U.S. patent application number 15/396102 was filed with the patent office on 2017-04-20 for system and method for a modular multi-panel display.
The applicant listed for this patent is Ultravision Technologies, LLC. Invention is credited to William Y. Hall.
Application Number | 20170112009 15/396102 |
Document ID | / |
Family ID | 53441747 |
Filed Date | 2017-04-20 |
United States Patent
Application |
20170112009 |
Kind Code |
A1 |
Hall; William Y. |
April 20, 2017 |
System and Method for a Modular Multi-Panel Display
Abstract
Embodiments of the present invention relate to integrated
modular display systems. In one embodiment, a modular multi-panel
display system includes a mechanical support structure, and a
plurality of display panels detachably mounted to the mechanical
support structure so as to form an integrated display panel. Each
LED panel includes an LED array and an LED driver coupled to the
LED array. Each panel further includes a power supply unit disposed
outside the housing and electrically coupled to the receiver
circuit. The mechanical structure is configured to provide
mechanical support to the plurality of display panels without
providing hermetic sealing. Each of the plurality of display panels
is hermetically sealed.
Inventors: |
Hall; William Y.; (Dallas,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ultravision Technologies, LLC |
Dallas |
TX |
US |
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|
Family ID: |
53441747 |
Appl. No.: |
15/396102 |
Filed: |
December 30, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14948939 |
Nov 23, 2015 |
9535650 |
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15396102 |
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14341678 |
Jul 25, 2014 |
9195281 |
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14948939 |
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62025463 |
Jul 16, 2014 |
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61922631 |
Dec 31, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21K 9/90 20130101; G06F
1/183 20130101; G06F 3/147 20130101; H05K 7/20 20130101; H05K
7/20954 20130101; H05K 7/20963 20130101; H05K 5/03 20130101; H05K
7/20127 20130101; F21Y 2115/10 20160801; G06F 1/1601 20130101; G09F
13/22 20130101; H05K 5/06 20130101; G09G 5/14 20130101; G09G
2300/04 20130101; G06F 3/1423 20130101; H05K 7/2039 20130101; G09G
2300/026 20130101; H04N 7/00 20130101; G06F 1/188 20130101; G09F
2013/222 20130101; H05K 2201/10106 20130101; H01B 11/02 20130101;
H05K 2201/066 20130101; G06F 1/20 20130101; H05K 2201/10128
20130101; G09G 3/32 20130101; H05K 2201/1028 20130101; H05K 5/0017
20130101; H05K 5/0256 20130101; H05K 5/0247 20130101; G06F 1/26
20130101; G06F 1/189 20130101; G09G 5/003 20130101; H01B 7/2825
20130101; H05K 3/32 20130101; G09G 2330/10 20130101; H01B 9/003
20130101; G09G 2320/029 20130101; F21V 23/023 20130101; G09F 9/3023
20130101; F21V 31/005 20130101; G06T 1/60 20130101; F21K 9/20
20160801; H05K 7/20136 20130101; H05K 1/181 20130101; G09G 2360/04
20130101; G06F 3/1446 20130101; G09G 2330/045 20130101; G09G 3/006
20130101; H05K 999/99 20130101; Y02P 70/50 20151101; G09G 2330/02
20130101; H05K 7/1422 20130101; H05K 7/1427 20130101; G06F 1/182
20130101 |
International
Class: |
H05K 5/02 20060101
H05K005/02; G09G 3/32 20060101 G09G003/32; H05K 7/20 20060101
H05K007/20; H05K 5/00 20060101 H05K005/00; H05K 5/03 20060101
H05K005/03; H05K 3/32 20060101 H05K003/32; F21K 9/20 20060101
F21K009/20; F21K 9/90 20060101 F21K009/90; F21V 23/02 20060101
F21V023/02; F21V 31/00 20060101 F21V031/00; H05K 1/18 20060101
H05K001/18; G06F 3/14 20060101 G06F003/14; H05K 5/06 20060101
H05K005/06 |
Claims
1. A method of assembling a modular multi-panel display system, the
method comprising: assembling a mechanical support structure; at a
first location, detachably mounting a plurality of display panels
to the mechanical support structure so as to assemble a plurality
of integrated display panel sub-assemblies, each sub-assembly
including a plurality of display panels arranged in rows and
columns, wherein each display panel includes: an array of display
elements comprising a plurality of rows of display elements and a
plurality of columns of display elements so as to form a display
panel surface, wherein the display panel surface is sealed to be
waterproof, a display driver coupled to the array of display
elements, a housing, a receiver circuit disposed inside the
housing, and a power supply electrically coupled to the receiver
circuit and the display driver, wherein the power supply is
configured to convert an alternative current (AC) received at an
input and output a direct current (DC); wherein the mechanical
support structure is configured to provide mechanical support to
the plurality of display panels without providing waterproof
sealing; wherein the plurality of integrated display panel
sub-assemblies are configured to be moved to a second location
remote from the first location; and wherein, at the second
location, the plurality of integrated display panel sub-assemblies
are configured to be built into a multi-panel display system by
assembling the sub-assemblies into an integrated display panel.
2. The method of claim 1, further comprising a catwalk attached to
the mechanical support structure at a back side, wherein the back
side is opposite the side to which the plurality of display panels
is detachably mounted.
3. The method of claim 1, wherein each display panel of each row is
electrically connected to an adjacent display panel within that
row; wherein, for each row, a first end display panel receives an
input data connection from a data source and has an output data
connection to a next display panel in the row, each further display
panel until a second end display panel providing data to a next
adjacent display panel; and wherein a power line is run across each
row to power the display panels in that row.
4. The method of claim 1, wherein the multi-panel display system
includes no cabinets, is cooled passively and includes no air
conditioning, fans, or heating units.
5. The method of claim 4, wherein each display panel includes a
board in contact with the housing.
6. The method of claim 5, wherein the board physically contacts a
thermally conductive material at a backside of the board, and
wherein the thermally conductive material physically contacts an
inner wall of the housing.
7. The method of claim 6, wherein the housing comprises a plastic
housing.
8. The method of claim 1, wherein the mechanical support structure
includes a top bar, a bottom bar, a left bar, a right bar, and at
least one vertical bar extending from the top bar to the bottom
bar, the vertical bar disposed between the left bar and the right
bar.
9. The method of claim 8, wherein the top bar, the bottom bar, the
left bar and the right bar are each capable of bearing a load of
1.738 lb/ft and wherein the vertical bar is capable of bearing a
load of 3.23 lb/ft.
10. A method of assembling a modular multi-panel display system,
the method comprising: assembling a plurality of mechanical support
structures that each include a plurality of beams; receiving from a
first location, a plurality of display panels mounted to a
plurality of beams of each of a plurality of mechanical support
structures so as to assemble a plurality of integrated display
panel sub-assemblies, each sub-assembly including a plurality of
display panels arranged in rows and columns, wherein the display
system includes no cabinets, wherein the display system is cooled
passively and includes no air conditioning, fans, or heating units,
and wherein the sub-assemblies are received at a second location
remote from the first location; and at the second location,
building a multi-panel display system by assembling the
sub-assemblies into an integrated display panel.
11. The method of claim 10, further comprising mounting a data
receiver box adjacent the array to provide power, data, and
communication to the array of display panels, wherein the power and
the data are supplied from the data receiver box through separate
wires within an integrated cable.
12. The method of claim 11, wherein the data receiver box provides
direct current (DC) power to each of the display panels and wherein
a power supply unit of each display panel is configured to convert
the DC power to DC power at a different voltage level.
13. The method of claim 10, wherein the plurality of display panels
are mounted to the plurality of mechanical support structures with
attachment plates.
14. The method of claim 13, wherein the attachment plates comprise
corner plates and wherein each display panel within an interior
portion of the array of display panels is attached to two
respective vertical beams by four of the corner plates, each corner
plate being mechanically connected to corners of four of the
display panels to secure the display panels to the respective
vertical beam.
15. A method of assembling a modular multi-panel display system,
the method comprising: receiving from a first location a plurality
of integrated display panel sub-assemblies comprising a plurality
of display panels detachably mounted to a mechanical support
structure, each sub-assembly including a plurality of display
panels arranged in rows and columns, wherein each display panel
comprises a waterproof outer front surface and includes: a shell
comprising a hollow region therein, an array of light emitting
diodes comprising a plurality of rows of light emitting diodes and
a plurality of columns of light emitting diodes so as to form a
display panel surface, first circuitry coupled to the array of
light emitting diodes and disposed within the hollow region of the
shell, second circuitry disposed within the hollow region of the
shell, and a power converter electrically coupled to the first
circuitry and the second circuitry, wherein the power converter is
configured to receive an alternative current (AC) at an input and
to output a direct current (DC); and at a second location remote
from the first location, building a multi-panel display system by
assembling the sub-assemblies into an integrated display panel.
16. The method of claim 15, wherein the mechanical support
structure provides mechanical support to the plurality of display
panels without providing waterproof sealing.
17. The method of claim 15, wherein the integrated display panel is
mounted to a wall.
