thermal management of lcd displays factory

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G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS

G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics

G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour

G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells

G02F1/133382—Heating or cooling of liquid crystal cells other than for activation, e.g. circuits or arrangements for temperature control, stabilisation or uniform distribution over the cell

G02F1/133385—Heating or cooling of liquid crystal cells other than for activation, e.g. circuits or arrangements for temperature control, stabilisation or uniform distribution over the cell with cooling means, e.g. fans

G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS

G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics

G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour

G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells

G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS

G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics

G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour

G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells

G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS

thermal management of lcd displays factory

The pace of development in the electronics and telecommunication fields has been accelerating in all aspects of the business. For example, electronics/telecommunications equipment has traditionally been housed in large buildings, smaller buildings (sheds) and outdoor cabinets.  The introduction of electronics to the outdoor environment has imposed serious constraints on enclosure design since temperature and humidity are the two major causes of electronics failure. Since most electronic systems do not include environmentally hardened designs, the enclosure must provide an environment in which they can survive. Among the equipment/systems involved are displays such as LCD, LED and other monitors.

The use of LEDs (Light Emitting Diodes) has been increasing exponentially in the last few years. In the beginning, heat dissipation was not a worrisome problem because of the low power the LED’s used. However, their power consumption and their useful life and reliability are dependent on how their temperature can be controlled, especially in view of high-power LEDs used for illumination and outdoor signage applications. The most important goal in LED cooling is to maintain junction temperature (Tj, the temperature at the p-n junction) from rising above prescribed levels since the junction temperature is a good predictor of the useful life of the LED component. In addition, the junction temperature in many cases must be kept relatively constant since fluctuations and shifts affect the intensity and the color of the LED light output. From a thermal standpoint, junction temperature, as with many other electronic components and systems, is influenced by power levels, heat sinking (high conductivity materials, convection cooling, extended surfaces, heat spreading, heat pipes, etc), ambient temperature, interface materials, applied pressures (clamping to reduce thermal contact resistance).

Thermal management of LEDs can range from the use of natural convection to the use of liquid cooling loops that allow for far higher heat removal rates than employing gases as the cooling medium. Air natural and forced convection, up to very recently, have been the cooling methodology of choice when cooling with a fluid. At the system level, and especially for outdoor applications, liquid cooling is normally not suitable; therefore, only cooling solutions that use natural or forced air convection are employed such as fans, blowers, air-to-air heat exchangers, air-conditioners and other passive cooling techniques.

What is more, display devices such as monitors have incorporated LED technology and must also be thermally managed outdoors since they require hardened enclosures to carry out their tasks.

The objective here is to cover the thermal management of LEDs at the system level, both discrete LED modules or outdoor enclosures (LED walls or LED monitors). This assumes that LED and board level thermal management has been dealt with separately. Nowadays, enclosures that contain LEDs are being installed in various environmental conditions. Most will be fitted with either air conditioning/thermoelectric cooling or air-to-air heat exchangers as needed because of relatively high heat dissipation requirements; for lower heat generation levels, flow-through fan cooling is sufficient. For example, there has been an unprecedented growth of the application of LEDs for outdoor (and indoor) signage or video systems such as sports displays, advertising billboards, and gas station pump customer information displays. These all are enclosures with one wall comprised of LEDs. In addition, recently LED display monitors have been installed in outdoor enclosures and therefore require thermal management. Figure 1 shows an illustration of these two types of enclosures.

The goal is to maintain peak temperatures in the enclosures below a certain level that is normally prescribed (the lowest junction temperature of the LED components) by the manufacturers. Humidity levels are of concern, but since most enclosures are either sealed or its temperatures are much higher than the air’s dew points, humidity is generally not a problem (after the transient effect of opening/closing the enclosure is eliminated.)

The designer should be aware that the air temperatures within the enclosures will be a function of: the amount of heat generated by all the electronic equipment in the enclosure; the amount of heat generated by auxiliary and cooling equipment (fans, etc.); ambient conditions (outdoor air), particularly temperature, solar radiation, wind speeds, etc.; objects surrounding the enclosure (shading, ground reflections, buildings, trees, etc.); enclosure design (surface area, shape, paint’s radiation characteristics, etc.) and air exchange with the outside air, either passive by infiltration, or active by fans or blowers.

Let us consider an enclosure that has installed LED equipment that dissipates a certain amount of heat. The first step is always to realize that the design temperature is that temperature that the enclosure air will attain when there is heat balance, or in equation form:

where, Qequipment comprises the LEDs and its electronics heat dissipation, Qsolar load is the solar heat load and Qcooling-system is the amount of heat removed by the cooling system. The solar load is a complicated term because it includes contributions from all modes or heat transfer. For example:

Normally, the value of Qradiated will always be positive (towards enclosure) but the other two can be either positive or negative, depending on the enclosure’s temperature. Thus, if Qbalance is not zero, this means that the temperature inside the enclosure is either higher/lower than the set temperature and the enclosure is losing/gaining heat by convection and conduction.

