Large scale LED display

• US 8,599,108 B2
• Filed: 12/11/2007
• Issued: 12/03/2013
• Est. Priority Date: 12/11/2007
• Status: Expired due to Fees

• Current Assignee: ADTI Media LLC, ADTI Media, LLC140
• Original Assignee: ADTI Media, LLC140
• Inventors: Kline, Daniel S., Shankle, Matthew W., Cox, David F., Lee, James C., Sarcia, Sam R.
• Primary Examiner(s): Lefkowitz, Sumati
• Assistant Examiner(s): HERNANDEZ, JESUS J
• Application Number:
  US12/001,315
• Publication Number:
  US 20090146918A1
• Time in Patent Office: 2,184 Days
• Field of Search: None
• 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; and

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

a first pair of flexible parallel cables,

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

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

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, wherein the rigid links are over-molded links, wherein the first set of rigid links are H-shaped links that directly connect the first pair of parallel cables on a first side of a first set of LED modules of the plurality of LED modules, and wherein the second set of rigid links are H-shaped links that directly connect the second pair of parallel cables on a second side of the first set of LED modules.

2. The LED display according to 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. The LED display according to claim 1, wherein the rigid links do not pivot about the cables.

4. The LED display according to 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.

5. The LED display according to claim 4, wherein the plates and cables are formed of steel.

6. The LED display according to claim 4, wherein the plates are at least slightly pivotable about the cables on which they are mounted.

7. The LED display according to claim 4, wherein at least one LED module is removably mounted on an associated plate.

8. The LED display according to claim 4, 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.

9. The LED display according to claim 4, 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.

10. The LED display according to claim 4, 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.

41. The LED display according to claim 1, wherein the rigid links are not cables.

42. The LED display according to claim 1, wherein the rigid links are made by a reel to reel molding process.

43. The LED display according to claim 1, wherein the plurality of LED modules are disposed in N columns, wherein the support structure includes N+1 flexible parallel cables and N+1 rigid links, and wherein N is an integer.

44. The LED display according to claim 1, wherein the rigid links are individual components.

45. The LED display according to claim 1, wherein the first set of rigid links cannot rotate around any of the cables of the first pair of parallel cables, and wherein respective back plates of the LED modules mounted on a particular cable of the first pair of parallel cables can rotate around the particular cables of the first pair of parallel cables.

46. The LED display according to claim 1, wherein the first side and the second side are opposite sides of the first set of LED modules.

47. The LED display according to claim 1, wherein the first set of rigid links only extend between the cables of the first cable pair.

48. The LED display according to claim 1, wherein the first set of rigid links do not connect parallel cables that are on opposite sides of the mounted LED modules.

49. The LED display according to claim 1, wherein a left side of the “

H”

is connected to a first cable of the first pair of parallel cables, and wherein a right side of the “

H”

is connected to a second cable of the second pair of cables.

50. The LED display according to claim 1, wherein the first pair of parallel cables are on opposite sides of the mounted LED modules as the second pair of parallel cables, and wherein the first pair is parallel to the second pair.

51. The LED display according to claim 1, wherein the LED modules include master LED modules and slave LED modules, wherein some of the rigid links couple one master LED module to another master LED module, and wherein other of the rigid links couple one slave LED module to another slave LED module.

52. The LED display according to claim 51, wherein the master LED modules are different from the slave LED modules.

53. The LED display according to claim 52, wherein a rigid link does not couple a master LED module to a slave LED module.

54. The LED display according to claim 1, wherein the LED modules include master LED modules and slave LED modules, wherein a rigid link of the first set or the second set of rigid links can couple a first master LED module to a second master LED module, but cannot couple the first master LED module to a slave LED module.

11. A LED display comprising:

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

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

a first pair of flexible parallel cables,

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

a second pair of flexible 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,

wherein the rigid links are over-molded links, wherein the first set of rigid links are H-shaped links that directly connect the first pair of parallel cables on a first side of a first set of LED modules of the plurality of LED modules, and wherein the second set of rigid links are H-shaped links that directly connect the second pair of parallel cables on a second side of the first set of LED modules.

12. The LED display according to claim 11, 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.

13. The LED display according to claim 11, 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.

14. The LED display according to claim 13, 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.

15. The LED display according to claim 11, 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.

16. The LED display according to claim 11, wherein each plate abuts a link from the first set of links and abuts a link from the second set of links.

17. The LED display according to claim 16, 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.

18. The LED display according to claim 11, wherein the plates and cables are formed of steel.

19. The LED display according to claim 11, wherein the plates are at least slightly pivotable about the cables on which they are mounted.