18. The method of claim 15, wherein the integrated display panel is
mounted to a preexisting billboard.
19. The method of claim 15, wherein the array of light emitting
diodes are attached to a printed circuit board, and wherein the
printed circuit board is disposed outside the hollow region of the
shell.
20. The method of claim 15, wherein the power converter is disposed
within the hollow region of the shell.
21. The method of claim 15, wherein the power converter is disposed
outside the hollow region of the shell.
22. The method of claim 15, further comprising replacing a
defective one of the plurality of display panels after building the
multi-panel display system.
23. A method of maintaining a modular multi-panel display that
includes a mechanical support structure and a plurality of LED
display panels detachably coupled to the mechanical support
structure, wherein each LED display panel is mechanically coupled
to the mechanical support structure, the method of maintaining
comprising: determining that a defective LED display panel has a
defect; electrically disconnecting the defective LED display panel
from the multi-panel display; removing the defective LED display
panel from the multi-panel display; placing a replacement LED
display panel at a location formerly taken by the defective LED
display panel; and electrically connecting the replacement LED
display panel to the multi-panel display.
24. The method of claim 23, wherein each of the plurality of LED
display panels comprises: a thermally conductive housing; a
plurality of LEDs attached to a first side of a printed circuit
board; circuitry coupled to a second side of the printed circuit
board, wherein the second side is opposite the first side, the
circuitry being disposed within the thermally conductive housing;
and a power supply coupled to the circuitry.
25. The method of claim 23, wherein determining that the defective
LED display panel has a defect comprises automatically monitoring
the defective LED display panel.
26. The method of claim 23, wherein determining that the defective
LED display panel has a defect comprises determining that a pixel
of the defective LED display panel is not drawing power.
27. The method of claim 23, wherein electrically connecting the
replacement LED display panel to the multi-panel display comprises
electrically connecting an input of the replacement LED display
panel to a first adjacent LED display panel and connecting an
output of the replacement LED display panel to a second adjacent
LED display panel.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No.
14/948,939 filed on Nov. 23, 2015, which is a continuation of
application Ser. No. 14/341,678 filed on Jul. 25, 2014 (now U.S.
Pat. No. 9,195,281), which claims the benefit of U.S. Provisional
Application No. 62/025,463, filed on Jul. 16, 2014 and also the
benefit of U.S. Provisional Application No. 61/922,631, filed on
Dec. 31, 2013, which applications are hereby incorporated herein by
reference.
[0002] U.S. patent application Ser. No. 14/328,624 (attorney
docket: UVI-004), filed Jul. 10, 2014, also claims priority to U.S.
Provisional Application No. 61/922,631 (attorney docket: UVI-004P)
and is also incorporated herein by reference. The following
applications are also related to this provisional application: U.S.
patent application Ser. No. 14/444,719 (attorney docket: UVI-006);
U.S. patent application Ser. No. 14/444,747 (attorney docket:
UVI-009); U.S. patent application Ser. No. 14/444,775 (attorney
docket: UVI-008); U.S. patent application Ser. No. 14/550,685
(attorney docket: UVI-011); U.S. patent application Ser. No.
14/582,908 (attorney docket: UVI-012); U.S. patent application Ser.
No. 14/627,923 (attorney docket: UVI-008C1); U.S. patent
application Ser. No. 14/641,130 (attorney docket: UVI-011C1); U.S.
patent application Ser. No. 14/641,189 (attorney docket:
UVI-012C1); U.S. patent application Ser. No. 14/664,526 (attorney
docket: UVI-009C1); U.S. patent application Ser. No. 14/720,544
(attorney docket: UVI-013); U.S. patent application Ser. No.
14/720,560 (attorney docket: UVI-0014); U.S. patent application
Ser. No. 14/720,610 (attorney docket: UVI-015); U.S. patent
application Ser. No. 14/829,469 (attorney docket: UVI-008C2); U.S.
patent application Ser. No. 14/850,632 (attorney docket:
UVI-006C1); U.S. Patent Application No. 62/065,510 (attorney
docket: UVI-011P); U.S. Patent Application No. 62/093,157 (attorney
docket: UVI-012P); U.S. Patent Application No. 62/113,342 (attorney
docket: UVI-013P); U.S. Patent Application No. 62/158,707 (attorney
docket: UVI-014P); U.S. Patent Application No. 62/158,989 (attorney
docket: UVI-015P); and PCT Patent Application No. PCT/US14/72373
(attorney docket: UVI-0112PCT).
TECHNICAL FIELD
[0003] The present invention relates generally to displays, and, in
particular embodiments, to a system and method for a modular
multi-panel display.
BACKGROUND
[0004] Large displays (e.g., billboards), such as those commonly
used for advertising in cities and along roads, generally have one
or more pictures and/or text that are to be displayed under various
light and weather conditions. As technology has advanced and
introduced new lighting devices such as the light emitting diode
(LED), such advances have been applied to large displays. An LED
display is a flat panel display, which uses an array of
light-emitting diodes. A large display may be made of a single LED
display or a panel of smaller LED panels. LED panels may be
conventional panels made using discrete LEDs or surface-mounted
device (SMD) panels. Most outdoor screens and some indoor screens
are built around discrete LEDs, which are also known as
individually mounted LEDs. A cluster of red, green, and blue diodes
is driven together to form a full-color pixel, usually square in
shape. These pixels are spaced evenly apart and are measured from
center to center for absolute pixel resolution.
SUMMARY
[0005] Embodiments of the invention relate to lighting systems and,
more particularly, to multi-panel lighting systems for providing
interior or exterior displays.
[0006] In one embodiment, a modular multi-panel display system
comprises a mechanical support structure. A plurality of LED
display panels is detachably mounted to the mechanical support
structure so as to form an integrated display panel. Each LED panel
includes an LED array and a receiver circuit disposed within a
housing. The receiver circuit includes an LED driver coupled to the
LED array. Each panel further includes a power supply unit disposed
outside the housing and electrically coupled to the receiver
circuit. The mechanical structure is configured to provide
mechanical support to the plurality of LED display panels without
providing hermetic sealing. Each of the plurality of LED display
panels is hermetically sealed.
[0007] In one embodiment, a modular multi-panel display system
comprises an outer frame including a top beam, a bottom beam, a
left outside beam, and a right outside beam. A plurality of
vertical beams extends from the top beam to the bottom beam within
the outer frame. Each of the vertical beams has a smaller diameter
and weighs less than any beam of the outer frame. An array of LED
display panels is arranged in rows and columns. Each LED display
panel is attached to at least one of the vertical beams. The array
forms an integrated display panel. The display system includes no
cabinets, and is cooled passively and includes no air conditioning,
fans, or heating units.
[0008] In another embodiment, a method of assembling a modular
multi-panel display system comprises assembling a mechanical
support structure that includes an outer frame including a top
beam, a bottom beam, a left outside beam, and a right outside beam.
A plurality of vertical beams extends from the top beam to the
bottom beam within the outer frame. Each of the vertical beams has
a smaller diameter and weighs less than any beam of the outer
frame. A plurality of LED display panels is mounted to the
mechanical support structure so as to form an integrated display
panel that includes an array of rows and columns of LED display
panels. Each of the LED display panels is hermetically sealed. Each
of the LED display panels is electrically connected to a data
source and to a power source. The assembled multi-panel display
system includes no cabinets, and is cooled passively and includes
no air conditioning or fans.