Furthermore, since incident solar radiation varies during the daylight hours, the designer must decide whether to conduct a steady state or transient analysis. Moreover, since Qradiation is a very complex term that includes, among other effects, solar declination, latitude, time of year, solar azimuth, atmospheric absorption, atmospheric clearness, re-radiation from other walls, buildings, ground etc., and incident wall surface properties, some simplifying measures must be taken into account. The result is that one can effectively double or triple the amount of heat flux being added into the enclosure depending on the calculation method. The calculation of the cooling load is carried out using several methods. One of these methods is the ASHRAE’s cooling load calculation methods. Normally, when calculating cooling loads, one would include a) Space heat gain, b) Space cooling load, and c) Space heat extraction rate. Space heat gain is the rate at which heat enters or is generated within the space at any given instant. This includes for the enclosure heat transferred into the conditioned space from the external walls and roof due to solar radiation, convection and temperature differential.

One normally includes instantaneous solar radiation effects and delayed effects. The delayed effects include the slow build-up of energy that the external walls accumulate as they absorb solar radiation. This happens because walls are normally thick and massive; making energy absorbed important. For LED enclosures this is not included since its walls are thin (at the most 3 cm when insulation might be added) and should not be included. Another component of heat gain is latent heat due to moisture infiltration. For sealed LED outdoor enclosures, the power electronics are kept in an airtight enclosure with negligible contribution.

where, α -absorptance of solar radiation surface, It – total solar radiation  [W/m2], ho– coefficient of heat by long wave radiation and convection  [W/K-m2], ε – hemispherical emittance, and ΔR a radiation correction factor [W/m2]. Figure 2 shows typical Sol-Air temperatures for various latitudes.

For roofs: ΔR =63 W/m2, for walls: ΔR = 0, for dark surfaces, α/It = 0.052, which is the maximum value for any surface. To calculate heat transfer into the conditioned space,

where U is the overall heat transfer coefficient for the wall and A is the surface area for the wall. The term, U, includes convective and radiation effects by the internal and external airflow (See AHSHRAE’s Fenestration Chapter for more details, ASHRAE, 1981, 1986) and the wind outside, in addition to conduction through the walls. The solar load calculated will be added to the equipment load to find the total cooling load. The solar load will include three surfaces that can be illuminated simultaneously, with the roof always included.

Display/signage enclosures have evolved. Typical LED system design has been the display shown in Figure 3. They typically were metal enclosures measuring 5-10 m wide, 250 mm deep and 5 m high. These enclosures could have thousands of LEDs each measuring, typically,5- 8 by 5-8 by 3 mm and dissipating an average of 1W each, all installed on the largest vertical wall. Therefore, the total amount of heat dissipation for this enclosure (including the electronics needed to control and manage the LEDs) could reach thousands of Watts. Figure 3 shows a CFD model of this enclosure using Phoenics by CHAM Ltd of the UK.

In the last few years, display outdoor enclosures are also being designed to house various display signage equipment configurations such as LED monitors with dissipating heat rates ranging from 200 to 1500 W, depending on the size and type of auxiliary equipment. These enclosures are installed in various environmental conditions, and typically the enclosures, without major structural modifications, may be fitted with fans, air conditioning or air-to-air heat exchangers as needed. Figure 4 shows at typical enclosure (CFD model).

Equipment housed in these enclosures include TV LED monitors that have been initially designed for indoor use and have been slightly hardened to be placed in a hot, dry environment without the support of an enclosure. Many manufacturers sell these monitors.

The goal of the designer is to maintain the peak temperatures in the enclosures, which are below a certain level that is normally prescribed by the electronic equipment manufacturer. Humidity levels are also of concern, but since in most enclosures, its temperatures are much higher than the air’s dew points, humidity is generally not an issue (after the transient effect of opening and closing the enclosure is eliminated). However, typically, the LED monitors are not fully outdoor rated, that is they must be protected from rain and moisture, therefore they must be installed in IP55/56/66 enclosures.

Most enclosures need to be designed to keep the system operating with slight internal overpressure. Cooling air is guided to flow into a gap between the LED screen surface and external transparent wall guided by guide-vanes, and the cooling system also must allow for air to flow to the rest of the enclosure, in addition to the flow in the LED/Wall gap. Overpressure is used to maintaining IP55 and IP66 design and a fan and filter inlet system construction allows for proper solar mitigation technology. For further solar mitigation purposes, if used, a solar shield overhang can reduce solar loading.

