Large scale LED display

• US 9,135,838 B2
• Filed: 03/21/2011
• Issued: 09/15/2015
• Est. Priority Date: 12/11/2007
• Status: Active Grant

• Current Assignee: ADTI Media LLC
• Original Assignee: ADTI Media LLC
• Inventors: Kline, Daniel S., Shankle, Matthew W., Cox, David F., Lee, James C., Sarcia, Sam R.
• Primary Examiner(s): Wang-Hurst, Kathy
• Assistant Examiner(s): Tung, David
• Application Number:
  US13/052,912
• Publication Number:
  US 20110221662A1
• Time in Patent Office: 1,639 Days
• Field of Search: None
• US Class Current: 1/1
• 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 module for a display, comprising:

a plurality of LEDs;

a circuit board on which the LEDs are mounted; and

an over-molded housing encasing the circuit board inside the housing, wherein;

the LEDs protrude through a front surface of the housing;

if the LED module is a slave module in the display, at least one channel is formed on a back surface of the housing for one or more cables that are not connected to the LED module to pass through in the channel, and the one or more cables directly connect two master modules in the display while passing through the LED module;

if the LED module is a master module which controls a corresponding group of slave modules in the display, a plurality of heat sinks are integrally formed on the back surface of the housing to aid in heat dissipation of the LED module; and

the LED module is either a master module or a slave module in the display.

2. The LED module according to claim 1, wherein the housing is formed of a black resin.

3. The LED module according to claim 1, 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 heat sink fins on the front surface of the housing.

4. The LED module according to claim 1, 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.

5. The LED module according to claim 4, wherein the first and second columns of LEDs are separated by one or more heat sink fins on the front surface of the housing.

6. The LED module according to claim 1, 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.

7. The LED module according to in claim 6, wherein each LED has an individual sunshade protrusion extending outwardly above the LED.

8. The LED module according to claim 1, wherein the LEDs comprise one or more red LEDs, one or more green LEDs and one or more blue LEDs.

9. The LED module according to claim 1, wherein the front surface of the housing includes a plurality of heat sink fins that are disposed between the LEDs of the LED module.

10. The LED module according to claim 1, wherein the LEDs are angled by a particular angle upward, downward or to a side depending upon a use of the display.

11. The LED module according to claim 10, wherein the particular angle is between 0°

and 20°

.

12. The LED module according to claim 1, wherein the LEDs are angled downward by 10°

when the display is in use.

13. The LED module according to claim 1, wherein the one or more cables comprise at least one low-voltage differential signaling (LVDS) cable that is not connected to the LED module.

14. The LED module according to claim 1, wherein the one or more cables comprise one or more power cables that are not connected to the LED module.

15. The LED module according to claim 1, wherein the housing is over-molded with a thermally conductive resin.

16. The LED module according to claim 1, wherein a color of the housing matches a particular color of a structure on which the display is mounted.

17. The LED module according to claim 1, wherein a color of the housing of the LED module matches a particular color so that when all LEDs of the display are turned off, the particular color along with housing colors of other LED modules of the display depict a fixed logo.

18. The LED module according to claim 1, wherein a color of the housing of the LED module matches a particular color so that when all LEDs of the display are turned off, the particular color along with housing colors of other LED modules of the display depict one or both of a graphic and a text message.

19. A LED module for a display, comprising:

a plurality of LEDs;

a circuit board on which the LEDs are mounted; and

an over-molded housing encasing the circuit board inside the housing, wherein;

the LEDs protrude through a front surface of the housing, and the front surface of the housing includes a first plurality of heat sink fins that are disposed between the LEDs of the LED module;

if the LED module is a slave module in the display, at least one channel is formed on a back surface of the housing for one or more cables that are not connected to the LED module to pass through in the channel, and the one or more cables directly connect two master modules in the display while passing through the LED module;

if the LED module is a master module which controls a corresponding group of slave modules in the display, a second plurality of heat sinks are integrally formed on the back surface of the housing to further aid in heat dissipation of the LED module; and

the LED module is either a master module or a slave module in the display.

20. A LED module for a display, comprising:

a plurality of LEDs which comprise one or more red LEDs, one or more green LEDs and one or more blue LEDs;

a circuit board on which the LEDs are mounted; and

an over-molded housing encasing the circuit board inside the housing, wherein;

the LEDs protrude through a front surface of the housing, and the front surface of the housing includes a first plurality of heat sink fins that are disposed between the LEDs of the LED module;

if the LED module is a slave module in the display, at least one channel is formed on a back surface of the housing for one or more cables that are not connected to the LED module to pass through in the channel, and the one or more cables directly connect two master modules in the display while passing through the LED module;

if the LED module is a master module which controls a corresponding group of slave modules in the display, a second plurality of heat sinks are integrally formed on the back surface of the housing to further aid in heat dissipation of the LED module; and

the LED module is either a master module or a slave module in the display.