[0009] In yet another embodiment, a method of maintaining a modular
multi-panel display that includes a mechanical support structure
and a plurality of LED display panels detachably coupled to the
mechanical support structure without a cabinet. Each LED display
panel is mechanically coupled to the mechanical support structure
and three other lighting panels by a corner plate. The method
further includes determining that a defective LED display panel has
a defect and electrically disconnecting the defective LED display
panel from the multi-panel display. The corner plate is removed
from the defective LED display panel. The defective LED display
panel is removed from the multi-panel display. A replacement LED
display panel is placed at a location formerly taken by the
defective LED display panel. The corner plate is attached to the
replacement LED display panel. The replacement LED display panel is
electrically connected to the multi-panel display.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more complete understanding, reference is now made to
the following description taken in conjunction with the
accompanying drawings in which:
[0011] FIGS. 1A and 1B illustrate one embodiment of a display that
may be provided according to the present disclosure;
[0012] FIGS. 2A-2C illustrate one embodiment of a lighting panel
that may be used with the display of FIGS. 1A and 1B;
[0013] FIGS. 3A-3I illustrate one embodiment of a housing and an
alignment plate that may be used with the panel of FIG. 2A;
[0014] FIGS. 4A and 4B illustrate a more detailed embodiment of the
panel of FIG. 2A;
[0015] FIG. 5 illustrates an alternative embodiment of the panel of
FIG. 4A;
[0016] FIGS. 6A and 6B illustrate a more detailed embodiment of the
panel of FIG. 2A;
[0017] FIG. 7 illustrates an alternative embodiment of the panel of
FIG. 6A;
[0018] FIGS. 8A-8M illustrate one embodiment of a frame that may be
used with the display of FIGS. 1A and 1B;
[0019] FIGS. 9A-9C illustrate one embodiment of a locking mechanism
that may be used with the display of FIGS. 1A and 1B;
[0020] FIGS. 10A-10D illustrate one embodiment of a display
configuration;
[0021] FIGS. 11A-11D illustrate another embodiment of a display
configuration;
[0022] FIGS. 12A-12D illustrate yet another embodiment of a display
configuration;
[0023] FIG. 13 illustrates a modular display panel in accordance
with an embodiment of the present invention;
[0024] FIG. 14 illustrates a modular display panel attached to a
supporting frame in accordance with an embodiment of the present
invention;
[0025] FIG. 15 illustrates a frame used to provide mechanical
support to the modular display panel in accordance with an
embodiment of the present invention;
[0026] FIGS. 16A-16E illustrate an attachment plate used to attach
one or more modular display panels to the frame in accordance with
an embodiment of the present invention, wherein FIG. 16A
illustrates a projection view while FIG. 16B illustrates a top view
and FIG. 16C illustrates a cross-sectional view of a first
embodiment while FIG. 16D illustrates a bottom view and FIG. 16 E
illustrates a bottom view of a second embodiment;
[0027] FIG. 17 illustrates a magnified view of the attachment plate
or a connecting plate, frame, and display panel after mounting in
accordance with embodiments of the present invention;
[0028] FIG. 18 illustrates one unit of the modular display panel in
accordance with an embodiment of the present invention;
[0029] FIG. 19 illustrates a magnified view of two display panels
next to each other and connected through the cables such that the
output cable of the left display panel is connected with the input
cable of the next display panel in accordance with an embodiment of
the present invention;
[0030] FIG. 20 illustrates a modular multi-panel display system
comprising a plurality of LED display panels connected together
using the afore-mentioned cables in accordance with an embodiment
of the present invention;
[0031] FIGS. 21A-21C illustrate an alternative embodiment of the
modular display panel attached to a supporting frame in accordance
with an embodiment of the present invention, wherein FIGS. 21B and
21C illustrate alternative structural embodiments of the supporting
frame;
[0032] FIG. 22 illustrates a method of assembling a modular
multi-panel display system in accordance with an embodiment of the
present invention;
[0033] FIG. 23 illustrates an assembled multi-panel display that is
ready for shipment;
[0034] FIG. 24 illustrates a method of maintaining a modular
multi-panel display that includes a mechanical support structure
and a plurality of LED display panels detachably coupled to the
mechanical support structure without a cabinet in accordance with
an embodiment of the present invention;
[0035] FIGS. 25A-25D illustrate specific examples of an assembled
display system; and
[0036] FIG. 26 illustrates a specific example of a frame that can
be used with the system of FIGS. 25A-25D.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0037] In the following discussion, exterior displays are used
herein for purposes of example. It is understood that the present
disclosure may be applied to lighting for any type of interior
and/or exterior display.
[0038] Embodiments of the invention provide display panels, each of
which provides a completely self-contained building block that is
lightweight. These displays are designed to protect against
weather, without a heavy cabinet. The panel can be constructed of
aluminum or plastic so that it will about 50% lighter than typical
panels that are commercially available. The lightweight design
allows for easier installation and maintenance, thus lowering total
cost of ownership.
[0039] In certain embodiments, the display is IP 67 rated and
therefore waterproof and corrosion resistant. Because weather is
the number one culprit for damage to LED displays, an IP 67 rating
provides weatherproofing with significant weather protection. These
panels are completely waterproof against submersion in up to 3 feet
of water. In other embodiments, the equipment can be designed with
an IP 68 rating to operate completely underwater. In lower-cost
embodiments where weatherproofing is not as significant, the panels
can have an IP 65 or IP 66 rating.
[0040] One aspect takes advantage of a no cabinet design-new
technology that replaces cabinets, which are necessary in
commercial embodiments. Older technology incorporates the use of
cabinets in order to protect the LED display electronics from rain.
This creates an innate problem in that the cabinet must not allow
rain to get inside to the electronics, while at the same time the
cabinet must allow for heat created by the electronics and ambient
heat to escape.
[0041] Embodiments that do not use this cabinet technology avoid a
multitude of problems inherent to cabinet-designed displays. One of
the problems that has been solved is the need to effectively cool
the LED display. Most LED manufacturers must use air-conditioning
(HVAC) to keep their displays cool. This technology greatly
increases the cost of installation and performance.
[0042] Displays of the present invention can be designed to be
light weight and easy to handle. For example, the average total
weight of a 20 mm, 14'.times.48' panel can be 5,500 pounds or less
while typical commercially available panels are at 10,000 to 12,000
pounds. These units are more maneuverable and easier to install
saving time and money in the process.
[0043] Embodiments of the invention provide building block panels
that are configurable with future expandability. These displays can
offer complete expandability to upgrade in the future without
having to replace the entire display. Installation is fast and easy
with very little down-time, which allows any electronic message to
be presented more quickly.
[0044] In some embodiments, the display panels are "hot swappable."
By removing one screw in each of the four corners of the panel,
servicing the display is fast and easy. Since a highly-trained,
highly-paid electrician or LED technician is not needed to correct
a problem, cost benefits can be achieved.
[0045] Various embodiments utilize enhanced pixel technology (EPT),
which increases image capability. EPT allows image displays in the
physical pitch spacing, but also has the ability to display the
image in a resolution that is four-times greater. Images will be as
sharp and crisp when viewed close as when viewed from a distance,
and at angles.
[0046] In some embodiments it is advantageous to build multipanel
displays where each of the LEDs is provided by a single LED
manufacturer, so that diodes of different origin in the manufacture
are not mixed. It has been discovered that diode consistency can
aid in the quality of the visual image. While this feature is not
necessary, it is helpful because displays made from different
diodes from different suppliers can create patchy inconsistent
color, e.g., "pink" reds and pink looking casts to the overall
image.
[0047] Referring to FIGS. 1A and 1B, one embodiment of a
multi-panel display 100 is illustrated. The display 100 includes a
display surface 102 that is formed by multiple lighting panels
104a-104t. In the present embodiment, the panels 104a-104t use
light emitting diodes (LEDs) for illumination, but it is understood
that other light sources may be used in other embodiments. The
panels 104a-104t typically operate together to form a single image,
although multiple images may be simultaneously presented by the
display 100. In the present example, the panels 104a-104t are
individually attached to a frame 106, which enables each panel to
be installed or removed from the frame 106 without affecting the
other panels.
[0048] Each panel 104a-104t is a self-contained unit that couples
directly to the frame 106. By "directly," it is understood that
another component or components may be positioned between the panel
104a-104t and the frame 106, but the panel is not placed inside a
cabinet that is coupled to the frame 106. For example, an alignment
plate (described later but not shown in the present figure) may be
coupled to a panel and/or the frame 106 to aid in aligning a panel
with other panels. Further a corner plate could be used. The panel
may then be coupled to the frame 106 or the alignment plate and/or
corner plate, and either coupling approach would be "direct"
according to the present disclosure.
[0049] Two or more panels 104a-104t can be coupled for power and/or
data purposes, with a panel 104a-104t receiving power and/or data
from a central source or another panel and passing through at least
some of the power and/or data to one or more other panels. This
further improves the modular aspect of the display 100, as a single
panel 104a-104t can be easily connected to the display 100 when
being installed and easily disconnected when being removed by
decoupling the power and data connections from neighboring
panels.
[0050] The power and data connections for the panels 104a-104t may
be configured using one or more layouts, such as a ring, mesh,
star, bus, tree, line, or fully-connected layout, or a combination
thereof. In some embodiments the LED panels 104a-104t may be in a
single network, while in other embodiments the LED panels 104a-104t
may be divided into multiple networks. Power and data may be
distributed using identical or different layouts. For example,
power may be distributed in a line layout, while data may use a
combination of line and star layouts.
[0051] The frame 106 may be relatively light in weight compared to
frames needed to support cabinet mounted LED assemblies. In the
present example, the frame 106 includes only a top horizontal
member 108, a bottom horizontal member 110, a left vertical member
112, a right vertical member 114, and intermediate vertical members
116. Power cables and data cables (not shown) for the panels
104a-104t may route around and/or through the frame 106.
[0052] In one example, the display 100 includes 336 panels
104a-104t, e.g., to create a 14'.times.48' display. As will be
discussed below, because each panel is lighter than typical panels,
the entire display could be built to weigh only 5500 pounds. This
compares favorably to commercially available displays of the size,
which generally weigh from 10,000 to 12,000 pounds.
[0053] Referring to FIGS. 2A-2C, one embodiment of an LED panel 200
is illustrated that may be used as one of the LED panels 104a-104t
of FIGS. 1A and 1B. FIG. 2A illustrates a front view of the panel
200 with LEDs aligned in a 16.times.32 configuration. FIG. 2B
illustrates a diagram of internal components within the panel 200.
FIG. 2C illustrates one possible configuration of a power supply
positioned within the panel 200 relative to a back plate of the
panel 200.
