Abstract:
A light-emitting diode (LED) curtain display system includes LED lighting units on at least one LED light string that are attached to a non-rigid curtain. Each LED lighting unit is held within a central opening of a washer. The washer is attached to the reverse face of the curtain fabric, such as with adhesive, so that central opening substantially aligns with a hole formed through the fabric. Each LED lighting unit is visible from the display side of the curtain through its respective hole. The LED lighting unit may be so mounted with or without a covering dome lens. The LED light strings are attached by Ethernet connections to a computer control so that the LED lighting units may be jointly or individually activated.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention pertains to a curtain with a plurality of LED lighting units mounted at desired spaced locations on the curtain providing selectable colors and visual effects controlled by a computer program, and methods for attaching said LED lighting units to the curtain.  
       BACKGROUND OF THE INVENTION  
       [0002]     Various image display systems have become very popular for use in arenas, in theatres, at special events, and at other public gatherings. These image display systems are used to communicate text and/or stationary or animated images to large audiences to enhance the entertainment or marketing experience.  
         [0003]     One popular backdrop for theater and special event lighting is a fiber optic curtain, such as shown in U.S. Pat. No. 5,066,085 to Gimbutas et al. The tips of fiber optic strands are bonded to a curtain fabric. The other ends of the strands are connected to a programmable light source. Before the light source is activated, the curtain has an attractive front face and the fiber optic tips are not visible to an audience. When the light source is activated, bright pin points of light are visible from the fiber optic strand tips. Color and lighting intensity is varied by varying the light source. The present invention seeks to improve upon the fiber optic curtains shown in the Gimbutas et al patent.  
         [0004]     Light emitting diodes (“LED”s) are available in the primary light colors of red, green and blue. When current is passed through an LED, energy is released to create light. The color of the emitted light is a function of the materials forming the diode. Generally, an LED is formed from a light-emitting semiconductor material or die mounted on a reflector cup. A cathode lead, an anode lead and a bonding wire are connected to the semiconductor material. Frequently, an LED has a light-transmitting dome or protective cap extending over the light-emitting semiconductor material and reflector cup. LEDs have been inserted into hard-wired boards to make signs or solid display systems.  
         [0005]     U.S. Pat. No. 6,016,038, issued to Mueller et al., describes an LED lighting assembly with a pulse width modulated current control where each current-controlled unit is uniquely addressable and capable of receiving intensity and color information from a computer software program. The Mueller et al. invention includes a binary tree network configuration of lighting units called nodes. The disclosed LED lighting assembly contains heat-dissipating housing made out of heat-conductive material. The heat dissipating housing contains two stacked circuit boards holding the power module and the light module. Each light module has at least two, but can contain up to three, primary colors, typically red, blue and/or green that can be combined in different proportions to generate almost any color in the visible spectrum. A computer program creates the LED illumination to provide complex, custom designed images in almost any environment. The present invention seeks to improve this technology by affixing LED nodes at predetermined position and orientation within a curtain to create an LED curtain display system.  
         [0006]     U.S. Pat. No. 5,900,850, issued to Bailey et al., discloses an image display system constructed of a plurality of panels formed by flexible straps that extend vertically and horizontally with a plurality of LEDs mounted on the straps at fixed positions to form an LED matrix supported by “upstanding towers” or “column members” of a “conventional truss type” construction. Bailey et al. indicate that their image display system is portable, and capable of being erected on, behind or adjacent to a performance stage. However, this display system requires a support structure, such as towers and beams shown in  FIG. 1 . The display system can never be retracted or extended during a performance or marketing presentation. Moreover, in the Bailey et al display system the support hardware remains visible to an audience even when the system is not activated. The system thus has an unattractive appearance both when activated and when not activated.  
         [0007]     U.S. Pat. No. 6,362,801, issued to Yuhara, is another example of an impractical image display system. Yuhara discloses a flexible net having a mesh portion with the LED display modules attached to the flexible net as pixels. A major disadvantage of this net-type LED display structure is that it is difficult to precisely position the individual LED pixels so that each LED beam projects in unison with other LED beams to create a clean, precise stationary or animated image. Another disadvantage is that the connecting wires and LED mounting hardware remain visible to an audience when the system is not activated for display. The system thus has an unattractive appearance both when activated and when not activated.  
         [0008]     U.S. Pat. No. 6,677,918, issued to Yuhara et al., discloses an LED display system comprising a plurality of rigid frames positioned in at least one vertical stack to form a planar vertical display. This display system has the same problems as Bailey et al, in that it must be assembled and disassembled each time, and cannot be retracted or extended once a performance has begun. Additionally, the Bailey et al and Yuhara et al systems cannot completely drape a typical stage or platform with their respective LED displays because of their inherent size limitations. By contrast, a curtain or drape may be designed to variably cover the length and height of a stage or any portion thereof. In addition, Yuhara et al suffers the same appearance drawbacks as Bailey et al and Yuhara.  