Finally, of paramount importance is to keep the LED surface (especially when in full solar exposure) under a maximum temperature. For the above LED monitor, this temperature is 110 C. Since, maximum solar radiation for latitudes below 35 N or S can generate surface temperatures higher than 110 C, then a typical construction would involve a gap between the outdoor facing glass plane and the LED monitor (see Figure 5).

thermal management of lcd displays factory

Outdoor digital displays are increasingly being used for information dissemination, interactive content location, and advertising in urban locations. While the existing thermal management approaches for indoor digital displays are well understood and generally sufficient due to their lower power dissipation, outdoor liquid crystal displays (LCDs) are subject to many additional constraints, such as harsher and changing ambient environment, solar insolation, and larger internal heat generation in the current state-of-the-art light emitting diodes (LEDs) and other associated electronics. Demands for larger and brighter displays continue to provide significant additional challenges to their thermal design. Here we review the current and emerging thermal management challenges, and current solutions for outdoor digital displays. We review the state-of-the-art of the multi-scale nature of the packaging of the digital displays, from the light sources to the display cabinet. The unique thermal management challenges for outdoor displays are next outlined. We review current thermal management methods for outdoor displays. We conclude by describing emerging applications of outdoor digital displays, and identify associated thermal challenges.

thermal management of lcd displays factory

The use of liquid crystal displays (LCDs) in user interface assemblies is widespread across nearly all industries, locations, and operating environments. Over the last 20 years, the cost of LCD displays has significantly dropped, allowing for this technology to be incorporated into many of the everyday devices we rely on.

The odds are high you are reading this blog post on a laptop or tablet, and it’s likely the actual screen uses LCD technology to render the image onto a low-profile pane of glass. Reach into your pocket. Yes, that smartphone likely uses LCD technology for the screen. As you enter your car, does your dashboard come alive with a complex user interface? What about the menu at your favorite local drive-thru restaurant? These are some everyday examples of the widespread use of LCD technology.

But did you know that the U.S. military is using LCD displays to improve the ability of our warfighters to interact with their equipment? In hospitals around the world, lifesaving medical devices are monitored and controlled by an LCD touchscreen interface. Maritime GPS and navigation systems provide real-time location, heading, and speed information to captains while on the high seas. It’s clear that people’s lives depend on these devices operating in a range of environments.

As the use of LCDs continues to expand, and larger screen sizes become even less expensive, one inherent flaw of LCDs remains: LCD pixels behave poorly at low temperatures. For some applications, LCD displays will not operate whatsoever at low temperatures. This is important because for mil-aero applications, outdoor consumer products, automobiles, or anywhere the temperature is below freezing, the LCD crystal’s performance will begin to deteriorate. If the LCD display exhibits poor color viewing, sluggish resolution, or even worse, permanently damaged pixels, this will limit the ability to use LCD technologies in frigid environments. To address this, there are several design measures that can be explored to minimize the impact of low temperatures on LCDs.

Most LCD displays utilize pixels known as TFT (Thin-Film-Transistor) Color Liquid Crystals, which are the backbone to the billions of LCD screens in use today. Since the individual pixels utilize a fluid-like crystal material as the ambient temperature is reduced, this fluid will become more viscous compromising performance. For many LCD displays, temperatures below 0°C represent the point where performance degrades.

Have you tried to use your smartphone while skiing or ice fishing? What about those of you living in the northern latitudes - have you accidently left your phone in your car overnight where the temperatures drop well below freezing? You may have noticed a sluggish screen response, poor contrast with certain colors, or even worse permanent damage to your screen. While this is normal, it’s certainly a nuisance. As a design engineer, the goal is to select an LCD technology that offers the best performance at the desired temperature range. If your LCD display is required to operate at temperatures below freezing, review the manufacturer’s data sheets for both the operating and storage temperature ranges. Listed below are two different off-the-shelf LCD displays, each with different temperature ratings. It should be noted that there are limited options for off-the-shelf displays with resilience to extreme low temperatures.

For many military applications, in order to comply with the various mil standards a product must be rated for -30°C operational temperature and -51°C storage temperature. The question remains: how can you operate an LCD display at -30°C if the product is only rated for -20°C operating temperature? The answer is to use a heat source to raise the display temperature to an acceptable range. If there is an adjacent motor or another device that generates heat, this alone may be enough to warm the display. If not, a dedicated low-profile heater is an excellent option to consider.

Made of an etched layer of steel and enveloped in an electrically insulating material, a flat flexible polyimide heater is an excellent option where space and power are limited. These devices behave as resistive heaters and can operate off a wide range of voltages all the way up to 120V. These heaters can also function with both AC and DC power sources. Their heat output is typically characterized by watts per unit area and must be sized to the product specifications. These heaters can also be affixed with a pressure sensitive adhesive on the rear, allowing them to be “glued” to any surface. The flying leads off the heater can be further customized to support any type of custom interconnect. A full-service manufacturing partner like Epec can help develop a custom solution for any LCD application that requires a custom low-profile heater.

