PCB Frame Support for LED Display Durability
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Solution Overview
Problem
LED display apparatuses with PCBs face challenges in durability and reliability due to deformation and breakage during installation, especially when using glass substrates, which affect the accuracy and integrity of the display screen.
Innovation Solution
A display apparatus design that includes frames to support PCBs, with extending portions and adhesive members to secure the PCBs to the chassis, preventing deformation and breakage by ensuring proper alignment and bonding without high-temperature soldering, thus enhancing durability and installation reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature soldering is used to mount LEDs on PCB, then electrical connection is achieved, but the PCB (especially glass substrate) deforms and breaks
Solution Approach 1:
The patent replaces the traditional high-temperature soldering process with a low-temperature bonding process using adhesive members. This substitution eliminates the thermal stress that causes glass substrate deformation and breakage, while still achieving reliable electrical and mechanical connection between LEDs and PCB.
Solution Approach 2:
The patent changes the bonding temperature parameter from high-temperature soldering to low-temperature adhesive bonding. This parameter change prevents thermal damage to the glass substrate while maintaining the functional connection requirements, directly resolving the contradiction between connection reliability and structural integrity.
2Weight of moving object
If PCB is made thinner for lightweight design, then weight is reduced, but rigidity and durability during installation decrease
Solution Approach 1:
The patent employs a composite structure combining thin glass substrate with a separate frame support structure. The glass substrate maintains its lightweight advantage while the frame provides the necessary mechanical strength and rigidity during installation, resolving the contradiction between weight reduction and durability enhancement.
Solution Approach 2:
The frame acts as an intermediary structural element between the thin PCB and the mounting environment. It provides mechanical support and protection during installation without adding significant weight to the PCB itself, enabling both lightweight design and installation durability.
3Strength
If frame extends beyond PCB boundaries for support, then structural support is improved, but alignment precision becomes more difficult
Solution Approach 1:
The patent incorporates alignment marks and positioning structures on the PCB that are prepared in advance during manufacturing. These pre-established reference features enable precise alignment of the extended frame with the PCB boundaries, eliminating alignment difficulties despite the frame extending beyond PCB limits.
Solution Approach 2:
The frame is designed with different local characteristics: extended portions for structural support and contact portions with precise positioning features for alignment. This local differentiation allows the frame to simultaneously provide both structural strength and manufacturing precision.
Data Source
AI summary
A display apparatus includes a PCB on which a plurality of LEDs emitting light in a first direction are mounted, a frame configured to support the PCB, and a chassis coupled to the frame. The frame has a length in a second direction perpendicular to the first direction that is longer than that of the PCB.