[0054] Referring specifically to FIG. 2A, in the present example,
the LED panel 200 includes a substrate 202 that forms a front
surface of the panel 200. The substrate 202 in the present
embodiment is rectangular in shape, with a top edge 204, a bottom
edge 206, a right edge 208, and a left edge 210. A substrate
surface 212 includes "pixels" 214 that are formed by one or more
LEDs 216 on or within the substrate 202. In the present example,
each pixel 214 includes four LEDs 216 arranged in a pattern (e.g.,
a square). For example, the four LEDs 216 that form a pixel 214 may
include a red LED, a green LED, a blue LED, and one other LED
(e.g., a white LED). In some embodiments, the other LED may be a
sensor. It is understood that more or fewer LEDs 216 may be used to
form a single pixel 214, and the use of four LEDs 216 and their
relative positioning as a square is for purposes of illustration
only.
[0055] In some embodiments, the substrate 202 may form the entire
front surface of the panel 200, with no other part of the panel 200
being visible from the front when the substrate 202 is in place. In
other embodiments, a housing 220 (FIG. 2B) may be partially visible
at one or more of the edges of the substrate 202. The substrate 202
may form the front surface of the panel 202, but may not be the
outer surface in some embodiments. For example, a transparent or
translucent material or coating may overlay the substrate 202 and
the LEDs 216, thereby being positioned between the substrate
202/LEDs 216 and the environment.
[0056] As one example, a potting material can be formed over the
LEDs 216. This material can be applied as a liquid, e.g., while
heated, and then harden over the surface, e.g., when cooled. This
potting material is useful for environmental protection, e.g., to
achieve an IP rating of IP 65 or higher.
[0057] Louvers 218 may be positioned above each row of pixels 214
to block or minimize light from directly striking the LEDs 216 from
certain angles. For example, the louvers 218 may be configured to
extend from the substrate 202 to a particular distance and/or at a
particular angle needed to completely shade each pixel 214 when a
light source (e.g., the sun) is at a certain position (e.g., ten
degrees off vertical). In the present example, the louvers 208
extend the entire length of the substrate 202, but it is understood
that other louver configurations may be used.
[0058] Referring specifically to FIG. 2B, one embodiment of the
panel 200 illustrates a housing 220. The housing 220 contains
circuitry 222 and a power supply 224. The circuitry 222 is coupled
to the LEDs 216 and is used to control the LEDs. The power supply
224 provides power to the LEDs 216 and circuitry 222. As will be
described later in greater detail with respect to two embodiments
of the panel 200, data and/or power may be received for only the
panel 200 or may be passed on to one or more other panels as well.
Accordingly, the circuitry 222 and/or power supply 224 may be
configured to pass data and/or power to other panels in some
embodiments.
[0059] In the present example, the housing 220 is sealed to prevent
water from entering the housing. For example, the housing 220 may
be sealed to have an ingress protection (IP) rating such as IP 67,
which defines a level of protection against both solid particles
and liquid. This ensures that the panel 200 can be mounted in
inclement weather situations without being adversely affected. In
such embodiments, the cooling is passive as there are no vent
openings for air intakes or exhausts. In other embodiments, the
housing may be sealed to have an IP rating of IP 65 or higher, e.g.
IP 65, IP 66, IP 67, or IP 68.
[0060] Referring specifically to FIG. 2C, one embodiment of the
panel 200 illustrates how the power supply 224 may be thermally
coupled to the housing 220 via a thermally conductive material 226
(e.g., aluminum). This configuration may be particularly relevant
in embodiments where the panel 200 is sealed and cooling is
passive.
[0061] Referring to FIGS. 3A-3I, one embodiment of a housing 300 is
illustrated that may be used with one of the LED panels 104a-104t
of FIGS. 1A and 1B. For example, the housing 300 may be a more
specific example of the housing 220 of FIG. 2B. In FIGS. 3B-3I, the
housing 300 is shown with an alignment plate, which may be separate
from the housing 300 or formed as part of the housing 300. In the
present example, the housing 300 may be made of a thermally
conductive material (e.g., aluminum) that is relatively light
weight and rigid. In other embodiments, the housing 300 could be
made out of industrial plastic, which is even lighter than
aluminum.
[0062] As shown in the orthogonal view of FIG. 3A, the housing 300
defines a cavity 302. Structural cross-members 304 and 306 may be
used to provide support to a substrate (e.g., the substrate 202 of
FIG. 2A) (not shown). The cross-members 304 and 306, as well as
other areas of the housing 300, may include supports 308 against
which the substrate can rest when placed into position. As shown,
the supports 308 may include a relatively narrow tip section that
can be inserted into a receiving hole in the back of the substrate
and then a wider section against which the substrate can rest.
[0063] The housing 300 may also include multiple extensions 310
(e.g., sleeves) that provide screw holes or locations for captive
screws that can be used to couple the substrate to the housing 300.
Other extensions 312 may be configured to receive pins or other
protrusions from a locking plate and/or fasteners, which will be
described later in greater detail. Some or all of the extensions
312 may be accessible only from the rear side of the housing 300
and so are not shown as openings in FIG. 3A.
[0064] As shown in FIG. 3B, an alignment plate 314 may be used with
the housing 300. The alignment plate is optional. The alignment
plate 314, when used, aids in aligning multiple panels on the frame
106 to ensure that the resulting display surface has correctly
aligned pixels both horizontally and vertically. To accomplish
this, the alignment plate 314 includes tabs 316 and slots 318 (FIG.
3F). Each tab 316 fits into the slot 318 of an adjoining alignment
plate (if present) and each slot 318 receives a tab from an
adjoining alignment plate (if present). This provides an
interlocking series of alignment plates. As each alignment plate
314 is coupled to or part of a housing 300, this results in
correctly aligning the panels on the frame 106.
[0065] It is understood that, in some embodiments, the alignment
plate 314 may be formed as part of the panel or the alignment
functionality provided by the alignment plate 314 may be achieved
in other ways. In still other embodiments, a single alignment panel
314 may be formed to receive multiple panels, rather than a single
panel as shown in FIG. 3B.
[0066] In other embodiments, the alignment functionality is
eliminated. The design choice of whether to use alignment
mechanisms (e.g., slots and grooves) is based upon a tradeoff
between the additional alignment capability and the ease of
assembly.
[0067] As shown in FIG. 3C, the housing 300 may include beveled or
otherwise non-squared edges 320. This shaping of the edges enables
panels to be positioned in a curved display without having large
gaps appear as would occur if the edges were squared.
[0068] Referring to FIGS. 4A and 4B, one embodiment of a panel 400
is illustrated that may be similar or identical to one of the LED
panels 104a-104t of FIGS. 1A and 1B. The panel 400 may be based on
a housing 401 that is similar or identical to the housing 300 of
FIG. 3A. FIG. 4A illustrates a back view of the panel 400 and FIG.
4B illustrates a top view. The panel 400 has a width W and a height
H.
[0069] In the present example, the back includes a number of
connection points that include a "power in" point 402, a "data in"
point 404, a main "data out" point 406, multiple slave data points
408, and a "power out" point 410. As will be discussed below, one
embodiment of the invention provides for an integrated data and
power cable, which reduces the number of ports. The power in point
402 enables the panel 400 to receive power from a power source,
which may be another panel. The data in point 404 enables the panel
to receive data from a data source, which may be another panel. The
main data out point 406 enables the panel 400 to send data to
another main panel. The multiple slave data points 408, which are
bi-directional in this example, enable the panel 400 to send data
to one or more slave panels and to receive data from those slave
panels. In some embodiments, the main data out point 406 and the
slave data out points 408 may be combined. The power out point 410
enables the panel 400 to send power to another panel.
[0070] The connection points may be provided in various ways. For
example, in one embodiment, the connection points may be jacks
configured to receive corresponding plugs. In another embodiment, a
cable may extend from the back panel with a connector (e.g., a jack
or plug) affixed to the external end of the cable to provide an
interface for another connector. It is understood that the
connection points may be positioned and organized in many different
ways.
[0071] Inside the panel, the power in point 402 and power out point
410 may be coupled to circuitry (not shown) as well as to a power
supply. For example, the power in point 402 and power out point 410
may be coupled to the circuitry 222 of FIG. 2B, as well as to the
power supply 224. In such embodiments, the circuitry 222 may aid in
regulating the reception and transmission of power. In other
embodiments, the power in point 402 and power out point 410 may by
coupled only to the power supply 224 with a pass through power
connection allowing some of the received power to be passed from
the power in point 402 to the power out point 410.
[0072] The data in point 404, main data out point 406, and slave
data out points 408 may be coupled to the circuitry 222. The
circuitry 222 may aid in regulating the reception and transmission
of the data. In some embodiments, the circuitry 222 may identify
data used for the panel 400 and also send all data on to other
coupled main and slave panels via the main data out point 406 and
slave data out points 408, respectively. In such embodiments, the
other main and slave panels would then identify the information
relevant to that particular panel from the data. In other
embodiments, the circuitry 222 may remove the data needed for the
panel 400 and selectively send data on to other coupled main and
slave panels via the main data out point 406 and slave data out
points 408, respectively. For example, the circuitry 222 may send
only data corresponding to a particular slave panel to that slave
panel rather than sending all data and letting the slave panel
identify the corresponding data.