       BRIEF SUMMARY OF THE INVENTION  
       [0009]     In a first aspect, an LED curtain display system includes a non-rigid curtain having a display side and a reverse side that may be mounted or hung for display such as at a special event or a theatrical performance. The curtain is thus retractable and portable, and presents an attractive appearance both when dormant and when illuminated.  
         [0010]     The non-rigid curtain preferably is of fabric, which may be treated to be flameproof. The curtain may be formed by joining multiple fabric panels together. The curtain defines one or more holes substantially therethrough and arranged in a desired display pattern. One or more washers each defining a central opening, are fastened to the reverse side of the curtain, with the central openings of the washers substantially aligned with the holes in the curtain in one to one relation. Preferably, the washers are fastened with an adhesive to the reverse side of the curtain. Each washer has an associated LED lighting unit from an LED light string. Each of said LED lighting units is inserted through the central opening of its respective washer, and may be held in place by force fit or by adhesive or other fastening means. The LED portion of the lighting units is visible from the display side of the curtain. Multiple LED lighting units form a visible display pattern on the display side of the curtain when said LED lighting units are activated.  
         [0011]     Preferably, the LEDs of the LED light string are capable of illuminating the primary colors of light. The LED curtain display system may be controlled by computer program control through an Ethernet connection. Each LED light string is electrically coupled to a cable connector affixed to said curtain and preferably located at one end of the curtain running vertically. The cable connector joins the LED light strings together and links them by cable through an Ethernet connection and Ethernet power supply to a computer and to a light systems engine adapted for use with LED light strings.  
         [0012]     In a second aspect, a method of making an LED curtain display system includes (a) forming a plurality of holes through the curtain fabric; (b) affixing a plurality of washers to the reverse side of the curtain fabric, wherein each washer defines a central opening and the washers are affixed such that the central opening of each washer substantially aligns with one of the holes through the curtain fabric; (c) fitting each LED lighting unit from an LED light string through the central opening of a respective washer in the plurality of washers, so that each of said LED lighting units is visible from the display side of the curtain fabric; (d) connecting said LED light string by male and female connectors to a main connector cable; (e) connecting said main connector cable to an Ethernet power supply, an Ethernet-based hardware controller and a computer containing an LED illumination control program. It is possible to pre-affix the washers to the respective LED lighting units before affixing the washers to the reverse side of the curtain fabric. It is also possible to affix the washers to the reverse side of the curtain before forming holes in the curtain fabric. Preferably, the washers are affixed to the curtain with an adhesive. Optionally, the LED lighting unit may be attached to the washer by force fit or may be attached with an adhesive.  
         [0013]     Novel features and advantages of the present invention in addition to those noted above will become apparent to those of ordinary skill in the art from a reading of the following detailed description in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is a schematic elevational view showing a curtain comprising an LED display connected to a computer;  
         [0015]      FIG. 2  is a fragmental front elevational view showing an LED lighting unit without a covering lens mounted to the curtain;  
         [0016]      FIG. 3  is a fragmental rear elevational view of the LED lighting unit of  FIG. 2  showing the rear face of the curtain with the LED housing inserted through a supporting washer, and the three-wire 18 AWG cable extending horizontally through the LED housing;  
         [0017]      FIG. 4  is a fragmental side elevational view partially in cross section showing one method of attaching an LED lighting unit to a curtain;  
         [0018]      FIG. 5  is side elevational view of a modified LED having a dome lens;  
         [0019]      FIG. 6  is a schematic view of an Ethernet-based control system for strands of LED lighting units of an LED curtain display system; and  
         [0020]      FIG. 7  is a pictorial view of a fiber optic curtain with light projector and controller. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     Referring particularly to the drawings, wherein like numerals denote identical parts in the various views,  FIG. 1  is a schematic front elevational view showing the display side of an LED curtain display system  10  of the invention. The LED curtain display system  10  has a curtain  24  formed of one or more panels of a fabric or cloth, such as a flame-proofed 100% cotton, black velour material with a weight of 18 to 21 oz. A flame-proofed polyester or cotton polyester blend or denim fabric may also be used. Other fabrics suited to the environment in which the curtain will be installed may be selected. The fabric should be of sufficient weight or thickness to hold the LEDs in desired orientation without pulling or tearing. In addition, other fabric colors may be used. The chosen fabric preferably does not permit light to permeate therethrough so that the curtain has an attractive appearance from its front or display side whether or not the light sources are activated.  
