Modular display panel

• US 10,540,917 B2
• Filed: 04/25/2018
• Issued: 01/21/2020
• Est. Priority Date: 12/31/2013
• Status: Expired due to Fees

• Current Assignee: Ultravision Technologies, LLC (Ultravision International Inc.)
• Original Assignee: Ultravision Technologies, LLC (Ultravision International Inc.)
• Inventors: Hall, William Y.
• Primary Examiner(s): Junge, Kristina N
• Application Number:
  US15/962,572
• Publication Number:
  US 20180247574A1
• Time in Patent Office: 636 Days
• CPC Class Codes: F21K 9/20 Light sources comprising attachment means
• CPC Class Codes: F21K 9/90 Methods of manufacture
• CPC Class Codes: F21V 23/023 Power supplies in a casing F21V23/003 takes precedence
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G06F 1/1601 Constructional details related to the housing of computer displays, e.g. of CRT monitors, of flat displays constructional details related to flat displays integrated in a portable computer, e.g. laptop, handheld computer G06F1/1637; constructional details related to television receivers H04N5/64
• CPC Class Codes: G06F 1/182 with special features, e.g. for use in industrial environments; grounding or shielding against radio frequency interference [RFI] or electromagnetical interference [EMI]
• CPC Class Codes: G06F 1/183 Internal mounting support structures, e.g. for printed circuit boards, internal connecting means for buses G06F13/409
• CPC Class Codes: G06F 1/188 Mounting of power supply units
• CPC Class Codes: G06F 1/189 Power distribution
• CPC Class Codes: G06F 1/20 Cooling means
• CPC Class Codes: G06F 1/26 Power supply means, e.g. regulation thereof for memories G11C
• CPC Class Codes: G06F 3/1423 controlling a plurality of local displays, e.g. CRT and flat panel display
• CPC Class Codes: G06F 3/1446 display composed of modules, e.g. video walls
• CPC Class Codes: G06F 3/147 using display panels
• CPC Class Codes: G06T 1/60 Memory management
• CPC Class Codes: G09F 13/22 electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: G09F 2013/222 with LEDs
• CPC Class Codes: G09F 9/3023 Segmented electronic displays
• CPC Class Codes: G09G 2300/026 Video wall, i.e. juxtaposition of a plurality of screens to create a display screen of bigger dimensions
• CPC Class Codes: G09G 2300/04 : Structural and physical details of display devices
• CPC Class Codes: G09G 2320/029 : by monitoring one or more pixels in the display panel, e.g. by monitoring a fixed reference pixel
• CPC Class Codes: G09G 2330/02 : Details of power systems and of start or stop of display operation
• CPC Class Codes: G09G 2330/045 : Protection against panel overheating
• CPC Class Codes: G09G 2330/10 : Dealing with defective pixels
• CPC Class Codes: G09G 2360/04 : Display device controller operating with a plurality of display units
• CPC Class Codes: G09G 3/006 : Electronic inspection or testing of displays and display drivers, e.g. of LED or LCD displays testing individual LED's G01R31/2635; testing lamps G01R31/44; testing of optical features of LCD displays G02F1/1309
• CPC Class Codes: G09G 3/32 : semiconductive, e.g. using light-emitting diodes [LED]
• CPC Class Codes: G09G 5/003 : Details of a display terminal, the details relating to the control arrangement of the display terminal and to the interfaces thereto specific for a CRT G09G1/165; for a flat panel G09G3/2092
• CPC Class Codes: G09G 5/14 : Display of multiple viewports
• CPC Class Codes: H01B 11/02 : Cables with twisted pairs or quads
• CPC Class Codes: H01B 7/2825 : using a water impermeable sheath
• CPC Class Codes: H01B 9/003 : including electrical control or communication wires
• CPC Class Codes: H04N 7/00 : Television systems details H04N3/00, H04N5/00; methods or arrangements, for coding, decoding, compressing or decompressing digital video signals H04N19/00; selective content distribution H04N21/00
• CPC Class Codes: H05K 1/181 : associated with surface mounted components
• CPC Class Codes: H05K 2201/066 : Heatsink mounted on the surface of the printed circuit board [PCB]
• CPC Class Codes: H05K 2201/10106 : Light emitting diode [LED]
• CPC Class Codes: H05K 2201/10128 : Display
• CPC Class Codes: H05K 2201/1028 : Thin metal strips as connectors or conductors
• CPC Class Codes: H05K 3/32 : electrically connecting electric components or wires to printed circuits
• CPC Class Codes: H05K 5/0017 : with operator interface units
• CPC Class Codes: H05K 5/0247 : Electrical details of casings, e.g. terminals, passages for cables or wiring
• CPC Class Codes: H05K 5/0256 : of interchangeable modules or receptacles therefor, e.g. cartridge mechanisms
• CPC Class Codes: H05K 5/03 : Covers
• CPC Class Codes: H05K 5/06 : Hermetically-sealed casings specially adapted for small components H05K5/0095
• CPC Class Codes: H05K 7/1422 : Printed circuit boards receptacles, e.g. stacked structures, electronic circuit modules or box like frames
• CPC Class Codes: H05K 7/1427 : Housings
• CPC Class Codes: H05K 7/20 : Modifications to facilitate cooling, ventilating, or heating
• CPC Class Codes: H05K 7/20127 : Natural convection
• CPC Class Codes: H05K 7/20136 : Forced ventilation, e.g. by fans H05K7/202 takes precedence
• CPC Class Codes: H05K 7/2039 : characterised by the heat transfer by conduction from the heat generating element to a dissipating body arrangements for increasing/decreasing heat-transfer, e.g. fins details, F28F13/00
• CPC Class Codes: H05K 7/20954 : for display panels
• CPC Class Codes: H05K 7/20963 : Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20972 takes precedence
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

