Light emitting diode (LED) display modules, display screens comprising a plurality of display modules and methods of forming display screens are disclosed. Each display module 10 forming a display screen comprises a flexible substrate 11 supporting a plurality of LEDs 14. A set of connectors 16, 50,
Light emitting diode (LED) display modules, display screens comprising a plurality of display modules and methods of forming display screens are disclosed. Each display module 10 forming a display screen comprises a flexible substrate 11 supporting a plurality of LEDs 14. A set of connectors 16, 50, 52, 54 comprising male connectors and female connectors are coupled to the flexible substrate for connecting the display module to a respective set of connectors 16, 50, 52, 54 of an adjacent display module along at least one first edge 18 of the display module such that horizontal and vertical alignment of the display modules and the LED pitch size is maintained during flexing of the display screen.
대표청구항▼
1. A planar flexible light emitting diode (LED) display module comprising: a planar flexible substrate supporting a plurality of LEDs; anda set of connectors fixed to the planar flexible substrate, the set of connectors comprising one or more connectors at each of three or more edges of the substrat
1. A planar flexible light emitting diode (LED) display module comprising: a planar flexible substrate supporting a plurality of LEDs; anda set of connectors fixed to the planar flexible substrate, the set of connectors comprising one or more connectors at each of three or more edges of the substrate for connecting the display module to connectors of three or more adjacent planar flexible LED display modules to form a flexible LED display screen, the one or more connectors at each of three or more edges of the substrate comprising: one or more male connectors each comprising a projection extending perpendicular to a plane of the planar substrate for insertion into an aperture of an aligned female connector of an adjacent display module; andone or more female connectors each comprising an aperture for reception of a projection of an aligned male connector of an adjacent display module;wherein the projections and apertures of the connectors of the display module and the three or more adjacent display modules connect together in a direction perpendicular to a plane of the substrate such that the display module can be connected to, or disconnected from, the three or more adjacent display modules in a direction perpendicular to a plane of the substrate; andwherein the one or more female connectors or the one or more male connectors protrude beyond the respective edge of the display module such that the one or more female connectors or the one or more male connectors overlap with the adjacent display module when connected and the male and female connectors are aligned such that adjacent display modules are secured abutting against one another when connected and during flexing of the display screen thus maintaining a distance between the centers of adjacent LEDs, and horizontal and vertical alignment of the LEDs between adjacent display modules, during flexing of the display screen. 2. The display module of claim 1, wherein the set of connectors comprises at least one connector at each of four edges of the display module. 3. The display module of claim 1, wherein both of the following protrude beyond an edge of the display module: the one or more female connectors; the one or more male connectors. 4. The display module of claim 1, wherein at least one of the following does not protrude beyond an edge of the display module: the one or more female connectors; the one or more male connectors. 5. The display module of claim 1, wherein one of the one or more female connectors is adjacent an edge of the flexible substrate opposite an edge of the flexible substrate having one of the one or more male connectors. 6. The display module of claim 1, wherein the one or more male connectors and the one or more female connectors connect adjacent display modules to maintain horizontal and vertical alignment of adjacent display modules to ±3% of the distance between the centers of adjacent LEDs in each display module. 7. The display module of claim 1, wherein the set of connectors are aligned with reference marks on the flexible substrate. 8. The display module of claim 1, further comprising a flexible housing mounted to a first side of the flexible substrate. 9. The display module of claim 1, further comprising a flexible cover mounted to a second side of the flexible substrate. 10. The display module of claim 8, further comprising at least one magnet coupled to the flexible housing for attaching the display module to a surface. 11. The display module of claim 1, further comprising a data plug and a data socket coupled to the flexible substrate. 12. The display module of claim 1, further comprising a power connector coupled to the flexible substrate. 13. The display module of claim 8, further comprising at least one channel in the flexible housing for accommodating one or more cables. 14. The display module of claim 8, further comprising at least one cable restraint adjustably coupled to the flexible housing. 15. The display module of claim 1, wherein the display module is waterproof. 16. The display module of claim 1, further comprising one or more elongate strengthening members to prevent over bending of the display module. 