Spring-Loaded Suspension Block Alignment for Tiled Display Wall Frames
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Solution Overview
Problem
Current installation methods for tiled display walls suffer from inaccurate positioning and deformation issues due to imprecise alignment of support structures, leading to optical defects and misalignment, which are difficult to address with existing tools and require skilled labor.
Innovation Solution
A kit comprising channel profiles, frame assemblies, and spring-loaded suspension blocks that align and fix frames within a tolerance range, using standard tools for precise alignment and uniform load distribution, reducing installation time and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If standard spirit levels and laser beams are used for alignment, then alignment can be performed with common tools, but the positioning accuracy is insufficient due to beam thickness and air bubble interpretation
Solution Approach 1:
The patent introduces an intermediary alignment system consisting of alignment channels and alignment blocks that mediate between the rough positioning (using simple spirit levels/laser) and the final precise positioning. The alignment blocks with precision holes provide a mechanical intermediary that transfers and refines the alignment from coarse tools to sub-millimeter accuracy, resolving the contradiction between simple tools and high precision requirements
Solution Approach 2:
The patent implements preliminary action by pre-drilling precision alignment holes in the alignment channels and pre-positioning alignment blocks before final mounting. This preliminary alignment structure is built first to establish the precise reference framework, allowing subsequent components to be aligned to this pre-established high-precision baseline rather than attempting to achieve precision during final installation
2Measurement precision
If iterative alignment methods are used to solve positioning inaccuracies, then alignment precision can be improved, but installation time increases significantly
Solution Approach 1:
The alignment channels and blocks are pre-manufactured with precision-drilled holes and pre-positioned features that establish the correct alignment geometry before installation. This preliminary preparation eliminates the need for iterative adjustments during installation, as components can be directly positioned using the pre-established alignment references, achieving high precision in a single positioning action rather than through repeated iterations
Solution Approach 2:
The alignment blocks serve as intermediary elements that provide fixed reference points and mechanical guides for positioning. These intermediaries translate complex alignment requirements into simple mechanical insertion operations, where the pre-drilled holes and block geometries automatically enforce correct positioning without requiring iterative measurement and adjustment cycles
3Measurement precision
If deformable attachment members are used to compensate for support structure misalignment, then display tile alignment can be maintained, but mechanical stability against wind, weather, and vibrations deteriorates
Solution Approach 1:
The patent segments the alignment and attachment functions into distinct components: rigid alignment channels provide precise positioning, while separate deformable attachment members (such as flexible mounting brackets or tensioning elements) handle compensation for support structure deviations. This segmentation allows the rigid alignment framework to maintain precision while the dedicated flexible attachment components absorb mechanical stresses from wind, weather, and vibrations without compromising overall stability
4Measurement precision
If drilling in concrete and mounting support frames with bolts is performed to achieve high accuracy, then positioning precision can reach 0.1 mm, but the complexity and skill requirement of the installation process increases
Solution Approach 1:
The alignment channels are pre-manufactured with precision-drilled holes and pre-assembled with alignment blocks in a controlled factory environment where high-precision drilling and machining can be performed with appropriate equipment and skill. This preliminary fabrication transfers the complexity and skill requirements to the manufacturing stage rather than the installation stage, allowing field installation to proceed with simpler tools and less skilled labor while maintaining 0.1 mm accuracy through the pre-established precision features
Solution Approach 2:
The alignment channels and blocks serve as intermediary components that encapsulate the high-precision mounting requirements. Instead of directly drilling and bolting display tiles to the support structure (which would require 0.1 mm precision in the field), the intermediary alignment system with pre-drilled precision holes provides a simplified interface where standard drilling and attachment operations can be performed while still achieving high overall precision through the pre-manufactured alignment features
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 kit ensures accurate alignment of frames to within ±0.1 mm, minimizing deformations and visual artifacts, and allows for efficient installation without high-skilled labor or complex tools.
Implementation Method 1
supporting means comprising a plurality of spring loaded suspension blocks configured to be attached to the bottom supports, such that, when the frame assemblies are laid on the supporting means, the supporting means receives the edges of the first row of frames and supports the frame assemblies while aligning and fixing the frame assemblies
Data Source
AI summary
A kit for aligning and fixing within a first tolerance range a support structure for a tiled display wall. The support structure comprises a plurality of channel profiles arranged vertically, and a plurality of frame assemblies configured to be arranged in a first row of frames. The kit further comprises a plurality of bottom supports to be aligned within a second tolerance range larger than the first tolerance range, and configured to be fixed to the channel profiles, a plurality of top supports configured to be fixed to the channel profiles, and supporting means comprising a plurality of spring loaded suspension blocks configured to be attached to the bottom supports, such that, when the frame assemblies are laid on the supporting means, the supporting means support the frame assemblies while aligning and fixing the frame assemblies, within the first tolerance range, to the top supports.