Abstract:
An assembly is provided for mounting an LED cluster to the front panel of an electronic sign cabinet. The assembly includes a forward section for connecting to and supporting the housing of the LED cluster. A rearward section is connected to the forward section and is selectively attachable to the sign such that an inner face of the rearward section is substantially flushly interengaged with the front panel of the sign. The forward and rearward sections include at least one conduit for communicating with corresponding openings in the cluster housing and the sign. The conduit accommodates wiring of the LED cluster. The forward and rearward sections are angularly oriented relative to one another such that when the forward section is connected to the cluster housing and the rearward section is connected to the sign, each pixel of the LED cluster is directed along an axis that extends at an acute angle relative to the front panel of the sign.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to an angled mounting assembly for an LED cluster and, in particular, to an assembly for operably mounting an LED cluster and associated wiring to the cabinet of an electronic sign or message board such that the LED pixels are directed at an acute angle relative to the front panel of the sign.  
         BACKGROUND OF THE INVENTION  
         [0002]    Illuminated display signs are presently in widespread use. Examples of such products include highway and roadway signs, stadium message boards, commercial signage and advertising billboards. Illuminated signs typically employ text and/or graphics.  
           [0003]    Traditionally, illuminated signs utilized incandescent bulbs. More recently however, this type of signage has been replaced in many cases by electronic signs and displays. Such products require significantly less energy and are far less costly to operate than incandescently illuminated signage. For example, a display sign which costs $1,000 per month to operate using incandescent lighting may cost only about $40 per month if LED (light emitting diode) bulbs are substituted. LED bulbs also tend to burn out and require replacement far less frequently than incandescent lights.  
           [0004]    Most known electronic signs utilize a plurality of electronically controlled LED clusters. Each cluster features a plurality of LED pixels mounted in a cluster housing. The housing is fastened to a generally front panel of the sign&#39;s cabinet. The pixels are interconnected to the electronic controls by appropriate wiring that is connected to the cluster through an opening at the front panel of the panel. Electronic signs and message boards of this type are presently used in many varied applications by federal, state and municipal governments, as well as by private businesses.  
           [0005]    Although they are fairly cost efficient to operate, known electronic signs, displays and message boards exhibit certain shortcomings. Quite often, the existing cabinet of an incandescent sign is retrofit to accommodate multiple LED clusters. This presents a particular problem for existing roadside signs, which are often oriented so that the front panel of the cabinet is substantially perpendicular to the direction of the roadway. When a conventional LED cluster is mounted to such a cabinet, the LED pixels extend outwardly in a generally straight or perpendicular direction from the front panel of the cabinet. As a result, the light is projected from the electronic sign in a fairly narrow conical pattern that generally parallels the roadway. Such signs tend to provide oncoming drivers with a relatively narrow and optically inferior viewing angle. The driver may have only a relatively short distance and period of time to adequately view and read the sign. Optimal viewing is achieved only when the driver views the LED clusters more or less directly. However, because the conventional LED clusters are directed more or less parallel to the highway, it becomes difficult, if not impossible, for the driver to obtain a direct view of the sign, particularly as he or she approaches the sign and arrives at a convenient viewing distance (e.g. 2-3 blocks from the illuminated sign). At this point, the LED clusters usually must be observed peripherally and an inadequate viewing quality is provided.  
           [0006]    The foregoing problem is further complicated because governmental rules and regulations often prevent the electronic sign from being angled toward the roadway or otherwise modified to provide drivers with a more direct view of the LED clusters. Even where retrofitting of the existing cabinet is permitted, many jurisdictions prohibit reconstruction or reconfiguration of the cabinet. In other situations, it is either logistically, structurally or economically infeasible to modify or otherwise reposition the sign to provide more direct and optically effective viewing. Even where structural modifications are permitted, it can be unduly complex and expensive to reposition an existing cabinet or to install an entirely new sign. LED clusters that provide wider viewing angles are currently available. However, such products tend to provide for rather poor viewing quality when observed from straight ahead. A significant need exists for a less expensive and yet more optically effective means for installing electronic signs and for retrofitting existing signage to accommodate LED clusters.  
         SUMMARY OF THE INVENTION  
         [0007]    It is therefore an object of the present invention to provide an assembly for mounting an LED cluster to an electronic sign so that the cluster may be positioned on the sign as needed to provide for more direct and thereby significantly improved viewing as the sign is approached at a convenient distance.  
           [0008]    It is a further object of the invention to provide an assembly for quickly and conveniently mounting LED clusters to an electronic sign cabinet and orienting such clusters at a selected angle to provide for improved optical quality and more effective viewing of the sign.  
           [0009]    It is the further object of this invention to provide an assembly for mounting LED clusters to an electronic sign in an angled manner so that an ideal view is achieved at a preferred, predetermined distance from the sign.  
