System and Method for a Modular Multi-Panel Display

• US 20170112009A1
• Filed: 12/30/2016
• Published: 04/20/2017
• 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.
• Granted Patent: US 9,642,272 B1
• Time in Patent Office: 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 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 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.

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.