         [0022]     Multiple LED light units  14  or nodes are installed in an LED light string  12 . The LED light string  12  preferably includes a three-wire 18 AWG cable  48 , and the LED light units  14  are spaced apart along the cable  48  to form the LED light string  12 . Preferably, multiple LED light units  14  from multiple LED light strings  12  are installed into the LED curtain display system  10 . As illustrated in  FIG. 1 , for example, at least six LED light strings  12  are incorporated into the LED curtain display system  10 . As illustrated, multiple rows of LED strings  12  are placed in parallel, horizontal rows with an equal distance A between each lighting unit  14  and an equal distance B between each row. The curtain display system  10  is illustrated in a partially cut away view in  FIG. 1 . Hence, any number of LED light strings  12  may be incorporated as desired. Moreover, any orientation may be provided, such as in regular rows forming a matrix as shown in  FIG. 1 , or in regular columns forming a matrix, or in an irregular orientation wherein the LED light strings  12  are curved or partly curved, or wherein the distances A and B are varied.  
         [0023]     In  FIG. 1 , a cable connector  18  runs lengthwise down one end of the curtain  24 . Preferably, the cable connector  18  is joined to the reverse side of the curtain  24  by hook and loop fasters (e.g., VELCRO fasteners), but may also be held in place by other fastening means, such as adhesive or a sewn pocket in the hem or selvage of the curtain  24 . Each LED light string  12  is provided with an electrical coupling  44  or multi-pin connector for connection to the cable connector  18 . The LED light strings  12  are joined together with the cable connector  18  to form an electrical circuit. One end of the cable connector  18 , the bottom end in  FIG. 1 , is joined to a multi-pin connector, which in turn is connected to one or more Ethernet power supplies. The power supply data runs to a Light System Manager that may be programmed by computer  16 . The vertically running cable connector  18  delivers the programmable signals from the computer  16  and the Light System Engine that control the LED display from the individual LED light units  14 .  
         [0024]     Preferably, the LED light strings  12  are iColor™Flex SL light strings manufactured by Color Kinetics, Inc. of Boston, Mass. An alternative LED light string is shown in U.S. Pat. No. 6,461,019. The iColor™Flex SL light strings include LEDs that may be activated to illuminate the three primary colors of light, red, green and blue, such that lighting displays featuring variant colors of the visible spectrum may be programmed. The computer controls the LED display by means of a “Light System Manager”, i.e., an integrated software/hardware product manufactured by Color Kinetics, Inc., of Boston, Mass. The Light System Manager™ is composed of the Light System Composer™, i.e., an illumination control software program, and the Light System Engine™ 70, an Ethernet-based hardware controller that stores and plays a large number of light show effects based on time of day and event scheduling. The Light System Manager  60  may be operatively connected between a computer and the LED light strings  12 . Further details of this connection are described below with reference to  FIG. 6 .  
         [0025]     At the top of the curtain  24  a webbing strip  20  with grommets  22  may provide a means for hanging the curtain  24  by straps or hooks  26  to a curtain rod (not shown). At the bottom of the curtain  24  a weighted pocket  28  is provided in the hem.  
         [0026]      FIG. 2  is a fragmental front elevational view showing the display side of the curtain  24  with an LED lighting unit  14 , without a dome lens, attached. The LED lighting unit  14  comprises one or more LEDs  15  within a reflector cup and held within a housing  30 . The housing  30  or node is inserted through a predetermined hole  32  formed in curtain  24 , and is supported by a washer  34 . The washer  34  is affixed (preferably glued) to the reverse side of the curtain fabric  36 . A layer of adhesive  38  substantially covers the washer surface adjacent to the reverse surface of the curtain  24  to hold the LED lighting unit  14  in place, as shown in  FIG. 4 . A preferred washer is a vulcanized fiber-reinforced washer with an adhesive backing that has an outer diameter of 1.25″, an inner diameter of 0.515″ and a thickness of 0.047″. Any washer or grommet that reinforces the hole  32  and retains the LED lighting unit  14  in place can be used. If the washer does not include an integral adhesive backing, a preferred adhesive that may be applied to the washer surface is a styrene-based clear adhesive sealant.  
         [0027]     The washer  34  simultaneously (a) reinforces the hole  32  formed in the curtain  24 , much like a grommet, and (b) securely holds the LED lighting unit  14  in a desired orientation. When viewed from the display side of the curtain  24 , preferably only the reflector cup and LEDs  15  are visible to the audience, and the housing  30 , washer  34 , and cable  48  remain at the reverse side of the curtain. Preferably, the LED lighting unit  14  is installed such that the LED and associated reflector cup are flush with or nearly flush with the display side surface of the curtain. Most preferably, the LED lighting unit  14  is installed such that the LED and associated reflector cup are substantially parallel with the display side surface of the curtain such that the LED lighting unit will project light outwardly and substantially orthogonally to the display side surface of the curtain.  