           [0010]    It is the further object of this invention to provide an assembly for quickly and conveniently retrofitting existing illuminated sign cabinets with LED clusters.  
           [0011]    It is the further object of this invention to provide an assembly for mounting LED clusters to existing incandescent sign cabinets, which permits such cabinets to be effectively retrofit according to applicable governmental rules and regulations.  
           [0012]    It is the further object of this invention to provide an assembly which permits LED clusters to be quickly and conveniently replaced as required on the panel of an illuminated display sign.  
           [0013]    It is the further object of this invention to provide an assembly for mounting LED clusters in an electronic sign, which may be used in virtually all electronic signage applications.  
           [0014]    It is the further object of this invention to provide a mounting assembly for an LED cluster, which may be utilized effectively to provide an angled LED orientation in either a new electronic sign or in a retrofit sign cabinet.  
           [0015]    This invention results from a realization that improved viewing of an electronic sign may be achieved by angling the LED clusters relative to the sign cabinet as needed to improve the optical quality of the sign as the viewer approaches the sign. This invention features an assembly for mounting an LED cluster to the front panel of an electronic sign cabinet. The LED cluster, which is known, includes a housing that supports a plurality of LED pixels directed outwardly from a forward face of the housing along respective axes substantially perpendicular to the forward face and one or more associated conductors (wires) electrically connected to the pixels. The mounting assembly includes a forward section for connecting to and supporting the cluster housing. There is a rearward section connected to the forward section. The rearward section is selectively attachable to the sign such that an inner face of the rearward section is substantially flushly interengaged with the front panel of the sign cabinet. The forward and rearward sections include at least one conduit for communicating with corresponding openings in the cluster housing and the sign cabinet and for accommodating the one or more associated conductors of the pixels. The forward and rearward sections are angularly oriented relative to one another, such that when the forward section is connected to the cluster housing and the rearward section is connected to the sign cabinet, each LED pixel is directed along an axis that extends at an acute angle relative to the front panel of the sign.  
           [0016]    In a preferred embodiment, the forward section includes an outer face that is flushly interengagable with a rearward face of the cluster housing. The outer face may include a connector that is selectively interengagable with a complementary connector carried by the rearward face of the cluster housing to attach the forward section to the cluster housing. The connector and the complementary connector may include at least one interengagable pin and receptacle. The forward section may include a threaded hole that is alignable with a corresponding threaded hole in the cluster housing for receiving a threaded component to attach the forward section to the cluster housing. Alternatively, the forward section may be permanently and unitarily attached to the cluster housing.  
           [0017]    The outer face of the forward section may be oriented at an acute angle relative to the inner face of the rearward section, which angle may correspond to the angle between the axis along which each pixel is directed and the front panel of the sign cabinet. A sealing component may be interposed between the interengaged inner face of the rearward section and front panel of the sign cabinet. A recess may be formed in the inner face for receiving the sealing component. The inner face may include a connector that is selectively engagable with a corresponding connector carried by the front panel of the sign to connect the rearward section to the sign. The connector and the complementary connector may again include at least one interengagable pin and receptacle. Typically, the acute angle is at least  1  and not greater than 45°.  
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0018]    Other objects, features and advantages will occur from the following description of a preferred embodiment and the accompanying drawings, in which:  
         [0019]    [0019]FIG. 1 a perspective view of a preferred mounting assembly in accordance with this invention, which is interposed between a respective LED cluster and a corresponding opening in the front panel of an illuminated electronic sign cabinet;  
         [0020]    [0020]FIG. 2 is a top plan view of the mounting assembly of FIG. 1;  
         [0021]    [0021]FIG. 3 is a front elevational view of the mounting assembly;  
         [0022]    [0022]FIG. 4A is a perspective view illustrating the mounting assembly operably interengaged with an associated LED cluster;  
         [0023]    [0023]FIG. 4B is a perspective view of an LED cluster that includes a mounting assembly in accordance with this invention permanently and unnaturally interconnected to the cluster housing;  
         [0024]    [0024]FIG. 5 is a top, partly schematic view of a plurality of LED clusters that are mounted to the front panel of an electronic sign and oriented at a desired angle through the use of the mounting assembly of this invention; and  
         [0025]    [0025]FIG. 6 is a schematic view illustrating an electronic sign featuring the mounting assemblies of this invention, which orient the LED clusters of the sign to direct light at an optimal viewing angle to an adjacent roadway. 
