Modular display panel

• US 10,741,107 B2
• Filed: 04/26/2019
• Issued: 08/11/2020
• Est. Priority Date: 12/31/2013
• Status: Active Grant

• 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:
  US16/396,011
• Publication Number:
  US 20190251879A1
• Time in Patent Office: 473 Days
• Field of Search: None
• 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 PCB heatsink inserted in the PCB H05K2201/10416
• 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: H05K 999/99 : dummy group
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

Embodiments of the invention are related to modular display panels. In one embodiment, a modular display panel includes a first side which includes a display surface, and an opposite second side. The modular display panel further includes a plastic enclosure including an outer surface that forms substantially all of the second side. The modular display panel further includes LEDs arranged as pixels attached to a printed circuit board which is attached to the plastic enclosure. The modular display panel further includes a circuit for controlling the LEDs and a power source for powering the LEDs. The front side of the printed circuit board is sealed to be waterproof and the plastic enclosure is sealed to be waterproof so that the modular display panel is sealed to be waterproof.

Claims

1. A modular display panel comprising:

a printed circuit board having a first side and an opposite second side;

a casing comprising a thermally conductive material, the casing being disposed at the opposite second side of the printed circuit board,

wherein the casing contacts the opposite second side of the printed circuit board

wherein the casing comprises plastic sidewalls and a plastic back wall substantially similar in area to the opposite second side of the printed circuit board, and

wherein the plastic back wall of the casing comprises a first outer surface of the modular display panel;

a driver circuit disposed in the casing at the opposite second side of the printed circuit board, the driver circuit electrically coupled to the printed circuit board;

a plurality of light emitting diodes (LEDs) arranged as pixels and attached to the first side of the printed circuit board, wherein the pixels are arranged in a rectangular array comprising at least fifty pixels;

a power supply housing mounted over the first outer surface of the casing, the power supply housing comprising sidewalls, a front wall, and an opposing back wall that is a second outer surface of the modular display panel;

a power supply for powering the plurality of LEDs, the power supply being disposed in the power supply housing, wherein the power supply comprises a power converter for converting alternating current (AC) power to direct current (DC) power, wherein a combination of the sidewalls, front wall, and opposing back wall of the power supply housing encloses the power supply on all sides, and wherein both a first portion of the casing and a second portion of the power supply housing are disposed between the printed circuit board and the power supply; and

a heat conducting structure configured to extract heat disposed proximate to the power supply,

wherein the modular display panel is sealed to be waterproof, and

wherein the modular display panel is configured to be independently operable and configured to be integrated with other displays to form a larger display, and wherein the modular display panel is configured to identify when the power supply ceases to supply power and communicate a message to a receiver box disposed outside the modular display panel when the panel identifies that the power supply has ceased to supply power.

2. The panel of claim 1, wherein the modular display panel comprises a receiving card and a processor, wherein the processor is configured to send the message to the receiving card, wherein the receiving card is configured to transmit the message to the receiver box.

3. The panel of claim 2, wherein the receiving card is configured to transmit the message wirelessly.

4. The panel of claim 1, wherein the power supply housing forms a power supply unit, wherein the power supply unit protrudes from the plastic back wall of the casing along a direction opposite a display side of the modular display panel, and wherein the power supply housing comprises the heat conducting structure.

5. The panel of claim 4, wherein the power supply housing comprises fins for extracting heat from the power supply.

6. The panel of claim 1, wherein the power supply is disposed inside a cage, wherein the cage comprises the heat conducting structure.

7. The panel of claim 1, wherein the modular display panel comprises an ingress protection (IP) rating of at least IP 65.

8. The panel of claim 1, wherein the modular display panel comprises an ingress protection (IP) rating of at least IP 66.

9. The panel of claim 1, wherein the modular display panel comprises an ingress protection (IP) rating of IP 68.

10. The panel of claim 1, wherein the thermally conductive material comprises a metal.

11. The panel of claim 10, wherein the metal comprises aluminum.

12. The panel of claim 1, wherein the thermally conductive material comprises plastic.

13. The panel of claim 1, wherein the modular display panel is hot swappable when integrated as part of the larger display.

