LED Display Module Louver Structure for Contrast and Weather Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Prior LED display modules suffer from reduced contrast and viewability due to visible white areas around LEDs, inadequate weather sealing leading to corrosion, ineffective heat dissipation, and significant electromagnetic interference (EMI) emissions.
Innovation Solution
The LED display module incorporates a dark-colored louver panel with overmolded cavity view ports, a thermal conductive pad, heat distribution plate, and heat sinks, along with a centrifugal air pump for cooling, and EMI-suppressing materials and screens to enhance contrast, sealing, heat dissipation, and EMI protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple LED packages are combined in a spaced square arrangement viewed through a single louver viewing port, then the display structure is simplified, but the visible white area around LEDs increases causing reduced contrast and halo effect
Solution Approach 1:
The patent divides the single louver viewing port into multiple individual viewing ports, each corresponding to a single LED package. This segmentation eliminates the visible white areas between LED packages that cause halo effects, as each LED is viewed through its own dedicated port with black background material surrounding it, thereby maintaining high contrast while simplifying the overall display structure.
2Reliability
If sealant is used to fill gaps between frame and louver panel, then initial sealing is achieved, but the sealant cracks after thermal expansion and contraction cycles
Solution Approach 1:
The patent removes the sealant entirely from the weather sealing system. Instead, it uses precision-machined peripheral lips on the louver panel that mate with corresponding recesses in the frame, creating a mechanical seal that accommodates thermal expansion and contraction without cracking. This extraction of the problematic sealant material eliminates the reliability issue while maintaining durable weather sealing.
3Strength
If Mattel pins with rubber gaskets are used to attach louver panel, then mechanical attachment is achieved, but water enters through the holes causing corrosion
Solution Approach 1:
The patent removes the Mattel pins with rubber gaskets and replaces them with a peripheral lip mechanism that attaches the louver panel to the frame without penetrating the LED circuit board. This eliminates the holes through which water could infiltrate and cause corrosion, while maintaining secure mechanical attachment through the lip-recess engagement system.
4Temperature
If conventional ventilation methods are used for heat dissipation, then heat removal is achieved, but the system becomes noisy, energy-intensive, and requires large openings
Solution Approach 1:
The patent implements a passive heat dissipation system that utilizes natural convection currents and the inherent airflow through the display structure. The design incorporates heat sinks and strategically positioned openings that allow hot air to rise and escape naturally, drawing in cooler air from below without requiring active fans or complex ventilation systems. This self-service approach eliminates noise and energy consumption while maintaining effective heat removal.
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 solution significantly improves contrast and viewability, ensures reliable weather sealing, effectively manages heat dissipation, and reduces EMI emissions, making the LED display module suitable for indoor and outdoor use while being compact and energy-efficient.
Implementation Method 1
a thermal conductive pad, a heat distribution plate and heat sinks associatively incorporated to draw and expel heat therefrom
Implementation Method 2
heat sinks associatively incorporated to draw and expel heat therefrom
Implementation Method 3
a centrifugal air pump for cooling
Implementation Method 4
a frame which is preferably made of plastic having EMI protective material
Data Source
AI summary
An LED display module having features for improvement over prior art devices by providing novel features for improved LED visibility, improved weather and climatological sealing, improved electromagnetic interference (EMI) suppression, improved heat dissipation, and improved airflow.