Embodiments of the present invention relate to integrated modular LED display devices. In one embodiment, a modular LED display devices comprises a plastic housing with an outer surface exposed to an external environment. The modular LED display device is configured to display images using an array of pixels attached to a front side of a printed circuit board attached to the plastic housing. The modular LED display device includes a circuit for controlling a plurality of LEDs, the circuit being attached to the opposite second side of the printed circuit board. The first side of the printed circuit board is sealed to be waterproof by an overlying compound. The modular LED display device further includes a power supply including a power converter for converting alternating current (AC) power to direct current (DC) power. The modular LED display device is configured to be exposed to the external environment without additional enclosures.

Claims

1. A modular light emitting diode (LED) display device comprising:

a first side and an opposite second side, wherein the first side of the modular LED display device comprises a display surface of the modular LED display device;

a plastic housing comprising

a first dimension that is between six inches and four feet,

a first recessed region, and

an outer surface of the modular LED display device that is exposed to an external environment and being sealed to be waterproof, the outer surface being part of the opposite second side of the modular LED display device;

a printed circuit board attached to the plastic housing, the printed circuit board comprising a first side and an opposite second side;

a plurality of LEDs arranged as pixels attached to the first side of the printed circuit board, wherein

the pixels are arranged in an array of pixels comprising a plurality of rows and a plurality of columns,

each pixel in the array of pixels is separated from adjacent pixels by a constant pixel pitch, and

the modular LED display device is configured to display images using the array of pixels;

a compound overlying the first side of the printed circuit board, wherein

the first side of the printed circuit board is sealed to be waterproof by the compound, and

the modular LED display device is configured to be exposed to the external environment without additional enclosures;

a circuit for controlling the plurality of LEDs, the circuit being attached to the opposite second side of the printed circuit board, wherein the circuit is disposed in the first recessed region of the plastic housing;

a power supply for powering the plurality of LEDs, the power supply comprising a power converter for converting alternating current (AC) power to direct current (DC) power;

a thermally conductive material thermally contacting both the power supply and the plastic housing;

a framework of louvers disposed over the first side of the printed circuit board, the framework of louvers being disposed between the plurality of rows; and

coupling structures, wherein

the modular LED display device is configured to be to be modularly attached with other modular LED display devices using the coupling structures to form an integrated display surface, and

the modular LED display device is configured to operate with the other modular LED display devices to display a single image on the integrated display surface.

2. The modular LED display device of claim 1, wherein the plastic housing further comprises a second recessed region, and wherein the power supply is disposed in the second recessed region of the plastic housing.

3. The modular LED display device of claim 1, wherein:

the LEDs of each of the pixels are configured as a surface-mounted device (SMD); and

a surface of each of the SMDs is exposed to the external environment.

4. The modular LED display device of claim 1, wherein an ingress protection rating of the modular LED display device is IP 65.

5. The modular LED display device of claim 1, wherein an ingress protection rating of the modular LED display device is IP 66.

6. The modular LED display device of claim 1, wherein an ingress protection rating of the modular LED display device is IP 67.

7. The modular LED display device of claim 1, wherein an ingress protection rating of the modular LED display device is IP 68.

8. The modular LED display device of claim 1, further comprising a monitoring circuit configured to monitor power consumption of the modular LED display device and send a warning message upon detecting a lack of power.

9. The modular LED display device of claim 1, further comprising a pixel health loop circuit configured to monitor power being consumed by each of the plurality of LEDs.