         [0028]      FIG. 3  is fragmental rear elevational view showing the reverse side of the curtain fabric  36 , a washer  34  fastened (e.g., glued) thereto, and the back of the LED housing  30  with its adjacent three-wire 18 AWG cable  48 , firmly supported by the washer  34  and force fit (e.g., snapped into a central opening of the washer  34 ) or glued into place through a central opening defined by the supporting washer  34 .  
         [0029]      FIG. 4  best illustrates one method of assembling an LED curtain display system  10  according to the invention. First, a plurality of holes  32  are formed into the curtain  24  at predetermined positions  32  as shown in  FIG. 1 . The holes  32  may be cut with a scissors, punched with an awl, drilled with a hollow drill bit, or other suitable punching means. If a matrix or design is desired, a template (not shown) may be used to direct placement of the holes  32  within the curtain  24 . Next, a washer  34  is fastened (e.g., glued with adhesive  38 ) to the reverse side  36  of the curtain  24  so that the central opening  40  of the washer is aligned with a respective hole  32  in the curtain  24 . Alternatively, the washers  34  may be applied to the reverse side of the curtain  24  before the holes  32  are formed therein.  
         [0030]     Once the washer  34  is applied and the hole  32  is formed in the curtain  24 , the node of the associated LED lighting unit  14  is inserted through the opening  40  in the washer and the hole  32  in the curtain so that the LED housing  30  slightly extends beyond the display side of the curtain fabric  36 . The washer  34  surrounds the housing  30  of the LED lighting unit  14  and holds the LED lighting unit  14  into place and in desired orientation with respect to the display side surface of the curtain  24 . The housing  30  is thus press-fit within the opening  40  in the washer  34 . Alternatively, if so desired, washers  34  can be pre-attached to the housings  30  of LED lighting units  14  on the LED light string  48  before each washer  34  is attached or glued to the reverse side of the curtain  24 .  
         [0031]      FIG. 5  shows an LED lighting unit  14   a  having a dome-shaped lens  46  attached to the housing  30 . The LED lighting unit  14  shown in  FIGS. 2-4  does not include a lens. However, different lighting effects and different curtain display effects can be provided with LED lighting units that incorporate lenses. Thus, a dome-shaped lens  46  or other shaped lenses can be affixed to an LED lighting unit to vary the light refraction as preferred.  
         [0032]     After the LED lighting units  14  are securely affixed to the reverse side of the curtain  24 , the leader portion of the three-wire 18 AWG cable  48  of the LED light strings  12  are connected by male and female connectors  44  to a vertically running cable connector  18  that is, in turn, connected by cable to an Ethernet power supply and an Ethernet hub, which is in turn connected to a computer  16 , completing an electrical circuit. The wire leads from the first LED lighting unit  14  are routed along the inside edge of the curtain and secured. All wire leads from the LED lighting units  14  on a string  12  are gathered and the ends are fitted into a multi-pin connector. The multi-pin connector runs to power supplies with either a multi-pin break out adapter cable or other form of connection.  
         [0033]     Referring to  FIG. 6 , wires  62   a ,  62   b  from the LED lighting units  14  extend to an Ethernet power supply  64  that is in turn routed through Ethernet control cable  66  to an Ethernet hub  68 . The Ethernet hub  68  is electrically connected through Ethernet control cable  72  to a Light Systems Engine  70 , such as available from Color Kinetics. The Ethernet hub  68  is further connected through Ethernet control cable  74  to computer  16  so that programmable data from the Light Systems Control software is transmitted to the hub  68 .  
         [0034]     With the capability to use a variety of light colors and patterns, the present invention can project light in a matrix or design such as a company or private logo, as well as in any random color display. The illumination patterns may be varied by varying the placement of the LED lighting units  14  within the curtain, and/or by varying the illumination color and intensity of individual LEDs  15  in the LED light strings  12  via computer program control. Thus, static illumination displays and active displays coordinated to music or other timed sequences may be presented. The curtain  24  can be used as a backdrop for the theatrical, special event and entertainment industry or other commercial and domestic use.  
         [0035]     It is also within the scope of this invention to combine LED lighting units and fiber optic lighting such as disclosed in U.S. Pat. No. 5,066,085, which patent is incorporated by reference herein, into one curtain display system. Thus, as shown in  FIG. 7 , the distal ends of one or more fiber optic strands  50  may be affixed, such as with adhesive, to the curtain so that the tips of the fiber optic strands are visible from the display side of the curtain. Then, the proximal ends of such fiber optic strands  50  may be connected to a light source  52  that is in turn connected to a controller  54  or computer.  
         [0036]     Many other desirable and advantageous features of this invention will become apparent from the foregoing disclosure. Moreover, while this disclosure explains important aspects of this invention in considerable detail for purposes of illustration, it will be understood by those skilled in the art that many of these details may be varied without departing from the spirit and scope of the invention.