20. The LED display according to claim 11, wherein at least one LED module is removably mounted on an associated plate by snapping the module onto the plate.

21. The LED display according to claim 11, 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.

22. The LED display according to claim 21, wherein a plurality of the LED module housings include a plurality of heat sink fins on a back surface of the housing.

23. The LED display according to claim 11, wherein each of a plurality of the plates form a heat sink for the LED module that is mounted thereon.

24. The LED display according to claim 11, 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.

25. The LED display according to claim 11, 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.

26. A LED display comprising:

a cable support structure including a plurality of parallel cables and a plurality of links mounted on and extending between a pair of adjacent cables of the plurality of parallel cables, wherein the cables are flexible and the links are rigid; and

a plurality of linear segments of LED modules in each of a plurality of columns or rows of the display, each LED module being mounted on the pair of the adjacent cables, 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,

wherein the rigid links are over-molded links, wherein a first set of rigid links are H-shaped links that directly connect a first pair of parallel cables on a first side of a first set of LED modules of the plurality of LED modules, and wherein a second set of rigid links are H-shaped links that directly connect a second pair of parallel cables on a second side of the first set of LED modules.

27. The LED display according to claim 26, including an individual LED module connected between a first segment of LED modules and a second segment of LED modules.

28. The LED display according to claim 27, 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.

29. The LED display according to claim 28, 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.

30. A large scale LED display comprising:

a cable support structure including a plurality of parallel cables and a plurality of links mounted on and extending between a pair of adjacent cables of the plurality of parallel cables, wherein the cables are flexible and the links are rigid; and

a plurality of LED modules mounted on and structurally supported by the cable support structure, each LED module being mounted on the pair of the adjacent cables, 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,

wherein the rigid links are over-molded links, wherein a first set of rigid links are H-shaped links that directly connect a first pair of parallel cables on a first side of a first set of LED modules of the plurality of LED modules, and wherein a second set of rigid links are H-shaped links that directly connect a second pair of parallel cables on a second side of the first set of LED modules.

31. The LED display according to claim 30, 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.

32. A large scale LED display comprising:

a cable support structure including a plurality of parallel cables and a plurality of links mounted on and extending between a pair of adjacent cables of the plurality of parallel cables, wherein the cables are flexible and the links are rigid; and

a plurality of LED modules mounted on and structurally supported by the cable support structure, each LED module being mounted on the pair of the adjacent cables, 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,

wherein the rigid links are over-molded links, wherein a first set of rigid links are H-shaped links that directly connect a first pair of parallel cables on a first side of a first set of LED modules of the plurality of LED modules, and wherein a second set of rigid links are H-shaped links that directly connect a second pair of parallel cables on a second side of the first set of LED modules.

33. The large scale LED display according to claim 32, wherein the different color module housings depict a fixed graphic and/or text when the LEDs of the modules are off.

34. A large scale LED display comprising:

a cable support structure including a plurality of parallel cables and a plurality of links mounted on and extending between a pair of adjacent cables of the plurality of parallel cables, wherein the cables are flexible and the links are rigid; and

a plurality of LED modules mounted on and structurally supported by the cable support structure, each LED module being mounted on the pair of the adjacent cables, 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,

wherein the rigid links are over-molded links, wherein a first set of rigid links are H-shaped links that directly connect a first pair of parallel cables on a first side of a first set of LED modules of the plurality of LED modules, and wherein a second set of rigid links are H-shaped links that directly connect a second pair of parallel cables on a second side of the first set of LED modules.

35. A LED display comprising:

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

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

wherein the rigid spacers are rigid links that are over-molded links, wherein a first set of rigid links are H-shaped links that directly connect a first pair of parallel cables on a first side of a first set of LED modules of the plurality of LED modules, and wherein a second set of rigid links are H-shaped links that directly connect a second pair of parallel cables on a second side of the first set of LED modules.

36. The LED display according to claim 35, wherein each back plate is mounted adjacent at least one spacer such that the spacer extends along a centerline of the back plate.

37. The LED display according to claim 35, wherein the spacers extending between a pair of adjacent cables are spaced at approximately equal distances along the length of the cables.

38. The LED display according to claim 35, wherein the support structure is flexible and capable of conforming to a curved surface.

39. The LED display according to claim 35, wherein a plurality of the LED modules snap onto the back plates.

40. The LED display according to claim 39, wherein a plurality of the LED modules are secured to the back plates by screws.