If LEDs are miniaturized for display applications, then display resolution improves, but mass transfer becomes more difficult and time-consuming
Solution Approach 1:
The invention groups miniaturized LEDs into modular assemblies that can be handled as larger units during transfer. Each module contains multiple miniaturized LEDs arranged in a fixed configuration, allowing the entire group to be transferred simultaneously rather than individually, dramatically reducing transfer time while maintaining the benefits of miniaturization
Solution Approach 2:
Multiple miniaturized LEDs are combined into integrated modules with shared control circuits and common mounting structures. This merging approach allows the miniaturized LEDs to be assembled once into modules at a higher level, after which the modules can be rapidly deployed across the display without repeated fine-positioning operations
4Ease of manufacture
If circuit boards are used to carry LEDs during mass transfer, then LEDs can be transported and installed, but the boards deform or warp due to uneven stress
Solution Approach 1:
By dividing the LED display into multiple smaller modules, the invention reduces the size and stress-bearing area of individual circuit boards. Smaller boards experience less uneven stress during handling and installation, minimizing deformation and warping while still enabling efficient transport and assembly through modular deployment
Solution Approach 2:
The patent designs the modular system to allow flexible configuration and reconfiguration of modules based on display requirements. This dynamic approach enables optimization of board sizes and support structures for each specific application, preventing stress concentration and deformation by adapting the mechanical structure to the operational requirements
Data Source
AI summary
An LED display device includes a system board, and multiple daughterboards that are assembled on the system board. The system board includes a drive power circuit, a first gate circuit and a second gate circuit. Each daughterboard includes a substrate, multiple LEDs that are disposed on the substrate, multiple first transistor switches that are respectively connected to the LEDs, and at least one second transistor switch that is connected to the LEDs. With respect to each daughterboard, the first transistor switches and the at least one second transistor switch cooperatively control current flows through the LEDs; the first transistor switches are further connected to the drive power circuit to respectively receive multiple drive currents, and are further connected to the first gate circuit to receive a timing signal; and the at least one second transistor switch is further connected to the second gate circuit to receive a timing signal.