17. A planar flexible light emitting diode (LED) display screen comprising a plurality of planar flexible LED display modules, each display module comprising a planar flexible substrate supporting a plurality of LEDs and a set of connectors coupled to the flexible substrate, the set of connectors comprising one or more connectors at each of three or more edges of the substrate for connecting one of the display modules to connectors of three or more adjacent planar flexible LED display modules to form the flexible LED display screen, the one or more connectors at each of three or more edges of the substrate comprising: one or more male connectors each comprising a projection extending perpendicular to a plane of the planar substrate for insertion into an aperture of an aligned female connector of an adjacent display module; andone or more female connectors each comprising an aperture for reception of a projection of an aligned male connector of an adjacent display module;wherein the projections and apertures of the connectors of the display modules connect together in a direction perpendicular to a plane of the substrate such that the one of the display modules can be connected to, or disconnected from, the three or more adjacent display modules in a direction perpendicular to a plane of the substrate; andwherein the one or more female connectors or the one or more male connectors protrude beyond the respective edges of the display modules such that the one or more female connectors or the one or more male connectors overlap with the adjacent display modules when connected and the male and female connectors are aligned such that adjacent display modules are secured abutting against one another when connected and during flexing of the display screen thus maintaining a distance between the centers of adjacent LEDs, and horizontal and vertical alignment of the LEDs between adjacent display modules, during flexing of the display screen. 18. The display screen of claim 17, wherein the set of connectors comprises at least one connector at each edge of the display module. 19. The display screen of claim 17, wherein the male and female connectors of each display module overlap with adjacent display modules. 20. The display screen of claim 17, wherein the set of connectors of each display module are aligned with reference marks on a respective flexible substrate for horizontal and vertical alignment of adjacent display modules to ±3% of the distance between the centers of adjacent LEDs in each display module. 21. The display screen of claim 17, wherein each display module further comprises a flexible housing mounted to a first side of a respective flexible substrate. 22. The display screen of claim 17, wherein each display module further comprises a flexible cover mounted to a second side of a respective flexible substrate. 23. The display screen of claim 17, wherein one or more of the display modules further comprises at least one magnet coupled to a respective flexible housing for attaching the display screen to a surface. 24. The display screen of claim 17, wherein a data plug coupled to a respective flexible substrate of one display module connects to a data socket coupled to a respective flexible substrate of an adjacent display module. 25. The display screen of claim 17, wherein a power connector coupled to a respective flexible substrate of one display module connects to a power socket coupled to a respective flexible substrate of an adjacent display module. 26. A method of forming a planar flexible light emitting diode (LED) display screen comprising four or more planar flexible LED display modules abutting against one another, each display module comprising a planar flexible substrate supporting a plurality of LEDs and a set of connectors coupled to the planar flexible substrate, wherein the set of connectors comprises one or more connectors at each of three or more edges of the substrate and the one or more connectors at each of three or more edges of the substrate comprise: one or more male connectors each comprising a projection extending perpendicular to a plane of the planar substrate for insertion into an aperture of an aligned female connector of an adjacent display module; andone or more female connectors each comprising an aperture for reception of a projection of an aligned male connector of an adjacent display module, the method including:connecting from a direction perpendicular to a plane of the substrate one of the display modules to one or more adjacent display modules by connecting in a direction perpendicular to a plane of the substrate the projections and apertures of the male and female connectors of the one or more adjacent display modules such that the one or more female connectors or the one or more male connectors overlap with the adjacent display modules when connected and the male and female connectors are aligned such that adjacent display modules are secured abutting against one another when connected and during flexing of the display screen thus maintaining a distance between the centers of adjacent LEDs, and horizontal and vertical alignment of the LEDs between adjacent display modules, during flexing of the display screen.
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Karlicek, Jr., Robert F., Close packing LED assembly with versatile interconnect architecture.
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