[0073] The back panel also has coupling points 412 and 414. In the
example where the housing is supplied by the housing 300 of FIG.
3A, the coupling points 412 and 414 may correspond to extensions
310 and 312, respectively.
[0074] Referring specifically to FIG. 4B, a top view of the panel
400 illustrates three sections of the housing 401. The first
section 416 includes the LEDs (not shown) and louvers 418. The
second section 420 and third section 422 may be used to house the
circuitry 222 and power supply 224. In the present example, the
third section 422 is an extended section that may exist on main
panels, but not slave panels, due to extra components needed by a
main panel to distribute data. Depths D1, D2, and D3 correspond to
sections 416, 420, and 422, respectively.
[0075] Referring to FIG. 5, one embodiment of a panel 500 is
illustrated that may be similar or identical to the panel 400 of
FIG. 4A with the exception of a change in the slave data points
408. In the embodiment of FIG. 4A, the slave data points 408 are
bi-directional connection points. In the present embodiment,
separate slave "data in" points 502 and slave "data out" points 504
are provided. In other embodiments, the data points can be
directional connection points.
[0076] Referring to FIGS. 6A and 6B, one embodiment of a panel 600
is illustrated that may be similar or identical to the panel 400 of
FIG. 4A except that the panel 600 is a slave panel. FIG. 6A
illustrates a back view of the panel 600 and FIG. 6B illustrates a
top view. The panel 400 has a width W and a height H. In the
present embodiment, these are identical to the width W and height H
of the panel 400 of FIG. 4A. In one example, the width W can be
between 1 and 4 feet and the height H can be between 0.5 and 4
feet, for example 1 foot by 2 feet. Of course, the invention is not
limited to these specific dimensions.
[0077] In contrast to the main panel of FIG. 4A, the back of the
slave panel 600 has a more limited number of connection points that
include a "power in" point 602, a data point 604, and a "power out"
point 606. The power in point 602 enables the panel 600 to receive
power from a power source, which may be another panel. The data
point 604 enables the panel to receive data from a data source,
which may be another panel. The power out point 606 enables the
panel 600 to send power to another main panel. In the present
example, the data point 604 is bi-directional, which corresponds to
the main panel configuration illustrated in FIG. 4A. The back panel
also has coupling points 608 and 610, which correspond to coupling
points 412 and 414, respectively, of FIG. 4A. As discussed above,
other embodiments use directional data connections.
[0078] Referring specifically to FIG. 6B, a top view of the panel
600 illustrates two sections of the housing 601. The first section
612 includes the LEDs (not shown) and louvers 614. The second
section 616 may be used to house the circuitry 222 and power supply
224. In the present example, the extended section provided by the
third section 422 of FIG. 4A is not needed as the panel 600 does
not pass data on to other panels. Depths D1 and D2 correspond to
sections 612 and 616, respectively. In the present embodiment,
depths D1 and D2 are identical to depths D1 and D2 of the panel 400
of FIG. 4B. In one example, the depth D1 can be between 1 and 4
inches and the depths D2 can be between 1 and 4 inches.
[0079] It is noted that the similarity in size of the panels 400 of
FIG. 4A and the panel 600 of FIG. 6A enables the panels to be
interchanged as needed. More specifically, as main panels and slave
panels have an identical footprint in terms of height H, width W,
and depth D1, their position on the frame 106 of FIGS. 1A and 1B
does not matter from a size standpoint, but only from a
functionality standpoint. Accordingly, the display 100 can be
designed as desired using main panels and slave panels without the
need to be concerned with how a particular panel will physically
fit into a position on the frame. The design may then focus on
issues such as the required functionality (e.g., whether a main
panel is needed or a slave panel is sufficient) for a particular
position and/or other issues such as weight and cost.
[0080] In some embodiments, the main panel 400 of FIG. 4A may weigh
more than the slave panel 600 due to the additional components
present in the main panel 400. The additional components may also
make the main panel 400 more expensive to produce than the slave
panel 600. Therefore, a display that uses as many slave panels as
possible while still meeting required criteria will generally cost
less and weigh less than a display that uses more main panels.
[0081] Referring to FIG. 7, one embodiment of a panel 700 is
illustrated that may be similar or identical to the panel 600 of
FIG. 6A with the exception of a change in the data point 604. In
the embodiment of FIG. 6A, the data point 604 is a bi-directional
connection. In the present embodiment, a separate "data out" point
702 and a "data in" point 704 are provided, which corresponds to
the main panel configuration illustrated in FIG. 5.
[0082] Referring to FIGS. 8A-8M, embodiments of a frame 800 are
illustrated. For example, the frame 800 may provide a more detailed
embodiment of the frame 106 of FIG. 1B. As described previously,
LED panels, such as the panels 104a-104t of FIGS. 1A and 1B, may be
mounted directly to the frame 800. Accordingly, the frame 800 does
not need to be designed to support heavy cabinets, but need only be
able to support the panels 104a-104t and associated cabling (e.g.,
power and data cables), and the frame 800 may be lighter than
conventional frames that have to support cabinet based structures.
For purposes of example, various references may be made to the
panel 200 of FIG. 2A, the housing 300 of FIG. 3A, and the panel 400
of FIG. 4A.
[0083] In the present example, the frame 800 is designed to support
LED panels 802 in a configuration that is ten panels high and
thirty-two panels wide. While the size of the panels 802 may vary,
in the current embodiment this provides a display surface that is
approximately fifty feet and four inches wide (50' 4'') and fifteen
feet and eight and three-quarters inches high (15' 8.75'').
[0084] It is understood that all measurements and materials
described with respect to FIGS. 8A-8M are for purposes of example
only and are not intended to be limiting. Accordingly, many
different lengths, heights, thicknesses, and other dimensional
and/or material changes may be made to the embodiments of FIGS.
8A-8M.
[0085] Referring specifically to FIG. 8B, a back view of the frame
800 is illustrated. The frame 800 includes a top bar 804, a bottom
bar 806, a left bar 808, a right bar 810, and multiple vertical
bars 812 that connect the top bar 804 and bottom bar 806. In some
embodiments, additional horizontal bars 814 may be present.
[0086] The frame 800 may be constructed of various materials,
including metals. For example, the top bar 804, the bottom bar 806,
the left bar 808, and the right bar 810 (e.g., the perimeter bars)
may be made using a four inch aluminum association standard channel
capable of bearing 1.738 lb/ft. The vertical bars 812 may be made
using 2''.times.4''.times.1/2'' aluminum tube capable of bearing a
load of 3.23 lb/ft. it is understood that other embodiments will
utilize other size components.
[0087] It is understood that these sizes and load bearing
capacities are for purposes of illustration and are not intended to
be limiting. However, conventional steel display frames needed to
support conventional cabinet-based displays are typically much
heavier than the frame 800, which would likely not be strong enough
to support a traditional cabinet-based display. For example, the
frame 800 combined with the panels described herein may weigh at
least fifty percent less than equivalent steel cabinet-based
displays.
[0088] Referring to FIG. 8C, a cutaway view of the frame 800 of
FIG. 8B taken along lines A1-A1 is illustrated. The horizontal bars
810 are more clearly visible. More detailed views of FIG. 8C are
described below.
[0089] Referring to FIG. 8D, a more detailed view of the frame 800
of FIG. 8C at location B1 is illustrated. The cutaway view shows
the top bar 804 and a vertical bar 812. A first flat bar 816 may be
used with multiple fasteners 818 to couple the top bar 804 to the
vertical bar 812 at the back of the frame 800. A second flat bar
820 may be used with fasteners 821 to couple the top bar 804 to the
vertical bar 812 at the front of the frame 800. A front plate 902
belonging to a coupling mechanism 900 (described below with respect
to FIG. 9A) is illustrated. The second flat bar 820 may replace a
back plate of the coupling mechanism 900. In embodiments where the
second flat bar 820 replaces the back plate, the second flat bar
820 may include one or more holes to provide accessibility to
fasteners of the coupling mechanism 900.
[0090] Referring to FIGS. 8E-8G, various more detailed views of the
frame 800 of FIG. 8C are illustrated. FIG. 8E provides a more
detailed view of the frame 800 of FIG. 8C at location B2. FIG. 8F
provides a cutaway view of the frame 800 of FIG. 8E taken along
lines C1-C1. FIG. 8G provides a cutaway view of the frame 800 of
FIG. 8E taken along lines C2-C2.
[0091] A clip 822 may be coupled to a vertical bar 812 via one or
more fasteners 824 and to the horizontal bar 814 via one or more
fasteners 824. In the present example, the clip 822 is positioned
above the horizontal bar 814, but it is understood that the clip
822 may be positioned below the horizontal bar 814 in other
embodiments. In still other embodiments, the clip 822 may be placed
partially inside the horizontal bar 814 (e.g., a portion of the
clip 822 may be placed through a slot or other opening in the
horizontal bar 814).