14. A modular display panel comprising:

a light emitting diode (LED) board enclosure comprising plastic sidewalls and a plastic back wall, the plastic back wall of the LED board enclosure comprising a part of a first outer surface of the modular display panel that is exposed to an external environment, wherein the modular display panel is configured to be independently operable and to be integrated with other displays to form a larger display;

a printed circuit board attached to the LED board enclosure;

a plurality of LEDs arranged as pixels attached to a first side of the printed circuit board, wherein the pixels are arranged in a rectangular array comprising at least fifty pixels;

a circuit for controlling the plurality of LEDs attached to a second side of the printed circuit board, the second side being opposite to the first side, wherein the circuit is disposed within the LED board enclosure;

a power supply enclosure mounted over the first outer surface of the LED board enclosure, the power supply enclosure comprising sidewalls, a front wall, and an opposing back wall that is a second outer surface of the modular display panel;

a power supply for powering the plurality of LEDs, the power supply being disposed in the power supply enclosure and comprising a power converter for converting alternating current (AC) power to direct current (DC) power, wherein a combination of the sidewalls, front wall, and opposing back wall of the power supply enclosure encloses the power supply on all sides, and wherein both a first portion of the LED board enclosure and a second portion of the power supply enclosure are disposed between the printed circuit board and the power supply;

a thermally conductive material disposed proximate the power supply; and

wherein the modular display panel is sealed to be waterproof, wherein the modular display panel is configured to determine when the power supply becomes defective, and communicate a message to a receiver box disposed outside the modular display panel when the modular display panel determines that the power supply has become defective.

15. The panel of claim 14, wherein the modular display panel comprises a receiving card and a processor, wherein the processor is configured to send the message to the receiving card, wherein the receiving card is configured to transmit the message to the receiver box.

16. The panel of claim 15, wherein the receiving card is configured to transmit the message wirelessly.

17. The panel of claim 14, wherein the modular display panel is hot swappable when integrated as part of the larger display.

18. The panel of claim 14, wherein the modular display panel is completely waterproof against submersion in up to 3 feet of water.

19. The panel of claim 14, wherein the modular display panel comprises an ingress protection (IP) rating of IP 65.

20. The panel of claim 14, wherein the modular display panel comprises an ingress protection (IP) rating of or IP 66.

21. The panel of claim 14, wherein the modular display panel comprises an ingress protection (IP) rating of IP 67 or IP 68.

22. A modular display panel comprising:

a casing comprising a first side and an opposite second side, wherein the first side of the casing comprises plastic sidewalls and a plastic back wall that is part of a first outer surface of the modular display panel;

a printed circuit board attached to the casing;

a plurality of LEDs arranged as pixels attached to a first side of the printed circuit board, wherein the pixels are arranged in a rectangular array comprising at least fifty pixels;

a circuit for controlling the plurality of LEDs attached to a second side of the printed circuit board, the second side being opposite to the first side of the printed circuit board, wherein the circuit is disposed within the casing;

a power supply housing mounted outside the casing over the first outer surface of the casing, the power supply housing comprising sidewalls, a front wall, and an opposing back wall that is a second outer surface of the modular display panel;

a power supply for powering the plurality of LEDs, the power supply being disposed in the power supply housing, wherein the power supply comprises a power converter for converting alternating current (AC) power to direct current (DC) power, wherein a combination of the sidewalls, front wall, and opposing back wall of the power supply housing encloses the power supply on all sides, and wherein both a first portion of the casing and a second portion of the power supply housing are disposed between the printed circuit board and the power supply; and

a thermally conductive material to extract heat disposed proximate to the power supply, wherein the modular display panel is sealed to be waterproof, wherein the modular display panel is configured to be independently operable and to be integrated with other displays to form a larger display, wherein the modular display panel is configured to determine when the power supply becomes defective, and communicate a message to a receiver box disposed outside the modular display panel when the modular display panel determines that the power supply has become defective.