With no thermal mass to dissipate the heat, polyimide heaters can reach temperatures in excess of 100°C in less than a few minutes of operation. Incorporating a heater by itself is not enough to manage the low temperature effects on an LCD display. What if the heater is improperly sized and damages the LCD display? What happens if the heater remains on too long and damages other components in your system? Just like the thermostat in your home, it’s important to incorporate a real-temp temperature sensing feedback loop to control the on/off function of the heater.

The first step is to select temperature sensors that can be affixed to the display while being small enough to fit within a restricted envelope. Thermistors, thermocouples, or RTDs are all options to consider since they represent relatively low-cost and high-reliability ways to measure the display’s surface temperature. These types of sensors also provide an electrical output that can be calibrated for the desired temperature range.

The next step is to determine the number of temperature sensors and their approximate location on the display. It’s recommended that a minimum of two temperature sensors be used to control the heater. By using multiple sensors, this provides the circuit redundancy and allows for a weighted average of the temperature measurement to mitigate non-uniform heating. Depending on the temperature sensors location, and the thermal mass of the materials involved, the control loop can be optimized to properly control the on/off function of the heater.

Another important consideration when selecting a temperature sensor is how to mount the individual sensors onto the display. Most LCD displays are designed with a sheet metal backer that serves as an ideal surface to mount the temperature sensors. There are several types of thermally conductive epoxies that provide a robust and cost-effective way to affix the delicate items onto the display. Since there are several types of epoxies to choose from, it’s important to use a compound with the appropriate working life and cure time.

For example, if you are kitting 20 LCD displays and the working life of the thermal epoxy is 8 minutes, you may find yourself struggling to complete the project before the epoxy begins to harden.

Before building any type of prototype LCD heater assembly, it’s important to carefully study the heat transfer of the system. Heat will be generated by the flexible polyimide heater and then will transfer to the LCD display and other parts of the system. Although heat will radiate, convect, and be conducted away from the heater, the primary type of heat transfer will be through conduction. This is important because if your heater is touching a large heat sink (ex. aluminum chassis), this will impact the ability of the heater to warm your LCD display as heat will be drawn toward the heat sink.

Insulating materials, air gaps, or other means can be incorporated in the design to manage the way heat travels throughout your system on the way toward an eventual “steady state” condition. During development, prototypes can be built with numerous temperature sensors to map the heat transfer, allowing for the optimal placement of temperature sensors, an adequately sized heater, and a properly controlled feedback loop.

Before freezing the design (no pun intended) on any project that requires an LCD display to operate at low temperatures, it’s critical to perform low temperature first. This type of testing usually involves a thermal chamber, a way to operate the system, and a means to measure the temperature vs time. Most thermal chambers provide an access port or other means to snake wires into the chamber without compromising performance. This way, power can be supplied to the heater and display, while data can be captured from the temperature sensors.

The first objective of the low-temperature testing is to determine the actual effects of cold exposure on the LCD display itself. Does the LCD display function at cold? Are certain colors more impacted by the cold than others? How sluggish is the screen? Does the LCD display performance improve once the system is returned to ambient conditions? These are all significant and appropriate questions and nearly impossible to answer without actual testing.

As LCD displays continue to be a critical part of our society, their use will become even more widespread. Costs will continue to decrease with larger and larger screens being launched into production every year. This means there will be more applications that require their operation in extreme environments, including the low-temperature regions of the world. By incorporating design measures to mitigate the effects of cold on LCD displays, they can be used virtually anywhere. But this doesn’t come easy. Engineers must understand the design limitations and ways to address the overarching design challenges.

A full-service manufacturing partner like Epec offers a high-value solution to be able to design, develop, and manufacture systems that push the limits of off-the-shelf hardware like LCD displays. This fact helps lower the effective program cost and decreases the time to market for any high-risk development project.

thermal management of lcd displays factory

Outdoor digital displays are increasingly being used for information dissemination, interactive content location, and advertising in urban locations. While the existing thermal management approaches for indoor digital displays are well understood and generally sufficient due to their lower power dissipation, outdoor liquid crystal displays (LCDs) are subject to many additional constraints, such as harsher and changing ambient environment, solar insolation, and larger internal heat generation in the current state-of-the-art light emitting diodes (LEDs) and other associated electronics. Demands for larger and brighter displays continue to provide significant additional challenges to their thermal design. Here we review the current and emerging thermal management challenges, and current solutions for outdoor digital displays. We review the state-of-the-art of the multi-scale nature of the packaging of the digital displays, from the light sources to the display cabinet. The unique thermal management challenges for outdoor displays are next outlined. We review current thermal management methods for outdoor displays. We conclude by describing emerging applications of outdoor digital displays, and identify associated thermal challenges.

thermal management of lcd displays factory

The use of liquid crystal displays (LCDs) in user interface assemblies is widespread across nearly all industries, locations, and operating environments. Over the last 20 years, the cost of LCD displays has significantly dropped, allowing for this technology to be incorporated into many of the everyday devices we rely on.

