LED Module Edge Gap Design for Replacement Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
During the replacement of LED modules in an LED display, adjacent modules often suffer damage due to physical interaction, and while increasing the physical gap between them reduces this risk, there are limitations to the gap size that can be achieved without compromising the common pitch distance between LEDs.
Innovation Solution
The use of smaller edge LEDs and larger interior LEDs at a common pitch distance, with the edge LEDs positioned closer to the edge of the board to create a larger physical gap, and dynamic adjustment of this gap based on temperature and brightness to maintain optimal pitch and reduce damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the physical gap between LED modules is increased to reduce damage during replacement, then the reliability of LED module replacement is improved, but the manufacturing precision of the LED display is worsened due to disruption of the common pitch distance
Solution Approach 1:
The patent applies local quality by creating two distinct types of LEDs with different functions: interior LEDs (larger size) for light emission and edge LEDs (smaller size) for gap management. The edge LEDs are specifically designed with reduced dimensions to enable the physical gap configuration, while interior LEDs maintain standard specifications for optimal light output. This localized differentiation resolves the contradiction by confining the gap-creating function to edge LEDs without compromising the pitch distance and light quality of the main display area.
Solution Approach 2:
The patent segments the LED array into two functional zones: interior LEDs that maintain the common pitch distance for display purposes, and edge LEDs that are positioned closer to module edges to create physical gaps. This segmentation allows the system to simultaneously achieve both objectives: maintaining manufacturing precision in the display area while improving replacement safety through edge gap creation.
2Ease of operation
If the physical gap between LED modules is increased to reduce damage during replacement, then the ease of operation for module replacement is improved, but the brightness uniformity across the display is worsened
Solution Approach 1:
The patent applies local quality by assigning different roles to different LED locations: interior LEDs provide primary illumination for display uniformity, while smaller edge LEDs provide supplementary light in gap regions. The edge LEDs are positioned to illuminate the physical gap areas, compensating for potential brightness discontinuities and maintaining overall uniformity across the display while enabling easier module replacement.
3Reliability
If smaller edge LEDs are used to create larger physical gaps, then the reliability of LED module replacement is improved, but the device complexity is worsened due to multiple LED sizes
Solution Approach 1:
The patent applies local quality by creating two distinct types of LEDs with different functions: interior LEDs (larger size) for light emission and edge LEDs (smaller size) for gap management. The edge LEDs are specifically designed with reduced dimensions to enable the physical gap configuration, while interior LEDs maintain standard specifications for optimal light output. This localized differentiation resolves the contradiction by confining the gap-creating function to edge LEDs without compromising the pitch distance and light quality of the main display area.
Data Source
AI summary
A light emitting diode (LED) module and display for hiding physical gaps between modules is provided. An LED module comprises: a board including at least one edge; and an array of LEDs at the board, the array comprising: first LEDs and second LEDs, smaller than the first LEDs, the second LEDs located along the at least one edge of the board, the first and second LEDs all being at a common pitch distance, adjacent sides of adjacent first LEDs separated by a first distance, and the second LEDs being at a second distance from the at least one edge of the board, the second distance smaller than the first distance. The modules may be incorporated into an LED display.