10. The modular LED display device of claim 1, further comprising:

an integrated data and power connector electrically coupled to the power supply, wherein

the integrated data and power connector is configured to be waterproof,

the integrated data and power connector comprises a set of power connectors and a set of data connectors, and

the integrated data and power connector is electrically coupled to the circuit and to the plurality of LEDs; and

a flexible cable comprising a first end and a second end, wherein the first end is coupled directly to the modular LED display device and the second end is coupled directly to the integrated data and power connector.

11. The modular LED display device of claim 1, further comprising:

a height extending from a first edge of the modular LED display device to an opposite second edge of the modular LED display device; and

a width extending from a third edge of the modular LED display device to an opposite fourth edge of the modular LED display device, wherein

the printed circuit board extends to within an edge distance of each of the first edge, the opposite second edge, the third edge, and the opposite fourth edge, and

the constant pixel pitch is greater than the edge distance.

12. The modular LED display device of claim 11, wherein the height is substantially half of the width.

13. A modular light emitting diode (LED) display device comprising:

a first side and an opposite second side, wherein the first side of the modular LED display device comprises a display surface of the modular LED display device, and wherein the modular LED display device is configured to be exposed to an external environment without additional enclosures;

a plastic housing comprising

a first dimension that is between six inches and four feet,

a second dimension that is between one foot and four feet, the second dimension being perpendicular to the first dimension,

a first recessed region, and

an outer surface of the modular LED display device that is exposed to the external environment and being sealed to be waterproof, the outer surface being part of the opposite second side of the modular LED display device;

a printed circuit board attached to the plastic housing, the printed circuit board comprising a first side and an opposite second side;

a plurality of LEDs arranged as pixels attached to the first side of the printed circuit board, wherein

the pixels are arranged in an array of pixels comprising a plurality of rows and a plurality of columns,

each pixel in the array of pixels is separated from adjacent pixels by a constant pixel pitch, and

the modular LED display device is configured to display images using the array of pixels;

a circuit for controlling the plurality of LEDs, the circuit being attached to the opposite second side of the printed circuit board, wherein the circuit is disposed in the first recessed region of the plastic housing;

a power supply for powering the plurality of LEDs;

a thermally conductive material thermally contacting both the power supply and the plastic housing;

a framework of louvers disposed over the first side of the printed circuit board, the framework of louvers being disposed between the plurality of rows; and

coupling structures, wherein

the modular LED display device is configured to be to be modularly attached with other modular LED display devices using the coupling structures to form an integrated display surface, and

the modular LED display device is configured to operate with the other modular LED display devices to display a single image on the integrated display surface.

14. The modular LED display device of claim 13, wherein:

the plastic housing further comprises a second recessed region;

the second recessed region comprises a third dimension and a fourth dimension that is perpendicular to the third dimension;

the third dimension is parallel to and smaller than the first dimension;

the fourth dimension is parallel to and smaller than the second dimension; and

the power supply is disposed in the second recessed region.

15. The modular LED display device of claim 13, wherein the power supply comprises a power converter for converting alternating current (AC) power to direct current (DC) power.

16. The modular LED display device of claim 13, wherein the power supply comprises a power converter for converting direct current (DC) power to DC power.

17. The modular LED display device of claim 13, wherein:

the LEDs of each of the pixels are configured as a surface-mounted device (SMD); and

a surface of each of the SMDs is exposed to the external environment.

18. The modular LED display device of claim 13, further comprising a monitoring circuit configured to monitor power consumption of the modular LED display device and send a warning message upon detecting a lack of power.

19. The modular LED display device of claim 13, further comprising a pixel health loop circuit configured to monitor power being consumed by each of the plurality of LEDs.

20. The modular LED display device of claim 13, further comprising:

an integrated data and power connector electrically coupled to the power supply, wherein

the integrated data and power connector is configured to be waterproof,

the integrated data and power connector comprises a set of power connectors and a set of data connectors, and

the integrated data and power connector is electrically coupled to the circuit and to the plurality of LEDs; and

a flexible cable comprising a first end and a second end, wherein the first end is coupled directly to the modular LED display device and the second end is coupled directly to the integrated data and power connector.

21. The modular LED display device of claim 13, further comprising:

a height extending from a first edge of the modular LED display device to an opposite second edge of the modular LED display device; and

a width extending from a third edge of the modular LED display device to an opposite fourth edge of the modular LED display device, wherein

the printed circuit board extends to within an edge distance of each of the first edge, the opposite second edge, the third edge, and the opposite fourth edge, and

the constant pixel pitch is greater than the edge distance.