The odds are high you are reading this blog post on a laptop or tablet, and it’s likely the actual screen uses LCD technology to render the image onto a low-profile pane of glass. Reach into your pocket. Yes, that smartphone likely uses LCD technology for the screen. As you enter your car, does your dashboard come alive with a complex user interface? What about the menu at your favorite local drive-thru restaurant? These are some everyday examples of the widespread use of LCD technology.

But did you know that the U.S. military is using LCD displays to improve the ability of our warfighters to interact with their equipment? In hospitals around the world, lifesaving medical devices are monitored and controlled by an LCD touchscreen interface. Maritime GPS and navigation systems provide real-time location, heading, and speed information to captains while on the high seas. It’s clear that people’s lives depend on these devices operating in a range of environments.

As the use of LCDs continues to expand, and larger screen sizes become even less expensive, one inherent flaw of LCDs remains: LCD pixels behave poorly at low temperatures. For some applications, LCD displays will not operate whatsoever at low temperatures. This is important because for mil-aero applications, outdoor consumer products, automobiles, or anywhere the temperature is below freezing, the LCD crystal’s performance will begin to deteriorate. If the LCD display exhibits poor color viewing, sluggish resolution, or even worse, permanently damaged pixels, this will limit the ability to use LCD technologies in frigid environments. To address this, there are several design measures that can be explored to minimize the impact of low temperatures on LCDs.

Most LCD displays utilize pixels known as TFT (Thin-Film-Transistor) Color Liquid Crystals, which are the backbone to the billions of LCD screens in use today. Since the individual pixels utilize a fluid-like crystal material as the ambient temperature is reduced, this fluid will become more viscous compromising performance. For many LCD displays, temperatures below 0°C represent the point where performance degrades.

Have you tried to use your smartphone while skiing or ice fishing? What about those of you living in the northern latitudes - have you accidently left your phone in your car overnight where the temperatures drop well below freezing? You may have noticed a sluggish screen response, poor contrast with certain colors, or even worse permanent damage to your screen. While this is normal, it’s certainly a nuisance. As a design engineer, the goal is to select an LCD technology that offers the best performance at the desired temperature range. If your LCD display is required to operate at temperatures below freezing, review the manufacturer’s data sheets for both the operating and storage temperature ranges. Listed below are two different off-the-shelf LCD displays, each with different temperature ratings. It should be noted that there are limited options for off-the-shelf displays with resilience to extreme low temperatures.

For many military applications, in order to comply with the various mil standards a product must be rated for -30°C operational temperature and -51°C storage temperature. The question remains: how can you operate an LCD display at -30°C if the product is only rated for -20°C operating temperature? The answer is to use a heat source to raise the display temperature to an acceptable range. If there is an adjacent motor or another device that generates heat, this alone may be enough to warm the display. If not, a dedicated low-profile heater is an excellent option to consider.

Made of an etched layer of steel and enveloped in an electrically insulating material, a flat flexible polyimide heater is an excellent option where space and power are limited. These devices behave as resistive heaters and can operate off a wide range of voltages all the way up to 120V. These heaters can also function with both AC and DC power sources. Their heat output is typically characterized by watts per unit area and must be sized to the product specifications. These heaters can also be affixed with a pressure sensitive adhesive on the rear, allowing them to be “glued” to any surface. The flying leads off the heater can be further customized to support any type of custom interconnect. A full-service manufacturing partner like Epec can help develop a custom solution for any LCD application that requires a custom low-profile heater.

With no thermal mass to dissipate the heat, polyimide heaters can reach temperatures in excess of 100°C in less than a few minutes of operation. Incorporating a heater by itself is not enough to manage the low temperature effects on an LCD display. What if the heater is improperly sized and damages the LCD display? What happens if the heater remains on too long and damages other components in your system? Just like the thermostat in your home, it’s important to incorporate a real-temp temperature sensing feedback loop to control the on/off function of the heater.

The first step is to select temperature sensors that can be affixed to the display while being small enough to fit within a restricted envelope. Thermistors, thermocouples, or RTDs are all options to consider since they represent relatively low-cost and high-reliability ways to measure the display’s surface temperature. These types of sensors also provide an electrical output that can be calibrated for the desired temperature range.

The next step is to determine the number of temperature sensors and their approximate location on the display. It’s recommended that a minimum of two temperature sensors be used to control the heater. By using multiple sensors, this provides the circuit redundancy and allows for a weighted average of the temperature measurement to mitigate non-uniform heating. Depending on the temperature sensors location, and the thermal mass of the materials involved, the control loop can be optimized to properly control the on/off function of the heater.

