LED display module

• US 8,172,097 B2
• Filed: 12/20/2006
• Issued: 05/08/2012
• Est. Priority Date: 11/10/2005
• Status: Active Grant

• Current Assignee: Daktronics Incorporated
• Original Assignee: Daktronics Incorporated
• Inventors: Nearman, Nathan Lane, Mutschelknaus, Shannon Lee, Mueller, Matt Ray, Wendler, Brett David, Bravek, Eric Steven, Lutz, Robert James, Hansen, Ryan Mark, Fanning, Nick Joeseph
• Primary Examiner(s): PUROL, SARAH L
• Application Number:
  US11/642,221
• Publication Number:
  US 20080078733A1
• Time in Patent Office: 1,966 Days
• Field of Search: 211/189, 404/07, 404/06, 404/48, D20/19, 340/815.45, 340/815, 340/45, 345/30
• US Class Current: 211/189
• 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: H05K 5/061 sealed by a gasket held between a removable cover and a body, e.g. O-ring, packing
• CPC Class Codes: H05K 7/20972 Forced ventilation, e.g. on heat dissipaters coupled to components
• CPC Class Codes: H05K 9/0054 specially adapted for display applications

Abstract

An LED display module having features for improvement over prior art devices by providing novel features for improved LED visibility, improved weather and climatological sealing, improved electromagnetic interference (EMI) suppression, improved heat dissipation, and improved airflow.

Claims

1. An LED display module comprising:

at least one display assembly, the at least one display assembly including;

a printed circuit board having a plurality of spaced LED packages, each LED package including one or more LEDS, coupled on a first major surface of said printed circuit board,

a louver panel adjacent the plurality of LED packages, the louver panel including a support grid having a plurality of overmold cavity view ports projecting from the support grid, each of the plurality of overmold cavity view ports is in respective alignment with each of the plurality of LED packages and each overmold cavity viewport covers and isolates a respective LED package and allows viewing of the respective covered LED package through the overmold cavity view port, and

a frame sealed to the louver panel with the printed circuit board and plurality of LED packages correspondingly sealed therebetween.

2. The LED display module of claim 1, comprising a thermal conductive pad adjacent a second major surface of the printed circuit board, the second major surface being opposite to the first major surface on which the plurality of LED packages are coupled.

3. The LED display module of claim 2, comprising a heat distribution plate adjacent the thermal conductive pad and positioned between the thermal conductive pad and the frame, and

wherein the heat distribution plate is made from or coated with an RFI suppression material.

4. The LED display module of claim 1, wherein the at least one display assembly includes at least a first display assembly and a second display assembly, the first and second display assemblies coupled in a side-by-side arrangement.

5. The LED display module of claim 1, wherein the frame includes at least one peripheral lip, and further comprising a rear cover including a peripheral lip, the rear cover positioned such that the frame is juxtaposed between the louver panel and the rear cover;

and wherein a peripheral lip of the frame is configured to engage with the peripheral lip of the rear cover, and wherein a weather sealing material is located between or adjacent such engagement to seal the frame and the rear cover, and wherein the rear cover includes an inner circumferential lip and the frame includes a corresponding inner recess for receiving the inner circumferential lip, and

wherein the weather sealing material is located at least partially between the inner circumferential lip and the inner recess to further seal the frame and the rear cover.

6. The LED display module of claim 1, wherein the frame includes at least one peripheral lip, and further comprising a rear cover including a peripheral lip, the rear cover positioned such that the frame is juxtaposed between the louver panel and the rear cover;

and wherein a peripheral lip of the frame is configured to engage with the peripheral lip of the rear cover, and wherein a weather sealing material is located between or adjacent such engagement to seal the frame and the rear cover, and wherein the louver panel includes a peripheral lip configured to engage with a second peripheral lip of the frame opposite the peripheral lip configured to engage with the rear cover, and

wherein a weather sealing material is located between or adjacent such engagement to seal the frame and the louver panel.

7. The LED display module of claim 3, comprising a weather sealing material disposed between the heat distribution plate and the frame.

8. The LED display module of claim 3, comprising a plurality of heat sinks attached to the heat distribution plate.

9. The LED display module of claim 1, wherein the frame includes at least one peripheral lip, and further comprising a rear cover including a peripheral lip, the rear cover positioned such that the frame is juxtaposed between the louver panel and the rear cover;

and wherein a peripheral lip of the frame is configured to engage with the peripheral lip of the rear cover, and wherein a weather sealing material is located between or adjacent such engagement to seal the frame and the rear cover, and wherein the rear cover includes means for circulating air through a non-viewing surface of the at least one display assembly.

10. The LED display module of claim 9, wherein the means include an air inlet and an air outlet in the rear cover and a centrifugal air pump adjacent the air outlet.

11. The LED display module of claim 10, wherein the rear cover encloses a first air filter assembly adjacent the air inlet and a second air filter assembly adjacent the air outlet, and

wherein one or both of the first air filter or the second air filter include or are disposed adjacent a screen having EMI inhibiting qualities.

12. The LED display module of claim 9, wherein the means include one or more pre-structured air passageways between the air inlet and the air outlet in the rear cover.

13. The LED display module of claim 1, wherein the overmold cavity view ports include a thermoplastic elastomer overmold material arranged over or around the plurality of LED packages, the overmold material configured to engage and seal the first major surface of the printed circuit board in close proximity to the sides of the plurality of LED packages.

14. The LED display module of claim 1, wherein each of the plurality of view ports includes an angled surface or a sub-lip surrounding at least a portion of each of the plurality of LED packages, the angled surface or the sub-lip configured to protect and shade the plurality of LED packages.

15. The LED display module of claim 1, wherein one or more of the louver panel, the frame, or the rear cover are constructed of a plastic having EMI inhibiting qualities or coated with a paint having EMI inhibiting qualities.

16. The LED display module of claim 1, wherein the frame includes at least one peripheral lip, and further comprising a rear cover including a peripheral lip, the rear cover positioned such that the frame is juxtaposed between the louver panel and the rear cover;

and wherein a peripheral lip of the frame is configured to engage with the peripheral lip of the rear cover, and wherein a weather sealing material is located between or adjacent such engagement to seal the frame and the rear cover.

17. An LED display module comprising:

at least one display assembly, the at least one display assembly including;

a printed circuit board having a plurality of spaced LED packages, each LED package including one or more LEDS, coupled on a first major surface of said printed circuit board,

a louver panel adjacent the plurality of LED packages, the louver panel including a support grid having a plurality of view ports projecting from the support grid, each of the plurality of view ports is in respective alignment with each of the plurality of LED packages and each view ports covers a respective LED package and allows viewing of the respective covered LED package through the view port,

a frame sealed to the louver panel with the printed circuit board and plurality of LED packages correspondingly sealed therebetween; and

a thermoplastic elastomer overmold material arranged over or around the plurality of LED packages, the overmold material configured to engage and seal the first major surface of the printed circuit board in close proximity to the sides of the plurality of LED packages.

18. The LED display module of claim 17, wherein each of the plurality of view ports includes an angled surface or a sub-lip surrounding at least a portion of each of the plurality of LED packages, the angled surface or the sub-lip configured to protect and shade the plurality of LED packages.

19. The LED display module of claim 17, wherein one or more of the louver panel, the frame, or the rear cover are constructed of a plastic having EMI inhibiting qualities or coated with a paint having EMI inhibiting qualities.