Large scale LED display

• US 20090146918A1
• Filed: 12/11/2007
• Published: 06/11/2009
• Est. Priority Date: 12/11/2007
• Status: Active Grant

• Current Assignee: ADTI Media LLC, ADTI Media, LLC140
• Original Assignee: ADTI Media LLC
• Inventors: Shankle, Matthew W., Cox, David F., Lee, James C., Kline, Daniel S., Sarcia, Sam R.
• Granted Patent: US 8,599,108 B2
• Time in Patent Office: Days
• US Class Current: 345/46
• CPC Class Codes: G09F 27/008 Sun shades, shades, hoods or louvres on electronic displays to minimise the effect of direct sun light on the display
• CPC Class Codes: G09F 9/3026 Video wall, i.e. stackable semiconductor matrix display modules video wall control systems G06F3/1446, G09G2300/026
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: G09G 2380/06 Remotely controlled electronic signs other than labels
• CPC Class Codes: G09G 3/2074 using sub-pixels
• CPC Class Codes: G09G 3/22 using controlled light sources

Abstract

A large scale LED display has a cable and rigid link support structure for a number of LED modules. The cable and rigid link support structure is flexible but has sufficient structural integrity to prevent misalignment of the pixel modules. The LED modules are removable from the support structure individually and as a group so as to facilitate repair of the display. The LED modules are rugged so as to withstand harsh outdoor conditions and they provide sufficient luminescence for use in sunlight.

Claims

1. A LED display comprising:

a plurality of LED modules, each LED module including a module housing supporting a plurality of colored LEDs;

a support structure for the plurality of LED modules of the display comprising;

a first pair of parallel cables;

a first set of rigid links, extending between the cables of the first cable pair;

a second pair of parallel cables, the cables of the second cable pair being parallel to the cables of the first cable pair;

a second set of rigid links, extending between the cables of the second cable pair;

wherein each LED module is mounted on one cable of the first cable pair and one cable of the second cable pair.

2. A LED display as recited in claim 1 wherein each LED module is mounted adjacent at least one link from the first set of links and adjacent at least one link from the second set of links, the links locating the position LED module along the cables.

3. A LED display as recited in claim 1 wherein the rigid links are H shaped links over-molded onto a pair of cables.

4. A LED display as recited in claim 1 wherein the rigid links do not pivot about the cables.

5. A LED display as recited in claim 1 further comprising a plurality of plates, each plate mounted on one cable of the first cable pair and one cable of the second cable pair and each plate supporting an LED module thereon to mount the LED module on the cables.

6. A LED display as recited in claim 5 wherein the rigid links are H shaped links over-molded onto a pair of cables.

7. A LED display as recited in claim 5 wherein the plates and cables are formed of steel.

8. A LED display as recited in claim 5 wherein the plates are at least slightly pivotable about the cables on which they are mounted.

9. A LED display as recited in claim 5 wherein at least one LED module is removably mounted on an associated plate.

10. A LED display as recited in claim 5 wherein at least one of the LED modules includes red, green and blue LEDs, the LEDs extending outwardly from a first surface of the LED module housing and the first surface of the LED module housing including a plurality of heat sink fins.

11. A LED display as recited in claim 5 wherein the housing of the at least one of the LED modules has at least one surface with at least one protrusion that snaps into an aperture of a plate to removably mount the LED module to the plate.

12. A LED display as recited in claim 5 wherein the housing of at least one of the LED modules has a back surface abutting the plate when the module is mounted thereon, the back surface of the module having a channel formed therein through which one or more cables pass.

13. A LED display comprising:

a plurality of LED modules, each LED module including a module housing supporting a plurality of colored LEDs;

a support structure for the plurality of LED modules of the display comprising;

a first pair of parallel cables;

a first set of rigid links extending between the cables of the first cable pair;

a second pair of parallel cables, the second pair of parallel cables being parallel to the first cable pair;

a second set of rigid links extending between the cables of the second cable pair; and

a plurality of plates, the plates being mounted on one cable of the first cable pair adjacent at least one link of the first set and on one cable of the second cable pair adjacent at least one link of the second set, wherein an LED module is removably mounted on a plate.

14. A LED display as recited in claim 13 wherein the rigid links are H shaped links over-molded onto a pair of cables.

15. A LED display as recited in claim 13 wherein the LED modules include a first set of modules and a second set of modules, a LED module in the first set being secured to a respective plate by a plurality of screws and a LED module in the second set being snapped onto a respective plate.

16. A LED display as recited in claim 13 wherein the LED modules include a first set of modules and a second set of modules, a LED module in the first set being individually replaceable and a LED module in the second set being fixedly connected to a plurality of LED modules in the second set to form a segment of modules that are removable from the display together.

17. A LED display as recited in claim 16 wherein a LED module in the first set is secured to a respective plate by a plurality of screws and a LED module in the second set being snapped onto a respective plate.