Another important consideration when selecting a temperature sensor is how to mount the individual sensors onto the display. Most LCD displays are designed with a sheet metal backer that serves as an ideal surface to mount the temperature sensors. There are several types of thermally conductive epoxies that provide a robust and cost-effective way to affix the delicate items onto the display. Since there are several types of epoxies to choose from, it’s important to use a compound with the appropriate working life and cure time.

For example, if you are kitting 20 LCD displays and the working life of the thermal epoxy is 8 minutes, you may find yourself struggling to complete the project before the epoxy begins to harden.

Before building any type of prototype LCD heater assembly, it’s important to carefully study the heat transfer of the system. Heat will be generated by the flexible polyimide heater and then will transfer to the LCD display and other parts of the system. Although heat will radiate, convect, and be conducted away from the heater, the primary type of heat transfer will be through conduction. This is important because if your heater is touching a large heat sink (ex. aluminum chassis), this will impact the ability of the heater to warm your LCD display as heat will be drawn toward the heat sink.

Insulating materials, air gaps, or other means can be incorporated in the design to manage the way heat travels throughout your system on the way toward an eventual “steady state” condition. During development, prototypes can be built with numerous temperature sensors to map the heat transfer, allowing for the optimal placement of temperature sensors, an adequately sized heater, and a properly controlled feedback loop.

Before freezing the design (no pun intended) on any project that requires an LCD display to operate at low temperatures, it’s critical to perform low temperature first. This type of testing usually involves a thermal chamber, a way to operate the system, and a means to measure the temperature vs time. Most thermal chambers provide an access port or other means to snake wires into the chamber without compromising performance. This way, power can be supplied to the heater and display, while data can be captured from the temperature sensors.

The first objective of the low-temperature testing is to determine the actual effects of cold exposure on the LCD display itself. Does the LCD display function at cold? Are certain colors more impacted by the cold than others? How sluggish is the screen? Does the LCD display performance improve once the system is returned to ambient conditions? These are all significant and appropriate questions and nearly impossible to answer without actual testing.

As LCD displays continue to be a critical part of our society, their use will become even more widespread. Costs will continue to decrease with larger and larger screens being launched into production every year. This means there will be more applications that require their operation in extreme environments, including the low-temperature regions of the world. By incorporating design measures to mitigate the effects of cold on LCD displays, they can be used virtually anywhere. But this doesn’t come easy. Engineers must understand the design limitations and ways to address the overarching design challenges.

A full-service manufacturing partner like Epec offers a high-value solution to be able to design, develop, and manufacture systems that push the limits of off-the-shelf hardware like LCD displays. This fact helps lower the effective program cost and decreases the time to market for any high-risk development project.

thermal management of lcd displays factory

The human cognitive ability to perceive and process data from several heterogeneous outputs and react correctly to the information is greatly enhanced with the proper representation of graphical data. Large format displays allow for the consolidation of multiple heterogeneous displays, fonts, dials, gauges, numbers, into a single homogeneous representation of situational awareness.

For example, for many years, firemen first to arrive on scene have been met with screeching fire alarms, indicator lights on a fire panel and “as built” drawings locked in a cabinet with a special key. Today they could now be greeted by a large format LCD with a 3D view of the building, smoke flow diagrams, and other information to help them understand the situation and make better decisions faster. Occupants leaving a building can also benefit from graphical mass notification information which can be tailored for the situation.

Ship systems comprised of different steam gauges and manual operations such as sticking tanks and closing valves can now be automated with their instruments consolidated on a single screen or redundant large screens, showing graphically status of fuel, water, and ballast, improving productivity and decreasing workload.

Similarities exist on industrial control systems where several CRTs or smaller LCDs are being replaced by a large LCD with clever graphics designed for human factors and perception.

The challenge of these applications is the proper integration of the COTS LCD technology to meet requirements of availability, reliability, and intended use.

Large LCD panels are coming out of the factory with brilliant colors and near perfect viewing angles using ASV (Advanced Super View) and IPS (In Plane Switching) innovations driven by consumer TV requirements. The challenge is ruggedizing a display to preserve as much of this as possible, this while shielding against objects, liquids, sunlight and EMI. These surface choices may adversely affect the optics of the panel, which can be reduced through bonding techniques to eliminate air gaps.

Depending on its intended use, mission critical displays may be required to operate in an environment subject to dust, sand, fog, chemicals, falling or spraying liquids (broken pipes, sprinklers, etc). Protection of the LCD panel involves designing an outer enclosure capable of keeping dust and liquids out while keeping the display operating in its proper temperature range.

In addition to isotropic display clearing, long-term reliability is adversely affected by running panels at or near the clearing temperature. Depending on the application, enclosures can be de signed to circulate air through filtered and louvered vents. This can prevent dust and water ingress while providing a cooling mechanism capable of keeping the panel within specified operating temperatures.