[0092] Referring to FIGS. 8H and 8I, various more detailed views of
the frame 800 of FIG. 8C are illustrated. FIG. 8H provides a more
detailed view of the frame 800 of FIG. 8C at location B3. FIG. 8I
provides a cutaway view of the frame 800 of FIG. 8H taken along
lines D1-D1.
[0093] The cutaway view shows the bottom bar 806 and a vertical bar
812. A first flat bar 826 may be used with multiple fasteners 828
to couple the bottom bar 806 to the vertical bar 812 at the back of
the frame 800. A second flat bar 830 may be used with fasteners 832
to couple the bottom bar 806 to the vertical bar 812 at the front
of the frame 800. A front plate 902 belonging to a coupling
mechanism 900 (described below with respect to FIG. 9A) is
illustrated. The second flat bar 830 may replace a back plate of
the coupling mechanism 900. In embodiments where the second flat
bar 830 replaces the back plate, the second flat bar 830 may
include one or more holes to provide accessibility to fasteners of
the coupling mechanism 900.
[0094] Referring to FIGS. 8J and 8K, various more detailed views of
the frame 800 of FIG. 8A are illustrated. FIG. 8H provides a more
detailed view of the frame 800 of FIG. 8B at location A2. FIG. 8K
provides a cutaway view of the frame 800 of FIG. 8J taken along
lines E1-E1. The two views show the bottom bar 806 and the left bar
808. A clip 834 may be used with multiple fasteners 836 to couple
the bottom bar 806 to the left bar 808 at the corner of the frame
800.
[0095] Referring to FIGS. 8L and 8M, an alternative embodiment to
FIG. 8E is illustrated. FIG. 8L provides a more detailed view of
the frame 800 in the alternate embodiment. FIG. 8M provides a
cutaway view of the frame 800 of FIG. 8L taken along lines F1-F1.
In this embodiment, rather than using a horizontal bar 814, a
vertical bar 812 is coupled directly to a beam 840 using a clip
838.
[0096] Referring to FIGS. 9A-9C, one embodiment of a coupling
mechanism 900 is illustrated that may be used to attach an LED
panel (e.g., one of the panels 104a-104t of FIGS. 1A and 1B) to a
frame (e.g., the frame 106 or the frame 800 of FIGS. 8A and 8B).
For purposes of example, the coupling mechanism 900 is described as
attaching the panel 200 of FIG. 2A to the frame 800 of FIG. 8B. In
the present example, a single coupling mechanism 900 may attach up
to four panels to the frame 800. To accomplish this, the coupling
mechanism 900 is positioned where the corners of four panels
meet.
[0097] The coupling mechanism 900 includes a front plate 902 and a
back plate 904. The front plate 902 has an outer surface 906 that
faces the back of a panel and an inner surface 908 that faces the
frame 106. The front plate 902 may include a center hole 910 and
holes 912. The center hole 910 may be countersunk relative to the
outer surface 906 to allow a bolt head to sit at or below the outer
surface 906. Mounting pins 914 may extend from the outer surface
906. The back plate 904 has an outer surface 916 that faces away
from the frame 106 and an inner surface 918 that faces the frame
106. The back plate 904 includes a center hole 920 and holes
922.
[0098] In operation, the front plate 902 and back plate 904 are
mounted on opposite sides of one of the vertical bars 808, 810, or
812 with the front plate 902 mounted on the panel side of the frame
800 and the back plate 904 mounted on the back side of the frame
800. For purposes of example, a vertical bar 812 will be used. When
mounted in this manner, the inner surface 908 of the front plate
902 and the inner surface 918 of the back plate 904 face one
another. A fastener (e.g., a bolt) may be placed through the center
hole 910 of the front plate 902, through a hole in the vertical bar
812 of the frame 800, and through the center hole 920 of the back
plate 904. This secures the front plate 902 and back plate 904 to
the frame 800 with the mounting pins 914 extending away from the
frame.
[0099] Using the housing 300 of FIG. 3A as an example, a panel is
aligned on the frame 800 by inserting the appropriate mounting pin
914 into one of the holes in the back of the housing 300 provided
by an extension 310/312. It is understood that this occurs at each
corner of the panel, so that the panel will be aligned with the
frame 800 using four mounting pins 914 that correspond to four
different coupling mechanisms 900. It is noted that the pins 914
illustrated in FIG. 9C are horizontally aligned with the holes 912,
while the extensions illustrated in FIG. 3A are vertically aligned.
As described previously, these are alternate embodiments and it is
understood that the holes 912/pins 914 and extensions 310/312
should have a matching orientation and spacing.
[0100] Once in position, a fastener is inserted through the hole
922 of the back plate 904, through the corresponding hole 912 of
the front plate 902, and into a threaded hole provided by an
extension 310/312 in the panel 300. This secures the panel to the
frame 800. It is understood that this occurs at each corner of the
panel, so that the panel will be secured to the frame 800 using
four different coupling mechanisms 900. Accordingly, to attach or
remove a panel, only four fasteners need be manipulated. The
coupling mechanism 900 can remain in place to support up to three
other panels.
[0101] In other embodiments, the front plate 902 is not needed. For
example, in displays that are lighter in weight the back of the
panel can abut directly with the beam. In other embodiments, the
center hole 920 and corresponding bolt are not necessary. In other
words the entire connection is made by the screws through the plate
904 into the panel.
[0102] The embodiment illustrated here shows a connection from the
back of the display. In certain applications, access to the back of
the panels is not available. For example, the display may be
mounted directly on a building without a catwalk or other access.
In this case, the holes in the panel can extend all the way through
the panel with the bolts being applied through the panel and
secured on the back. This is the opposite direction of what is
shown in FIG. 9C.
[0103] More precise alignment may be provided by using an alignment
plate, such as the alignment plate 314 of FIG. 3B, with each panel.
For example, while positioning the panel and prior to tightening
the coupling mechanism 900, the tabs 316 of the alignment plate 314
for that panel may be inserted into slots 318 in surrounding
alignment plates. The coupling mechanism 900 may then be tightened
to secure the panel into place.
[0104] It is understood that many different configurations may be
used for the coupling mechanism 400. For example, the locations of
holes and/or pins may be moved, more or fewer holes and/or pins may
be provided, and other modifications may be made. It is further
understood that many different coupling mechanisms may be used to
attach an panel to the frame 106. Such coupling mechanisms may use
bolts, screws, latches, clips, and/or any other fastener suitable
for removably attaching a panel to the frame 800.
[0105] FIG. 10A illustrates power connections, FIG. 10B illustrates
data connections, FIG. 10C illustrates power connections, and FIG.
10D illustrates data connections.
[0106] Referring to FIGS. 10A and 10B, one embodiment of a
13.times.22 panel display 1000 is illustrated that includes two
hundred and eighty-six panels arranged in thirteen rows and
twenty-two columns. For purposes of example, the display 1000 uses
the previously described main panel 400 of FIG. 4A (a `B` panel)
and the slave panel 600 of FIG. 6A (a `C` panel). As described
previously, these panels have a bi-directional input/output
connection point for data communications between the main panel and
the slave panels. The rows are divided into two sections with the
top section having seven rows and the bottom section having six
rows. The B panels form the fourth row of each section and the
remaining rows are C panels. FIGS. 10C and 10D provide enlarged
views of a portion of FIGS. 10A and 10B, respectively.
[0107] As illustrated in FIG. 10A, power (e.g., 220V single phase)
is provided to the top section via seven breakers (e.g., twenty amp
breakers), with a breaker assigned to each of the seven rows. Power
is provided to the bottom section via six breakers, with a breaker
assigned to each of the six rows. In the present example, the power
is provided in a serial manner along a row, with power provided to
the first column panel via the power source, to the second column
panel via the first panel, to the third column panel via the second
panel, and so on for the entire row. Accordingly, if a panel is
removed or the power for a panel is unplugged, the remainder of the
panels in the row will lose power.
[0108] As illustrated in FIG. 10B, data is sent from a data source
1002 (e.g., a computer) to the top section via one line and to the
bottom section via another line. In some embodiments, as
illustrated, the data lines may be connected to provide a loop. In
the present example, the data is provided to the B panels that form
the fourth row of each section. The B panels in the fourth row feed
the data both vertically along the column and in a serial manner
along the row. For example, the B panel at row four, column two
(r4:c2), sends data to the C panels in rows one, two, three, five,
six, and seven of column two (r1-3:c2 and r5-7:c2), as well as to
the B panel at row four, column three (r4:c3). Accordingly, if a B
panel in row four is removed or the data cables are unplugged, the
remainder of the panels in the column fed by that panel will lose
their data connection. The next columns will also lose their data
connections unless the loop allows data to reach them in the
opposite direction.
[0109] It is understood that the data lines may be bi-directional.
In some embodiments, an input line and an output line may be
provided, rather than a single bi-directional line as illustrated
in FIGS. 10A and 10B. In such embodiments, the panels may be
configured with additional input and/or output connections. An
example of this is provided below in FIGS. 11A and 11B.
