Sealed pixel assemblies, kits and methods

• US 9,052,092 B2
• Filed: 09/16/2013
• Issued: 06/09/2015
• Est. Priority Date: 10/14/2004
• Status: Active Grant

• Current Assignee: Daktronics Incorporated
• Original Assignee: Daktronics Incorporated
• Inventors: Wendler, Brett David, Bravek, Eric Steven, Grebel, Erich J.
• Primary Examiner(s): Amini, Javid A
• Application Number:
  US14/027,419
• Publication Number:
  US 20140016319A1
• Time in Patent Office: 631 Days
• Field of Search: 362/249
• US Class Current: 1/1
• CPC Class Codes: F21V 15/01 Housings, e.g. material or assembling of housing parts F21V15/02 takes precedence housings forming signs or letters G09F13/04
• CPC Class Codes: F21V 23/06 the elements being coupling devices , e.g. connectors
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G09F 13/22 electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: G09F 9/301 flexible foldable or roll-able electronic displays, e.g. thin LCD, OLED
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: G09G 2300/04 Structural and physical details of display devices
• CPC Class Codes: G09G 2300/0426 Layout of electrodes and connections
• CPC Class Codes: G09G 2310/0221 with use of split matrices G09G3/3644 and G09G3/3666 take precedence
• CPC Class Codes: G09G 3/06 using controlled light sources
• CPC Class Codes: G09G 3/12 using electroluminescent elements
• CPC Class Codes: G09G 3/32 semiconductive, e.g. using light-emitting diodes [LED]
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: H05K 3/32 electrically connecting electric components or wires to printed circuits
• CPC Class Codes: H05K 3/368 parallel to each other H05K3/361 takes precedence
• CPC Class Codes: H05K 5/064 sealed by potting, e.g. waterproof resin poured in a rigid casing
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base

Abstract

Discrete flexible pixel assemblies can be hermetically sealed from the environment and can comprise unitary, self-contained replaceable modules which enable efficient, economical production of large scale, free-form electronic displays, signs and lighting effects for outdoor use. The method and means for producing hermetically sealed discrete flexible pixel assemblies can include encapsulation means, exterior encasement means, and cable connector means.

Claims

1. A sealed module comprising:

a circuit board including one or more light-emitting elements coupled to a first surface of the circuit board;

a potting shell coupled to the circuit board, the potting shell including at least one cavity, the potting shell at least partially enclosing the one or more light-emitting elements; and

an encapsulating material disposed within the cavity, the encapsulating material encapsulating and sealing at least a portion of the first surface of the circuit board from an environment exterior.

2. The sealed module of claim 1, comprising an encasement cover having an internal cavity configured to receive at least a portion of the potting shell, the circuit board, the one or more light emitting elements, and the encapsulating material.

3. The sealed module of claim 2, wherein the portion of the first surface of the circuit board being encapsulated and sealed includes a portion surrounding each of the light-emitting elements.

4. The sealed module of claim 1, wherein the encapsulating material encapsulates and seals at least a portion of each of the light-emitting elements.

5. The sealed module of claim 1, wherein the at least one cavity is a first cavity and wherein the potting shell includes a second cavity extending from the circuit board in an opposed direction to the first cavity, the second cavity configured to receive encapsulating material.

6. The sealed module of claim 1, wherein the encapsulating material comprises at least one of a ductile foam, a malleable solid potting material, a potting resin configured harden on exposure to the atmosphere, heat, or a reactive agent, and a potting gell configured to harden on exposure to the atmosphere, heat, or a reactive agent, a potting resin and a potting gel that is configured to harden on exposure to the atmosphere, heat, or a reactive agent.

7. The sealed module of claim 1, wherein the encapsulating material hermetically seals at least the first surface of the circuit board from the environment exterior.

8. The sealed module of claim 1, wherein the potting shell is coupled to a perimeter of the circuit board.

9. The sealed module of claim 1, comprising one or more connectors coupled to the circuit board, the one or more connectors configured for input to the circuit board or output from the circuit board, or both.

10. The sealed pixel module of claim 9, wherein each of the one or more connectors are configured for coupling with at least one other sealed module.

11. The sealed module of claim 1, wherein encapsulating and sealing from the environment exterior includes protecting the portion of the first surface of the circuit board from at least one of moisture, humidity, solar radiation, atmospheric pressure changes, vacuum, corrosive chemicals, electrical shock, thermal shock, and mechanical shock.

12. A method, comprising:

providing or receiving a circuit board including one or more light-emitting elements coupled to a first surface of the circuit board;

coupling a potting shell to a perimeter of the circuit board so that the potting shell at least partially encloses the one or more light-emitting elements, the potting shell forming at least one cavity;

disposing an encapsulating material within the at least one cavity, the encapsulating material encapsulating and sealing at least a portion of the first surface of the circuit board from an environment exterior.

13. The method of claim 12, comprising coupling an encasement cover to the potting shell to form a sealed module, the encasement cover having an internal cavity that receives at least a portion of the potting shell, the circuit board, the one or more light emitting elements, and the encapsulation material.

14. The method of claim 12, wherein disposing the encapsulating material within the at least one cavity is performed subsequent to coupling the encasement cover to the potting shell.

15. The method of claim 12, comprising coupling the sealed module to a mounting surface to form an electronic display capable of presenting graphics and video.

16. The method of claim 12, wherein the sealed module is a first sealed module, the method comprising connecting the first sealed module to a second sealed module.

17. The method of claim 16, wherein connecting the first sealed module to the second sealed module includes coupling an output connector of the first sealed module to an input connector of the second sealed module.

18. The method of claim 12, comprising connecting a plurality of sealed modules to form a flexible pixel string.

19. The method of claim 12, wherein the encapsulating and sealing at least the portion of the first surface comprises protecting the portion of the first surface of the circuit board from at least one of moisture, humidity, solar radiation, atmospheric pressure changes, vacuum, corrosive chemicals, electrical shock, thermal shock, and mechanical shock.

20. A method comprising:

providing or receiving a plurality of sealed modules, wherein each sealed module includes;

a circuit board including one or more light-emitting elements coupled to a first surface of the circuit board,

a potting shell coupled to the circuit board, the potting shell including at least one cavity, the potting shell at least partially enclosing the one or more light-emitting elements, and

an encapsulating material disposed within the cavity, the encapsulating material encapsulating and sealing at least a portion of the first surface of the circuit board from an environment exterior; and

coupling the plurality of sealed modules to a mounting surface to form an electronic display.