     
    
       [0026]    There is shown in FIG. 1 a wedged-shaped mounting assembly or adapter  10  for supporting an LED (light emitting diode) cluster  12  on the front panel  14  of an electronic sign cabinet  16 . It should be understood that LED cluster  12  panel  14  and cabinet  16  are conventional items, which will be well-know to persons skilled in the art. In particular, cluster  12  includes a plastic housing  18  having a forward face  20  through which project a plurality of LED pixels  22 . The pixels are mounted such that they extend generally perpendicularly outwardly from front face  20 . Various numbers and arrangements of pixels  22  may be utilized. The pixels are electrically connected to conventional conductive wiring  24 . According to the prior art, a plurality of LED clusters  12  are mounted directly to the front panel  14  of sign cabinet  16 . In particular, the reverse side of housing  18  of LED cluster  12  (obscured in FIG. 1) carries a pair of mounting pins (see pins  64  in FIG. 5) which are received in corresponding slots or receptacles  26  (FIG. 1) of panel  14 . Wiring  24  extends through panel opening  28  and is connected to the electronic power source and controls of the sign in a known manner. As with the LED cluster, panel  14  and sign cabinet  16  are conventional components that are presently available in various electronic and incandescent display signs. In electronic signage applications, an appropriate electronic power source and controller are utilized to operate the LED clusters.  
         [0027]    The present invention modifies the existing and commercially available electronic signs by utilizing a wedge-shaped adapter or mounting assembly  10 , which enables cluster  12  to be mounted to the cabinet and directed or pointed at a desired angle. Assembly  10 , which is shown alone in FIGS. 2 and 3, preferably features a plastic construction, which is the same or analogous to that utilized by housing  18  of LED cluster  12 . Typically, assembly  10  features a one piece molded construction. In particular, assembly  10  includes a forward section comprising a generally planar outer face  30  and an oppositely facing rearward section comprising a generally planar inner face  32 . An intermediate body portion  34  extends unitarily between the inner and outer faces. As best shown in FIG. 2, outer and inner faces  30  and  32  are oriented at an acute angle relative to one another. This angle is preferably at least 1° and no greater than 45°. The angle is selected to position the LED cluster at a corresponding angle relative to the sign panel. This is explained and described more fully below.  
         [0028]    Outer face  30  includes a shallow annular groove  38  (FIG. 1) that surrounds a concentric annular flange  40 . As best shown in FIG. 3, the opposite, inner face  32  includes an annular recess  42  that accommodates an elastomeric “O” ring or seal  44 . A plurality of openings are formed through the intermediate body portion  34  between outer face  30  and inner face  32 . In particular, upper and lower rectangular openings  46  and  48  extend fully through the mounting assembly from the outer face to the inner face. Likewise, a smaller pair of circular openings  50  extend completely through the mounting assembly. Inner face  32  includes a central pocket  52 . A central orifice  54  is formed in the bottom of pocket  52 . As shown in FIG. 1, orifice  54  extends from the bottom of the pocket through outer face  30 . The function of these openings is explained more fully below.  
         [0029]    A pair of receptacles  56  (FIG. 1) are formed in outer face  30 . Again, these receptacles are formed interiorly of annual flange  40 . These openings are designed to be interengaged by the standard pins carried by the back of housing  18  of LED cluster  12  (See pins  64  in FIG. 5). This operation is likewise described more fully below.  
         [0030]    As best shown in FIG. 3, a pair of positioning and mounting pins  58  extend unitarily from inner face  32  of mounting assembly  10 . These pins are positioned to engage respective receptacles  26  (FIG. 1) in sign panel  14 . This enables the mounting assembly and attached LED cluster to be properly positioned and mounted on the front panel of the electronic sign cabinet.  
         [0031]    Wedged-shaped mounting assembly  10  is attached to LED cluster  12  in the manner best shown in FIG. 4A. Outer face  30  of assembly  10  has a configuration that generally matches the rearward profile of housing  18  of LED cluster  12 . The outer face  30  of mounting assembly  10  is juxtaposed against the back surface of the LED cluster housing in the manner best shown in FIG. 5. The standard rearward extending connector pins  64  of cluster  12  are inserted, as indicated by arrows  66 , into respective slots  56  of assembly  10 . The mounting assembly and LED cluster are then pushed together and joined as shown in FIG. 4A. When the outer face  30  of mounting assembly  10  interengages the rearward face of LED cluster housing  18 , the standard “O” ring carried by the LED cluster surrounds flange  40  and effectively seats in narrow groove  38  of outer face  30 . As a result, the mounting assembly sealably interengages the rearward face of the LED cluster. Wiring  24  (FIG. 1) is disposed through one of the openings  46 ,  48  and  50  formed through mounting assembly  10 . It should be noted that the openings formed through the mounting assembly may vary in number, size and position so that the wiring and conductor arrangements of various known LED clusters may be conveniently accommodated. Wiring  24  thereby extends outwardly from the inner surface  32  of mounting assembly  10  and is introduced into cabinet  16  through opening  28 . An appropriate electrical connection is made with the electronic controls and power source of the sign in a known manner.  