The transition of display backlights from CCFL to LED has also helped reduce the amount of energy in a panel, which has been a great benefit to thermal management. Displays that are used in direct sunlight, however, have to deal with solar gain which can add as much as 1000W /m2 to the problem on a sunny, cloudless day at high noon. The amount absorbed depends on the enclosure’s material and color, but typically blocking IR films or a laminar flow of air over the display are used to prevent the display from “blacking out”. In sub freezing environments, such as outdoor, or non temperature controlled areas, supplemental heaters may be required to prevent slow response of the LCDs due to low temperature.

The deployment of large screen LCDs in control rooms, ships, industrial areas, or public venues requires consideration of tampering, vibration, and shock. It is important to understand the nature of the vibration or shock in magnitude and frequency to which the screen may be subjected. Sources can be motors, conveyors, engines, propeller blades or even seismic events. In many industries, there are published standards, which represent shock and vibration experienced by the display in both transit and operation. Some of the component considerations when designing a display requiring ruggedization are listed in Table 3.

There are several touchscreen technologies available, each having its own set of strengths and weaknesses. It is important to understand the end use and user to choose the best solutions. For instance, using an infrared touch screen in an outdoor location at night can attract insects which can actually cause false touches if they land on the screen and break the IR light beam. Other touch screen technologies such as capacitive are sensitive to metal enclosures making them difficult choices for very rugged applications. Some of the more popular technologies and their strengths and weaknesses are listed in Table 4.

Parts within a large screen display are considered to have a large Mean Time Between Failures (MTBF) usually measured in tens of thousands of hours or higher. The first reaction is to divide this number by 8760 hours per year and feel assured your 24X7 display will last that many years before it fails. However the MTBF is just a probability of failure and is calculated during the “useful life” of a part, typically at room temperature. As a part starts to wear out, or gets used at high temperature, its reliability can decrease rapidly. Solid-state components such as ICs are thought of as lasting virtually forever, but within an LCD there are several components that, when routinely maintained or changed out, will keep the reliability at its maximum. The use of intelligent health monitoring such as temperature, brightness, fan speed or air flow to trigger maintenance events will increase overall reliability and availability.

Leveraging the performance and value of large format commercial off the shelf (COTS) displays requires careful attention and understanding of the environment and operation by the end user. Using this information to develop specific design requirements, engineering a design that meet these requirements, and finally developing test steps that validate the product meets these requirements will ensure a successful large format COTS display implementation.

thermal management of lcd displays factory

(One Drop Filling) high quality displays can be produced. However micro bubbles can arise during this procedure. The micro bubbles are not visible directly after the ODF process,

but visible bubbles can be formed after some time. Using an autoclave can ensure, that no visible bubbles will be formed later and therefore quality and lifespan of the LCDs is increased noticeably.

thermal management of lcd displays factory

Republic of Korea 10-2021-7017568 06/08/2021 10-2400990 05/18/2022 THERMAL MANAGEMENT SYSTEM

Republic of Korea 10-2016-7027996 03/11/2015 10-2379046 03/22/2022 ELECTRONIC DISPLAY REAR COVER AND MOUNTING BRACKET

Republic of Korea 10-2020-7028827 10/7/2020 10-2306650 9/23/2021 THERMAL MANAGEMENT SYSTEM

Republic of Korea 10-2019-7034747 4/17/2018 10-2267374 6/15/2021 FIELD SERVICEABLE AND REPLACEABLE ASSEMBLY

Republic of Korea 10-2019-7034746 4/27/2018 10-2262912 6/3/2021 SYSTEM AND METHOD FOR PREVENTING DISPLAY BOWING

Republic of Korea 10-2020-7000902 1/10/2020 10-2165778 10/7/2020 A DUAL-MODE COOLING SYSTEM AND AN ELECTRONIC DISPLAY ASSEMBLY WITH DUAL-MODE COOLING

Republic of Korea 10-2017-7026230 2/15/2016 10-2109072 5/4/2020 PERIMETER VENTILATION SYSTEM FOR ELECTRONIC DISPLAY

Republic of Korea 10-2018-7028017 3/6/2017 10-2104342 4/20/2020 COOLING SYSTEM FOR DOUBLE SIDED DISPLAY ASSEMBLY

Republic of Korea 10-2019-7006670 3/6/2019 10-2067751 1/13/2020 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Republic of Korea 10-2019-7023014 8/5/2019 10-2063885 1/2/2020 SYSTEM FOR COOLING AN ELECTRONIC IMAGE ASSEMBLY

Republic of Korea 10-2018-7027437 9/20/2018 10-2010515 8/7/2019 SYSTEM FOR COOLING AN ELECTRONIC IMAGE ASSEMBLY

Republic of Korea 10-2018-7011272 4/20/2018 10-1958375 3/8/2019 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Brazil PI0820231-1 11/17/2008 PI0820231-1 2/12/2019 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Republic of Korea 10-2012-7031800 5/4/2011 10-1904363 9/27/2018 SYSTEM FOR COOLING AN ELECTRONIC IMAGE ASSEMBLY