22. The modular LED display device of claim 21, wherein the height is substantially half of the width.

23. A modular multi-device display system comprising:

a mechanical support structure comprising a plurality of beams;

a plurality of light emitting diode (LED) display devices, wherein the plurality of LED display devices is arranged in an array and mounted to the mechanical support structure so as to form an integrated display;

a box disposed in a first housing and mounted to the mechanical support structure, wherein the box comprises a power management unit for providing power to each of the plurality of LED display devices, wherein the box comprises a receiver card that is configured to receive data to be displayed and feed the data to be displayed and communication to each of the plurality of LED display devices; and

a plurality of electrical connections electrically connecting the box with each of the plurality of LED display devices,

wherein each of the plurality of LED display devices comprises

a first side and an opposite second side, wherein the first side of the LED display device comprises a display surface of the LED display device,

a plastic housing comprising

a first dimension that is between six inches and four feet,

a first recessed region, and

an outer surface of the LED display device that is exposed to an external environment and being sealed to be waterproof, the outer surface being part of the opposite second side of the LED display device, wherein the first housing is separate from the plastic housing,

a printed circuit board attached to the plastic housing, the printed circuit board comprising a first side and an opposite second side,

a plurality of LEDs arranged as pixels attached to the first side of the printed circuit board, wherein the pixels are arranged in an array of pixels comprising a plurality of rows and a plurality of columns, wherein each pixel in the array of pixels is separated from adjacent pixels by a constant pixel pitch, and wherein the LED display device is configured to display images using the array of pixels,

a compound overlying the first side of the printed circuit board, wherein the first side of the printed circuit board is sealed to be waterproof by the compound, and wherein the LED display device is configured to be exposed to the external environment without additional enclosures,

a circuit for controlling the plurality of LEDs, the circuit being attached to the opposite second side of the printed circuit board, wherein the circuit is disposed in the first recessed region of the plastic housing,

a power supply for powering the plurality of LEDs, the power supply comprising a power converter for converting alternating current (AC) power to direct current (DC) power,

a thermally conductive material thermally contacting both the power supply and the plastic housing, and

a framework of louvers disposed over the first side of the printed circuit board, the framework of louvers being disposed between the plurality of rows.

24. The modular multi-device display system of claim 23, wherein each of the plurality of LED display devices is configured to be supported by both a first interior beam of the plurality of beams and a second interior beam of the of the plurality of beams, wherein the first interior beam is perpendicular to the second interior beam.

25. The modular multi-device display system of claim 23, wherein the plastic housing of each of the LED display devices further comprises a second recessed region, and wherein the power supply of each of the LED display devices is disposed in the second recessed region of the plastic housing.

26. The modular multi-device display system of claim 23, wherein for each of the LED display devices:

the LEDs of each of the pixels are configured as a surface-mounted device (SMD); and

a surface of each of the SMDs is exposed to the external environment.

27. The modular multi-device display system of claim 23, wherein an ingress protection rating of each of the LED display devices is IP 65.

28. The modular multi-device display system of claim 23, wherein an ingress protection rating of each of the LED display devices is IP 66.

29. The modular multi-device display system of claim 23, wherein an ingress protection rating of each of the LED display devices is at least IP 67.

30. A modular light emitting diode (LED) display device comprising:

a first side and an opposite second side, wherein the first side of the modular LED display device comprises a display surface of the modular LED display device;

means for encasing components of the modular LED display device, the means for encasing comprising

plastic,

a first dimension that is between six inches and four feet,

a first recessed region, and

an outer surface of the modular LED display device that is exposed to an external environment and being sealed to be waterproof, the outer surface being part of the opposite second side of the modular LED display device;

means for emitting light from the modular LED display device, the means for emitting light comprising a plurality of pixels, wherein

the pixels are arranged in an array of pixels comprising a plurality of rows and a plurality of columns,

each pixel in the array of pixels is separated from adjacent pixels by a constant pixel pitch, and

the modular LED display device is configured to display images using the array of pixels;

means for supporting the means for emitting light, the means for supporting being attached to the means for encasing, wherein the means for emitting light are attached to a first side of the means for supporting;

a means for protecting the modular LED display device overlying the first side of the means for supporting, wherein

the means for supporting is protected by the means for protecting, and

the modular LED display device is configured to be exposed to the external environment without additional enclosures;

means for controlling operation of the means for emitting light attached to an opposite second side of the means for supporting, the means for controlling operation being disposed in the first recessed region;

means for supplying power to the means for emitting light, the means for supplying power comprising a power converter for converting alternating current (AC) power to direct current (DC) power;

means for transferring heat thermally contacting both the means for supplying power and the means for encasing; and

means for coupling the modular LED display device, wherein

the modular LED display device is configured to be to be modularly attached with other modular LED display devices using the means for coupling to form an integrated display surface, and

the modular LED display device is configured to operate with the other modular LED display devices to display a single image on the integrated display surface.