[0110] Referring to FIGS. 11A and 11B, one embodiment of a
16.times.18 panel display 1100 is illustrated that includes two
hundred and eighty-eight panels arranged in sixteen rows and
eighteen columns. Each power line connects to a single 110 v 20 amp
breaker. All external power cables are 14 AWG SOW UL while internal
power cables must be 14 AWG UL. For purposes of example, the
display 1100 uses the previously described main panel 500 of FIG. 5
(a `B` panel) and the slave panel 700 of FIG. 7 (a `C` panel). As
described previously, these panels have separate input and outpoint
connection points for data communications between the main panel
and the slave panels. FIGS. 11C and 11D provide enlarged views of a
portion of FIGS. 11A and 11B, respectively.
[0111] As illustrated in FIG. 1A, power is provided from a power
source directly to the first column panel and the tenth column
panel of each row via a power line connected to a single 110V, 20 A
breaker. Those panels then feed the power along the rows in a
serial manner. For example, the power is provided to the first
column panel via the power source, to the second column panel via
the first panel, to the third column panel via the second panel,
and so on until the ninth column panel is reached for that row. The
ninth column panel does not feed power to another panel because
power is provided directly to the tenth column panel via the power
source. Power is then provided to the eleventh column panel via the
tenth panel, to the twelfth column panel via the eleventh panel,
and so on until the end of the row is reached. Accordingly, if a
panel is removed or the power for a panel is unplugged, the
remainder of the panels in the row that rely on that panel for
power will lose power.
[0112] Although not shown in FIG. 11B, the panels of the display
1100 may be divided into two sections for data purposes as
illustrated previously with respect to FIG. 10B. Accordingly, as
illustrated in FIG. 10B, data may be sent from a data source (e.g.,
a computer) to a top section via one line and to a bottom section
via another line. As the present example illustrates the use of
separate input and outpoint connection points for data
communications between the main panel and the slave panels, data
connections between B panels have been omitted for purposes of
clarity.
[0113] In the present example, the data is provided to the B panels
that form the fourth row of each section. The B panels in the
fourth row feed the data both vertically along the column and in a
serial manner along the row (as shown in FIG. 10B). For example,
the B panel at row four, column two (r4:c2), sends data to the C
panels in rows one, two, three, five, six, seven, and eight of
column two (r1-3:c2 and r5-8:c2), as well as to the B panel at row
four, column three (r4:c3). Accordingly, if a B panel in row four
is removed or the data cables are unplugged, the remainder of the
panels in the column fed by that panel will lose their data
connection. The next columns will also lose their data connections
unless the loop allows data to reach them in the opposite
direction.
[0114] Referring to FIGS. 12A and 12B, one embodiment of a
19.times.10 panel two face display 1100 is illustrated that
includes three hundred and eighty panels arranged in two displays
of nineteen rows and ten columns. Each face requires 19 110 V 20
AMP circuit breakers. For purposes of example, the display 1100
uses the previously described main panel 500 of FIG. 5 (a `B`
panel) and the slave panel 700 of FIG. 7 (a `C` panel). As
described previously, these panels have separate input and outpoint
connection points for data communications between the main panel
and the slave panels. FIGS. 12C and 12D provide enlarged views of a
portion of FIGS. 12A and 12B, respectively.
[0115] As illustrated in FIG. 12A, power is provided from a power
source directly to the first column panel of each face via a power
line connected to a single 110V, 20 A breaker. Those panels then
feed the power along the rows in a serial manner. For example, the
power is provided to the first column panel of the first face via
the power source, to the second column panel via the first panel,
to the third column panel via the second panel, and so on until the
last panel is reached for that row of that face. The tenth column
panel does not feed power to the next face because power is
provided directly to the first column of the second face via the
power source. Power is then provided to the second column panel via
the first panel, to the third column panel via the second panel,
and so on until the last panel is reached for that row of that
face. Accordingly, if a panel is removed or the power for a panel
is unplugged, the remainder of the panels in the row that rely on
that panel for power will lose power.
[0116] Although not shown in FIG. 12B, the panels of the display
1200 may be divided into three sections for data purposes as
illustrated previously with respect to FIG. 10B. Accordingly, as
illustrated in FIG. 10B, data may be sent from a data source (e.g.,
a computer) to the top section via one line, to a middle section
via a second line, and to a bottom section via a third line. Each
master control cabinet has six data cables and is configured to be
in row 4. Two rows of cabinets use only 5 cables while the sixth
cable is unused and tied back.
[0117] As the present example illustrates the use of separate input
and outpoint connection points for data communications between the
main panel and the slave panels, data connections between B panels
have been omitted for purposes of clarity. However, a separate line
may be run to the B panels in the first column of each face (which
would require six lines in FIG. 12B), or the B panel in the last
column of a row of one face may pass data to the B panel in the
first column of a row of the next face (which would require three
lines in FIG. 12B).
[0118] In the present example, the data is provided to the B panels
that form the fourth row of each section. The B panels in the
fourth row feed the data both vertically along the column and in a
serial manner along the row (as shown in FIG. 10B). For example,
the B panel at row four, column two (r4:c2), sends data to the C
panels in rows one, two, three, five, and six of column two
(r1-3:c2 and r5-6:c2), as well as to the B panel at row four,
column three (r4:c3). Accordingly, if a B panel in row four is
removed or the data cables are unplugged, the remainder of the
panels in the column fed by that panel will lose their data
connection. The next columns will also lose their data connections
unless the loop allows data to reach them in the opposite
direction.
[0119] FIG. 13 illustrates a modular display panel in accordance
with embodiments of the present invention. FIG. 14 illustrates a
modular display panel attached to a supporting frame in accordance
with an embodiment of the present invention. FIG. 15 illustrates a
frame used to provide mechanical support to the modular display
panel in accordance with an embodiment of the present
invention.
[0120] The multi-panel modular display panel 1300 comprises a
plurality of LED display panels 1350. In various embodiments
describe herein, the light emitting diode (LED) display panels 1350
are attached to a frame 1310 or skeletal structure that provides
the framework for supporting the LED display panels 1350. The LED
display panels 1350 are stacked next to each other and securely
attached to the frame 1310 using attachment plate 1450, which may
be a corner plate in one embodiment. The attachment plate 1450 may
comprise holes through which attachment features 1490 may be
screwed in, for example.
[0121] Referring to FIGS. 13 and 14, the LED display panels 1350
are arranged in an array of rows and columns. Each LED display
panel 1350 of each row is electrically connected to an adjacent LED
display panel 1350 within that row.
[0122] Referring to FIG. 15, the frame 1310 provides mechanical
support and electrical connectivity to each of the LED display
panels 1350. The frame 1310 comprises a plurality of beams 1320
forming the mechanical structure. The frame 1310 comprises a top
bar, a bottom bar, a left bar, a right bar, and a plurality of
vertical bars extending from the top bar to the bottom bar, the
vertical bars disposed between the left bar and the right bar. The
top bar, the bottom bar, the left bar and the right bar comprise
four inch aluminum bars and wherein the vertical bars comprise
2''.times.4''.times.1/2'' aluminum tubes. The top bar, the bottom
bar, the left bar and the right bar are each capable of bearing a
load of 1.738 lb/ft and wherein the vertical bars are each capable
of bearing a load of 3.23 lb/ft.
[0123] The frame 1310 may include support structures for the
electrical cables, data cables, electrical power box powering the
LED displays panels 1350, and data receiver box controlling power,
data, and communication to the LED displays panels 1350.
[0124] However, the frame 1310 does not include any additional
enclosures to protect the LED panels, data, and power cables from
the environment. Rather, the frame 1310 is exposed to the elements
and further exposes the LED display panels 1350 to the environment.
The frame 1310 also does not include air conditioning, fans, or
heating units to maintain the temperature of the LED display panels
1350. Rather, the LED display panels 1350 are hermetically sealed
themselves and are designed to be exposed to the outside ambient.
Further, in various embodiments, there are not additional cabinets
that are attached to the frame 1310 or used for housing the LED
display panels 1350. Accordingly, in various embodiments, the
multi-panel modular display panel 1300 is designed to be only
passively cooled.
[0125] FIGS. 25A-25D illustrate specific examples of an assembled
display system 1300 and FIG. 26 illustrates a specific example of a
frame 1310. As shown in FIG. 25A, the modular display system 1300
includes a number of LED display panels 1350 mounted to frame 1310.
One of the display panels has been removed in the lower corner to
illustrate the modular nature of the display. In this particular
example, access is provided to the back of the modular display
through a cage 1390 that includes an enclosed catwalk. Since the
display system 1300 is generally highly elevated, a ladder (see
FIG. 25C) provides access to the catwalk. A side view of the
display system is shown in FIG. 25B and back views are shown in
FIGS. 25C and 25D.
[0126] FIG. 26 illustrates the frame 1310 without the display
panels 1350. In this embodiment the beams 1320 that form that outer
frame are bigger than the interior beams 1325. In this case, the
interior beams 1325 are aligned in a plane outside those of the
frame beams 1322. The plates 1315 are also shown in the figure.