18. A LED display as recited in claim 13 wherein each plate includes a first member and a second member that abut opposite sides of one link from the first set and each plate includes a third member and a fourth member that abut opposite sides of one link from the second set.

19. A LED display as recited in claim 13 wherein each plate abuts a link from the first set of links and abuts a link from the second set of links.

20. A LED display as recited in claim 19 wherein the links are spaced along the respective cable such that the spacing between adjacent links on a cable is constant, the links locating the position of the plates along the cables.

21. An LED display as recited in claim 13 wherein the plates and cables are formed of steel.

22. A LED display as recited in claim 13 wherein the plates are at least slightly pivotable about the cables on which they are mounted.

23. A LED display as recited in claim 13 wherein at least one LED module is removably mounted on an associated plate by snapping the module onto the plate.

24. A LED display as recited in claim 13 wherein at least one of the LED modules includes red, green and blue LEDs, the LEDs extending outwardly from a first surface of the LED module housing and the first surface of the LED module housing including a plurality of heat sink fins.

25. A LED display as recited in claim 24 wherein a plurality of the LED module housings include a plurality of heat sink fins on a back surface of the housing.

26. A LED display as recited in claim 13 wherein each of a plurality of the plates form a heat sink for the LED module that is mounted thereon.

27. A LED display as recited in claim 13 wherein the housing of the at least one of the LED modules has at least one surface with at least one protrusion that snaps into an aperture of a plate to retain the LED module on the plate.

28. A LED display as recited in claim 13 wherein the housing of at least one of the LED modules has a back surface abutting the plate when the module is mounted thereon, the back surface of the module having a channel formed therein through which one or more cables pass.

29. A LED module for a display comprising:

one or more red LEDs;

one or more green LEDs;

one or more blue LEDs;

a circuit board on which the LEDs are mounted; and

an over-molded housing encasing the circuit board, the LEDs protruding through a front surface of the housing, and the front surface of the housing including a plurality of heat sink fins.

30. A LED module as recited in claim 29 wherein the housing is formed of a black resin.

31. A LED module as recited in claim 29 wherein the LEDs are arranged in at least two columns, each column having a red LED, a green LED and a blue LED wherein the columns are separated by one or more of the heat sink fins.

32. A LED module as recited in claim 29 wherein the LEDs are arranged in columns including a first column having an order of red, green and blue LEDs and a second column having an order of green, blue and red LEDs.

33. A LED module as recited in claim 32 wherein the first and second columns of LEDs are separated by one or more of the heat sink fins.

34. A LED module as recited in claim 29 wherein the front surface of the housing includes a plurality of sunshade protrusions, each protrusion extending outwardly above one or more of the LEDs of the module.

35. A LED module as recited in claim 34 wherein each LED has an individual sunshade protrusion extending outwardly above the LED.

36. A LED module as recited in claim 29 wherein the housing has a back surface with at least one channel formed therein to accommodate at least one cable in the channel.

37. A LED display comprising:

a plurality of linear segments of LED modules in each of a plurality of columns or rows of the display, each LED module having a housing supporting a plurality of multicolor LEDs and each segment including a plurality of LED modules coupled together so that the LED modules of a segment are removable from the display only as a group and each segment of LED modules is removable from the display independent of the LED modules of another segment.

38. A LED display as recited in claim 37 including an individual LED module connected between a first segment of LED modules and a second segment of LED modules.

39. A LED display as recited in claim 38 wherein each segment includes at one end a first electrical connector adapted to be connected to one individual LED module and a second electrical connector at an opposite end of the segment, the second electrical connector adapted to be connected to another individual LED module, each LED module of a segment having a module housing with a back wall having a channel formed therein for at least one data cable to pass therethrough, the data cable extending directly between the first electrical connector and the second electrical connector so as to directly connect one individual LED module to another individual LED module.

40. A LED display as recited in claim 39 wherein the channel formed in the module housing of the LED modules of a segment allows at least one power cable to pass therethrough as well as the data cable.

41. A segment of LED modules for use in a display comprising:

a first electrical connector fixedly attached to a first end of the segment;

a second electrical connector fixedly attached to a second end of the segment.

a plurality of spaced LED modules connected between the first electrical connector and the second electrical connector, the spaced LED modules being connected end to end by at least one cable capable of carrying power and data to each of the LED modules;

a further cable connected directly between the first connector and the second connector for carrying data directly between the first and second connectors.

42. A segment of LED modules as recited in claim 41 wherein each LED module includes a housing with a back wall having a channel formed therein for the further cable to pass therethrough under the LED module housing.

43. A segment of LED modules as recited in claim 41 wherein each LED module includes:

one or more red LEDs;

one or more green LEDs;

one or more blue LEDs;

a circuit board on which the LEDs are mounted; and

an over-molded housing encasing the circuit board, the LEDs protruding through a front surface of the housing, and the front surface of the housing including a plurality of heat sink fins.