23. The panel of claim 22, wherein the modular display panel comprises a receiving card and a processor, wherein the processor is configured to send the message to the receiving card, wherein the receiving card is configured to transmit the message to the receiver box.

24. The panel of claim 23, wherein the receiving card is configured to transmit the message wirelessly.

25. The panel of claim 22, wherein the modular display panel is hot swappable when integrated as part of the larger display.

26. The panel of claim 22, further comprising:

a first integrated data and power cable connector electrically coupled to the printed circuit board and the power supply; and

a second integrated data and power cable connector electrically coupled to the printed circuit board and the power supply.

27. The panel of claim 22, wherein the modular display panel comprises an ingress protection (IP) rating of IP 65.

28. The panel of claim 22, wherein the modular display panel comprises an ingress protection (IP) rating of IP 66.

29. The panel of claim 22, wherein the modular display panel comprises an ingress protection (IP) rating of IP 67 or IP 68.

30. The panel of claim 22, wherein the modular display panel comprises only one printed circuit board.

31. A modular display panel comprising:

a first side and a second side opposite to the first side, wherein the first side of the modular display panel comprises a display surface of the modular display panel, wherein the modular display panel is configured to be directly attached to other modular display panels to form a multi-panel modular display;

a plastic enclosure comprising plastic sidewalls and a plastic back wall that comprises an outer surface of the modular display panel that is exposed to an external environment, the outer surface of the plastic enclosure forming the modular display panel, the plastic enclosure comprising a first recess and a second recess protruding outwardly from the first recess;

a printed circuit board comprising a front side and an opposite back side, the opposite back side being directly attached to the plastic enclosure and disposed in the first recess;

a plurality of light emitting diodes (LEDs) arranged as pixels attached to the front side of the printed circuit board, wherein the pixels are arranged in a rectangular array comprising at least fifty pixels;

a framework of louvers disposed over the front side of the printed circuit board between rows of the plurality of LEDs;

a power supply for powering the plurality of LEDs and disposed in the second recess, the first recess being disposed between the second recess and the first side of the modular display panel;

wherein the front side of the printed circuit board is sealed to be waterproof and the plastic enclosure is sealed to be waterproof so that the modular display panel is sealed to be waterproof;

wherein the modular display panel is configured to be exposed to the external environment without additional protective waterproof enclosures; and

wherein the modular display panel is configured to be cooled passively without fans.

32. The modular display panel of claim 31, further comprising:

a network of support structures extending from the plastic enclosure towards the printed circuit board, wherein the printed circuit board is attached to the plastic enclosure by the network of support structures.

33. The modular display panel of claim 31, wherein the modular display panel is configured to be operational when submerged in water up to a depth of one meter.

34. The modular display panel of claim 33, wherein the modular display panel is further configured to be operational when submerged in water to a depth greater than one meter.

35. The modular display panel of claim 31, wherein the power supply comprises an alternating current/direct current (AC/DC) converter, and wherein the power supply is configured to receive AC power and output DC power to the plurality of LEDs.

36. The modular display panel of claim 31, wherein the power supply comprises a down converter that down converts a direct current (DC) voltage at a first level to a DC voltage at a second level, the second level being lower than the first level.

37. The modular display panel of claim 31, wherein a surface of each of the plurality of LEDs is exposed to the external environment.

38. The modular display panel of claim 31, further comprising an integrated data and power connector comprising:

data connectors surrounded by an end enclosure, each of the data connectors configured to fit into an opposite type of data connectors of another integrated data and power connector, wherein the data connectors are configured to carry data to a circuit for controlling the plurality of LEDs;

power connectors surrounded by the end enclosure, each of the power connectors configured to fit into an opposite type of power connectors of the another integrated data and power connector, wherein the power connectors are configured to carry power to the plurality of LEDs; and

a sealing cover configured to prevent moisture from reaching inside the integrated data and power connector.

39. The modular display panel of claim 31, further comprising a receiver card configured to receive external data and provide the external data to a circuit for controlling the plurality of LEDs, the receiver card comprising a unique network address.