         [0032]    After mounting assembly  10  is joined to LED cluster  12  in the foregoing manner, the assembled product, shown in FIG. 4A, is attached to the front panel  14  of sign cabinet  16  in the manner best shown in FIG. 5. Specifically, the rearwardly extending pins  58  are engaged in the direction of arrows  70  against the front panel  14 . The inwardly extending pins  58  of each other assembly  10  are similarly inserted into respective mounting/positioning slots  26  (FIG. 1) formed in front panel  14  of sign  16 . When the inner surface  32  of mounting assembly  10  is engaged against panel  14 , “O” ring  44  sealably interengages the front panel. This prevents moisture and heat from the sign from entering the cabinet and interfering with operation of the sign. As shown in FIG. 5, an array of any number of LED clusters  12  are secured in an analogous manner to the front panel of the sign. In each case, the attached mounting assembly  10  supports the LED cluster at a predetermined or selected acute angle relative to front panel  14 . This angle corresponds to the previously described acute angle formed between outer face  30  and inner face  32  of assembly  10 . Each LED pixel is thereby directed along a respective axis  80  that forms the selected acute angle with front panel  14  of sign  16 . The LED clusters, which are connected through conductive wiring  24  to the electronic power source controls of the sign, are then operated in a known manner to provide the desired textural and/or graphic display. The LED clusters may be arranged and powered in any manner required to relay a selected message or graphic display.  
         [0033]    Because the LED pixels direct their light along angled axes  80 , the electronic sign provides for significantly improved optical viewing. This advantage is best exhibited in FIG. 6. Therein, electronic.sign cabinet  16  includes a pair of opposing front panels  14  that face in opposite directions adjacent to a highway H. When LED clusters are mounted in a manner according to the prior art, a viewing cone or region  100  is generated. This provides an undesirable viewing angle as the driver approaches the sign. The sharpest, straight-ahead view of the sign is unavailable from the roadway, at least at the optimally proximate zone Z of vehicle V 1  approaching the sign. Moreover, due to commonplace governmental regulations, the existing sign  16  cannot be reconfigured to angle panel  14  toward zone Z for optimal viewing. Accordingly, a significantly viewing angle is achieved by utilizing the mounting assembly described above. Assemblies  10  angle and redirect the LED pixels so that they project the light through optimal viewing regions  102  in opposing directions along the roadway. The angle at which the light is redirected may be adjusted by selecting mounting assemblies having a corresponding acute angle so that the optimal viewing region  102  is entered by a driver within a reasonable and convenient distance from sign  16  (i.e. within zone Z). The angle can be selected as needed for any particular application and highway environment. The range of angles may vary from at least 1° to preferable not greater than 45°. It has been determined that this provides for optimal viewing characteristics at a distance of about 2-3 city blocks from the sign. At the same time, the structure and orientation of underlying sign cabinet  16  and panels  14  do not have to be altered.  
         [0034]    In the alternative embodiment of this invention shown in FIG. 4B, a wedge-shaped mounting assembly is formed integrally and unitarily with housing  18   a  of LED cluster  12   a . In this version, the inner face of the LED cluster is simply formed at a selected acute angle relative to the forward face  20   a  of the cluster. The previously described interconnection between the mounting assembly and the housing of the LED cluster is eliminated. Instead, the housing of the LED cluster effectively includes a wedge-shaped inner or rearward section that directly engages the front panel of the cabinet in the previously described manner so that the LED pixels are supported at an acute angle. This angle is equivalent to the angle formed between the rearward face of the LED housing and the forward face of the LED cluster. The openings formed through the rearward section of LED housing  18   a  (i.e. through the unitary mounting assembly  10   a ) are similar or identical to those shown in the previously described embodiment. In this version, only a single seal is utilized. The rearward face of the LED housing effectively resembles the inner face of the preferred mounting assembly  10  shown in FIG. 3. In this embodiment, only a single sealing element is utilized. The complexity and additional structure required for releasably innerconnecting the mounting assembly to the LED housing are eliminated. This version allows selectively angled LED housings to be installed or retrofit into electronic display panels. The version of FIGS. 1-5 allows conventional, non-angled LED clusters to be attached to the panel in an angled manner.  
         [0035]    From the foregoing it may be seen that the apparatus of this invention provides for an assembly for mounting an LED cluster to the cabinet of an electronic sign at a selected angle. While this detailed description has set forth particularly preferred embodiments of the apparatus of this invention, numerous modifications and variations of the structure of this invention, all within the scope of the invention, will readily occur to those skilled in the art. Accordingly, it is understood that this description is illustrative only of the principles of the invention and is not limitative thereof.  
         [0036]    Although specific features of the invention are shown in some of the drawings and not others, this is for convenience only, as each feature may be combined with any and all of the other features in accordance with this invention.