Upon installation, these plates will be rotated by 90 degrees and
fasten to the display panels.
[0127] FIG. 16, which includes FIGS. 16A-16C, illustrates an
attachment plate used to attach one or more modular display panels
to the frame in accordance with an embodiment of the present
invention. FIG. 16A illustrates a projection view while FIG. 16B
illustrates a top view and FIG. 16C illustrates a cross-sectional
view.
[0128] Referring to FIGS. 16A-16C, the attachment plate 1450 may
comprise one or more through openings 1460 for enabling attachment
features such as screws to go through. Referring to FIG. 16C, the
attachment plate 1450 comprises a top surface 1451 and a bottom
surface 1452. The height of the pillars 1480 may be adjusted to
provide a good fit for the display panel. Advantageously, because
the frame 1310 is not screw mounted to the display panel 1350, the
display panel 1350 may be moved during mounting. This allows for
improved alignment of the display panels resulting in improved
picture output. An alignment plate could also be used as described
above.
[0129] Accordingly, in various embodiments, the height of the
pillars 1480 is about the same as the beams 1320 of the frame 1310.
In one or more embodiments, the height of the pillars 1480 is
slightly more than the thickness of the beams 1320 of the frame
1310.
[0130] FIGS. 16D and 16E illustrate another embodiment of the
attachment plate 1450. In this example, the plate is rectangular
shaped and not a square. For example, the length can be two to four
times longer than the width. In one example, the length is about 9
inches while the width is about 3 inches. The holes in the center
of the plate are optional. Conversely, these types of holes could
be added to the embodiment of FIGS. 16A and 16B. In other
embodiments, other shaped plates 1450 can be used.
[0131] FIG. 17 illustrates a magnified view of the attachment plate
or a connecting plate, frame, and display panel after mounting in
accordance with embodiments of the present invention.
[0132] Referring to FIG. 17, one or more attachment features 1490
may be used to connect the attachment plate 1450 to the display
panel 1350. In the embodiment illustrated in FIG. 17, the
attachment plate 1450 is a corner plate. Each corner plate is
mechanically connected to corners of four of the LED display panels
1350 to secure the LED display panels 1350 to the respective beams
1320 of the frame 1310.
[0133] FIG. 17 illustrates that the attachment features 1490 is
attached using the through openings 1460 in the attachment plate
1450. The frame is between the attachment plate 1450 and the
display panel 1350.
[0134] In the embodiment of FIG. 17, the beam 1320 physically
contacts the display panel 1350. In another embodiment, a second
plate (not shown here) could be included between the beam 1320 and
the display panel 1350. The plate could be a solid material such as
a metal plate or could be a conforming material such as a rubber
material embedded with metal particles. In either case, it is
desirable that the plate be thermally conductive.
[0135] FIG. 18 illustrates one unit of the modular display panel in
accordance with an embodiment of the present invention.
[0136] FIG. 18 illustrates one of the multi-panel modular display
panel 1300 comprising an input cable 1360 and an output cable 1365.
The LED display panels 1350 are electrically connected together for
data and for power using the input cable 1360 and the output cable
1365.
[0137] Each modular LED display panel 1350 is capable of receiving
input using an integrated data and power cable from a preceding
modular LED display panel and providing an output using another
integrated data and power cable to a succeeding modular LED display
panel. Each cable ends with an endpoint device or connector, which
is a socket or alternatively a plug.
[0138] Referring to FIG. 18, in accordance with an embodiment, a
LED display panel 1350 comprises an attached input cable 1360 and
an output cable 1365, a first connector 1370, a second connector
1375, a sealing cover 1380. The sealing cover 1380 is configured to
go over the second connector 1375 thereby hermetically sealing both
ends (first connector 1370 and the second connector 1375). The
sealing cover 1380, which also includes a locking feature, locks
the two cables together securely. As will be described further, the
input cable 1360 and the output cable 1365 comprise integrated data
and power wires with appropriate insulation separating them.
[0139] FIG. 19 illustrates two display panels next to each other
and connected through the cables such that the output cable 1365 of
the left display panel 1350 is connected with the input cable 1360
of the next display panel 1350. The sealing cover 1380 locks the
two cables together as described above.
[0140] FIG. 20 illustrates a modular multi-panel display system
comprising a plurality of LED display panels connected together
using the afore-mentioned cables.
[0141] Referring to FIG. 20, for each row, a LED display panel 1350
at a first end receives an input data connection from a data source
and has an output data connection to a next LED display panel in
the row. Each further LED display panel 1350 provides data to a
next adjacent LED display panel until a LED display panel 1350 at
second end of the row is reached. The power line is run across each
row to power the LED display panels 1350 in that row.
[0142] In one embodiment, the plurality of LED display panels 1350
includes 320 LED display panels 1350 arranged in ten rows and
thirty-two columns so that the integrated display panel 1300 has a
display surface that is approximately fifty feet and four inches
wide and fifteen feet and eight and three-quarters inches high.
[0143] In various embodiments, as illustrated in FIGS. 14 and 20, a
data receiver box 1400 is mounted to the mechanical support
structure or frame 1310. The data receiver box 1400 is configured
to provide power, data, and communication to the LED display panels
1350. With a shared receiver box 1400, the panels themselves do not
need their own receiver card. This configuration saves cost and
weight.
[0144] FIG. 21, which includes FIGS. 21A-21C, illustrates an
alternative embodiment of the modular display panel attached to a
supporting frame in accordance with an embodiment of the present
invention. FIGS. 21B and 21C illustrate alternative structural
embodiments of the supporting frame.
[0145] This embodiment differs from embodiment described in FIG. 14
in that the horizontal beams 1320A may be used to support the
display panels 1350. In one embodiment, both horizontal beams 1320A
and vertical beams 1320B may be used to support the display panels
1350. In another embodiment, horizontal beams 1320A but not the
vertical beams 1320B may be used to support the display panels
1350.
[0146] FIG. 21B illustrates an alternative embodiment including
additional beams 1320C, which may be narrower than the other beams
of the frame. One or more of the thinner beams 1320C may be placed
between the regular sized vertical beams 1320B.
[0147] FIG. 21C illustrates a further embodiment illustrating both
a top view, bottom view and side view of a frame. The frame 1310
may be attached to a wall or other structure using plates 1315. The
frame 1310 may comprise a plurality of vertical beams and
horizontal beams. In one embodiment, the frame 1310 comprises an
outer frame having a top bar, a bottom bar, a left bar and a right
bar. A display panel 1350 may be supported between two adjacent
beams 1320 marked as L3 beams, which may be thinner (smaller
diameter) and lighter than the thicker and heavier load bearing
beams 1321 marked as L2 beams used for forming the outer frame. As
an illustration, the L2 beams may be 4'' while the L3 beams may be
3'' in one example.
[0148] FIG. 22 illustrates a method of assembling a modular
multi-panel display system in accordance with an embodiment of the
present invention. FIG. 22 illustrates a method of assembling the
multi-panel display system discussed in various embodiments, for
example, FIG. 14.
[0149] A mechanical support structure such as the frame 1310
described above is assembled taking into account various parameters
such as the size and weight of the multi-panel display, location
and zoning requirements, and others (box 1501). For example, as
previously described, the mechanical support structure includes a
plurality of vertical bars and horizontal bars. The mechanical
support structure may be fabricated from a corrosion resistant
material in one or more embodiments. For example, the mechanical
support structure may be coated with a weather-proofing coating
that prevents the underlying substrate from corroding.
[0150] A plurality of LED display panels are mounted on to the
mechanical support structure so as to form an integrated display
panel that includes an array of rows and columns of LED display
panels as described in various embodiments (box 1503). Each of the
LED display panels is hermetically sealed. Mounting the LED display
panels may comprise mounting each LED display panel a respective
vertical beam using an attachment plate.
[0151] Each of the LED display panels is electrically connected to
a data source and to a power source (box 1505). For example, a
first LED display panel in each row is electrically coupled to the
display source. The other LED display panels in each row may be
daisy-chain coupled to an adjacent LED display panel (e.g., as
illustrated in FIG. 20).
[0152] Since the assembled display structure is light weight,
significant assembly advantages can be achieved. For example, the
panels can be assembled within a warehouse that is remote from the
final location where the display will be utilized. In other words,
the panels can be assembled at a first location, shipped to second
location and finalized at the second location.
[0153] An illustration of two assembled displays that are ready for
shipment is provided in FIG. 23. These displays can be quite large,
for example much larger than a 14.times.48 panel display. In some
cases, a single display system is shipped as a series of
sub-assemblies, e.g., as shown in the figure, and then assembled
into a full display on location.
[0154] In various embodiments, the assembled multi-panel display
system includes no cabinets. The assembled multi-panel display
system is cooled passively and includes no air conditioning or
fans.
[0155] Although the preferred embodiment has been described in
detail, it should be understood that various changes, substitutions
and alterations can be made therein without departing from the
spirit and scope of the invention as defined by the appended
claims
* * * * *