Canada 2,809,019 8/17/2011 2,809,019 9/25/2018 SYSTEM FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY WITH REDUCED NOISE EMISSIONS

United States 15/095,880 4/11/2016 10,080,316 9/18/2018 ELECTRONIC DISPLAY ASSEMBLY HAVING THERMAL COOLING PLATE AND OPTIONAL CONVECTIVE AIR COOLING LOOP

Republic of Korea 10-2016-7001569 7/8/2014 10-1894027 8/27/2018 FIGURE EIGHT CLOSED LOOP COOLING SYSTEM FOR ELECTRONIC DISPLAY

Canada 2,915,261 11/17/2008 2,915,261 8/21/2018 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Republic of Korea 10-2015-7012613 10/16/2013 10-1868077 6/8/2018 BACK PAN COOLING ASSEMBLY FOR ELECTRONIC DISPLAY

Republic of Korea 10-2017-7021171 7/27/2017 10-1853885 4/25/2018 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Republic of Korea 10-2013-7007111 8/17/2011 10-1847151 4/3/2018 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY WITH REDUCED NOISE EMISSIONS

Canada 2,705,814 11/17/2008 2,705,814 2/13/2018 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

United States 14/923,164 10/26/2015 9,835,893 12/5/2017 HEAT EXCHANGER FOR BACK TO BACK ELECTRONIC DISPLAYS

United States 15/069,154 3/14/2016 9,797,588 10/24/2017 EXPANDED HEAT SINK FOR ELECTRONIC DISPLAYS

Republic of Korea 10-2015-7033690 11/25/2015 10-1764381 7/27/2017 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

United States 14/253,543 4/15/2014 9,448,569 9/20/2016 SYSTEM FOR REDUCING THE THERMAL INERTIA OF AN ELECTRONIC DISPLAY

United States 14/457,611 8/12/2014 9,451,733 9/20/2016 SYSTEM FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY WITH REDUCED NOISE EMISSIONS

United States 13/954,469 7/30/2013 9,313,917 4/12/2016 THERMAL PLATE WITH OPTIONAL COOLING LOOP IN ELECTRONIC DISPLAY

United States 14/326,053 7/8/2014 9,285,108 3/15/2016 EXPANDED HEAT SINK FOR ELECTRONIC DISPLAYS

Republic of Korea 10-2010-7013306 11/17/2008 10-1573505 11/25/2015 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

United States 14/702,443 5/1/2015 9,173,325 10/27/2015 HEAT EXCHANGER FOR BACK TO BACK ELECTRONIC DISPLAYS

United States 13/692,657 12/3/2012 9,030,641 5/12/2015 HEAT EXCHANGER FOR BACK TO BACK ELECTRONIC DISPLAYS

United States 13/211,887 8/17/2011 8,804,091 8/12/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY WITH REDUCED NOISE EMISSIONS

United States 12/905,704 10/15/2010 8,773,633 7/8/2014 EXPANDED HEAT SINK FOR ELECTRONIC DISPLAYS

Finland 8848846.5 11/17/2008 2225603 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

France 8848846.5 11/17/2008 2225603 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Great Britain 8848846.5 11/17/2008 2225603 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Italy 8848846.5 11/17/2008 2225603 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Norway 8848846.5 11/17/2008 2225603 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Sweden 8848846.5 11/17/2008 2225603 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

European Patent Convention 8848846.5 11/17/2008 2225603 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Switzerland 8848846.5 11/17/2008 2225603 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Germany 8848846.5 11/17/2008 602008000000 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Spain 8848846.5 11/17/2008 2493592 T3 6/25/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Taiwan 97144317 11/17/2008 I437950 5/11/2014 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

Japan 2010-534262 11/17/2008 5351898 8/30/2013 SYSTEM AND METHOD FOR THERMALLY CONTROLLING AN ELECTRONIC DISPLAY

United States 12/630,469 12/3/2009 8,497,972 7/30/2013 THERMAL PLATE WITH OPTIONAL COOLING LOOP IN ELECTRONIC DISPLAY

United States 12/556,029 9/9/2009 8,373,841 2/12/2013 SHARED ISOLATED GAS COOLING SYSTEM FOR OPPOSITELY FACING ELECTRONIC DISPLAYS

United States 12/753,298 4/2/2010 8,351,014 1/8/2013 HEAT EXCHANGER FOR BACK TO BACK ELECTRONIC DISPLAYS

thermal management of lcd displays factory

The displays feature a Full HD or 4K LCD with a high brightness LED backlight producing an image up to 1,000 nits. The DI Series features models which are dust proof IP5X rated for protection from contaminants and debris and features a fanless thermal management system for virtually silent operation. With the industry’s thinnest form factors—as thin as 29 mm—the displays are ideal for premium high-end applications such as retail and banking enviro