44. A segment of LED modules as recited in claim 43 wherein the LEDs are arranged in at least two columns, each column having a red LED, a green LED and a blue LED wherein the columns are separated by one or more of the heat sink fins.

45. A segment of LED modules as recited in claim 43 wherein the LEDs are arranged in columns including a first column having an order of red, green and blue LEDs and a second column having an order of green, blue and red LEDs.

46. A segment of LED modules as recited in claim 45 wherein the first and second columns of LEDs are separated by one or more of the heat sink fins.

47. A segment of LED modules as recited in claim 43 wherein the front surface of the housing includes a plurality of sunshade protrusions, each protrusion extending outwardly above one or more of the LEDs of the module.

48. A segment of LED modules as recited in claim 47 wherein each LED has an individual sunshade protrusion extending outwardly above the LED.

49. A large scale LED display comprising:

a cable support structure; and

a plurality of LED modules mounted on and structurally supported by the cable support structure, the LED modules including at least one red LED, at least one green LED and at least one blue LED supported on a dark color module housing, wherein the center to center spacing between adjacent LED modules is 50 mm or greater and the light output is 5,000 nits or greater.

50. A LED display as recited in claim 49 wherein the LED modules include a plurality of red LEDs, a plurality of green LEDs and a plurality of blue LEDs and the center to center spacing between adjacent LED modules is 75 mm or greater.

51. A large scale LED display comprising:

a cable support structure; and

a plurality of LED modules mounted on and structurally supported by the cable support structure, each LED module having at least one LED supported on a module housing wherein at least two of the module housings of the display have different colors.

52. A large scale LED display as recited in claim 51 wherein the different color module housings depict a fixed graphic and/or text when the LEDs of the modules are off.

53. A large scale LED display comprising:

a cable support structure; and

a plurality of LED modules mounted on and structurally supported by the cable support structure, the LED modules including at least one LED supported on a module housing, the LEDs of the display having the same color and wherein the center to center spacing between adjacent LED modules is 50 mm or greater and the light output is 5,000 nits or greater.

54. A LED display comprising:

a plurality of LED modules, each LED module including a module housing supporting a plurality of colored LEDs;

a flexible support structure on which the LED modules are mounted, the support structure including a plurality of parallel cables and a plurality of rigid members, each rigid member being mounted on and extending between a pair of adjacent cables, wherein the LED display is capable of conforming to a curved surface.

55. A LED display as recited in claim 54 wherein a plurality of the rigid members are rigid links.

56. A LED display as recited in claim 55 wherein the rigid links extending between a pair of adjacent cables are spaced at approximately equal distances along the length of the cables.

57. A LED display as recited in claim 54 wherein a plurality of the rigid members are back plates on which LED modules are mounted.

58. A LED display as recited in claim 54 wherein a group of the rigid members are rigid links and another group of the rigid members are module supports on which LED modules are mounted.

59. A LED display as recited in claim 58 wherein a module support is mounted on a pair of cables adjacent a rigid link mounted on one cable of the cable pair and adjacent a rigid link mounted on the other cable of the cable pair.

60. A LED display as recited in claim 54 wherein a group of the rigid members are capable of at least some rotation about the cables on which the members are mounted and another group of rigid members are not rotatable about the cables on which the members are mounted.

61. A LED display as comprising:

a plurality of LED modules, each LED module including a module housing supporting a plurality of colored LEDs;

a support structure for the plurality of LED modules of the display, the support structure including a plurality of parallel cables and a plurality of spacers mounted on and extending between a pair of adjacent cables, each LED module being mounted on a pair of adjacent cables adjacent to at least one spacer.

62. A LED display as recited in claim 61 wherein the spacers are spaced at approximately equal distances along the length of the cables.

63. A LED display as recited in claim 61 wherein the support structure is flexible and capable of conforming to a curved surface.

64. A LED display comprising:

a plurality of LED modules, each LED module including a module housing supporting a plurality of colored LEDs;

a support structure for the plurality of LED modules of the display, the support structure including a plurality of parallel cables, a plurality of spacers mounted on and extending between a pair of adjacent cables, and a plurality of back plates mounted on a pair of adjacent cables, each back plate supporting an LED module and each spacer maintaining the spacing between adjacent LED modules.

65. A LED display as recited in claim 64 wherein each back plate is mounted adjacent at least one spacer such that the spacer extends along a centerline of the back plate.

66. A LED display as recited in claim 64 wherein the spacers extending between a pair of adjacent cables are spaced at approximately equal distances along the length of the cables.

67. A LED display as recited in claim 64 wherein the support structure is flexible and capable of conforming to a curved surface.

68. A LED display as recited in claim 64 wherein a plurality of the LED modules snap onto the back plates.

69. A LED display as recited in claim 68 wherein a plurality of the LED modules are secured to the back plates by screws.

70. A LED display as recited in claim 64 wherein the spacers are rigid links.