Front and rear removable panel for electronic displays

Display apparatus and methods of making them are disclosed. The display apparatus includes frame members assembled to form a frame for the display apparatus and display modules configured for displaying at least a portion of an adaptable image. Each display module is coupled to the frame members to form a matrix organization of display modules for the display apparatus. The display module includes a removable panel and apertures formed therethrough. The apertures are arranged as pixel rows including pixel arrangements distributed along each pixel row. The display module also includes coupling devices attached to the removable panel, which are configured for detachably coupling the removable panel to the frame members, wherein the coupling devices may be operated to attach or remove the removable panel. Furthermore, the coupling devices are configured such that they can be operated from a front side or from a back side of the removable panel.

CROSS-REFERENCE TO RELATED APPLICATION

This application is related to U.S. patent application Ser. No. 12/416,856, filed on Apr. 1, 2009, pending, titled “Incident Light Management Devices and Related Methods and Systems,” assigned to the assignee of the present application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to displaying images, more specifically, to displaying images on display boards and billboards.

2. State of the Art

Billboards and large signs have been used for many years to convey information to passersby such as advertising, traffic messages, and the like. Traditionally these signs and billboards were only capable of delivering a single message or advertisement. This message was generally printed on strips of paper that were then adhered to the billboard. To change the message, new paper needed to be printed and adhered to the billboard.

More recently, display boards and billboards have become electronic using lights, light-emitting diodes (LEDs), and combinations of the two to display a visual message that could be easily adaptable to display a wide variety of messages in the form of words and images from the same sign without having to physically change the characteristics of the sign. These electronic boards can easily modify a graphic image or message to create video displays and modify the type of message or advertisement that is shown on the electronic board at regular intervals, or at targeted times depending on expected traffic near the sign, or public interest. These possible images are generally referred to herein as adaptable images.

While the adaptable images may be changed easily on these electronic boards, maintaining and servicing an electronic board with thousands (or even hundreds of thousands) of lights attached to the electronic boards can be problematic. Smaller removable panels, which may be tiled together, have been proposed to make this maintenance task easier. With smaller removable panels, a single panel may be removed for service or replacement.

Furthermore, removable panels create joints between the panels. These joints can be sources of misalignment between panels, which may cause an image that spans many panels to be distorted. In addition, these joints may lead to problems with protecting the LEDs, lights, circuit boards, and other electronic components from damage due to environmental factors.

Therefore, there is a need for an electronic display capable of displaying an adaptable image that can be easily serviced from both the front and the rear. Furthermore, there is a need for a modular design wherein the electronic display comprises a plurality of removable panels that are easily removable from both the front and rear for service or replacement. There is also a need to protect the electronic elements of the display apparatus and removable panels from environmental elements to increase the service life, reliability, and performance of the removable panels. In addition, there is a need for easily aligning these removable panels relative to each other to minimize image distortion for images that span multiple removable panels.

BRIEF SUMMARY OF THE INVENTION

The present invention provides electronic display apparatuses and methods of making the apparatuses, as well as removable panels configured as portions of a modular design for the electronic displays, wherein the removable panels may be attached and removed from both the front and rear of the electronic display. The removable panels may also be configured for attachment to a frame in such a manner that electronic elements are substantially protected from potentially damaging environmental elements.

One embodiment of the present invention comprises a display module for displaying an adaptable image or a portion of an adaptable image. The display module includes a removable panel including a plurality of apertures formed through the removable panel. The plurality of apertures are arranged as at least one pixel row comprising a plurality of pixel arrangements distributed along the at least one pixel row. Each pixel arrangement includes at least one aperture of the plurality of apertures. The display module also includes a plurality of coupling devices attached to the removable panel. The coupling devices are configured for detachably coupling the removable panel to a frame member, wherein the coupling devices may be operated to attach or remove the removable panel. Furthermore, the coupling devices are configured such that they can be operated from a front side of the removable panel or from a back side of the removable panel.

Another embodiment of the present invention comprises display apparatus for displaying an adaptable image. The display apparatus includes a plurality of frame members to form a frame for the display apparatus and a plurality of display modules configured for displaying an adaptable image or a portion of an adaptable image. The display module includes a removable panel including a plurality of apertures formed through the removable panel. The plurality of apertures is arranged as at least one pixel row comprising a plurality of pixel arrangements distributed along the at least one pixel row. Each pixel arrangement includes at least one aperture of the plurality of apertures. The display module also includes a plurality of coupling devices attached to the removable panel. The coupling devices are configured for detachably coupling the removable panel to a frame member, wherein the coupling devices may be operated to attach or remove the removable panel. Furthermore, the coupling devices are configured such that they can be operated from a front side of the removable panel or from a back side of the removable panel. In addition, each display module of the plurality of display modules is coupled to at least one of the frame members to form a matrix organization of display modules for the display apparatus.

Yet another embodiment of the present invention comprises a method of making a display apparatus, comprising forming a removable panel and forming a plurality of apertures through the removable panel such that the plurality of apertures is arranged in at least one pixel row. Each pixel row includes a plurality of pixel arrangements distributed along the pixel row wherein each pixel arrangement includes at least one of the plurality of apertures. The method also includes attaching a plurality of coupling devices to the removable panel, wherein the coupling devices are configured for detachable coupling to a frame member. Furthermore, the coupling devices are configured such that they can be operated from a front side of the removable panel or from a back side of the removable panel.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides apparatuses and methods of making the apparatuses for electronic displays and removable panels configured as portions of a modular design for the electronic displays, wherein the removable panels may be attached and removed from both the front and rear of the electronic display. The removable panels may also be configured for attachment to a frame such that electronic elements are substantially protected from potentially damaging environmental elements.

FIGS. 1A and 1Billustrate a front portion and a rear portion, respectively, of a display module100according to a representative embodiment of the present invention. A plurality of display modules100may be organized together to form a display apparatus. The display module100includes a removable panel110, which includes a plurality of apertures135(which may also be referred to herein as pixel holes, or simply as holes) formed though the removable panel110. The removable panel110may include multiple pixel rows120, wherein each pixel row120includes a plurality of pixel arrangements130, and each pixel arrangement130may include three apertures135for receiving light-emitting diodes (LEDs) (not shown), or other suitable light-emitting devices. Although the removable panel110is illustrated with a plurality of rows, those of ordinary skill in the art will recognize that within the scope of the present invention, the removable panel110may be formed of a single pixel row120. The removable panel110may be formed of any suitable material, such as, for example, plastic, fiberglass, or metal.

In the representative embodiments illustrated herein, the display module100includes a horizontal fin140(which may also be referred to herein as a louver) disposed above each pixel row120for shading the LEDs. The horizontal fin140creates a means for shading the pixel arrangements130from direct sunlight when installed outdoors, or from overhead light when installed indoors. Consequently, the horizontal fin140enables a higher contrast ratio, which may assist in viewing the billboard and making an adaptable image appear as if it includes greater intensity and more vibrant colors. In addition, the horizontal fins140may assist in drawing heat away from the LEDs and circuitry mounted behind the removable panel110. In the representative embodiments illustrated herein, the removable panel110is formed of plastic with the horizontal fins140also formed of plastic and as an integral part of the removable panel110. However, the horizontal fins140may be formed separately and, for example, be overlayed onto the front of the removable panel110. Embodiments of the present invention also may be formed of a dark colored material, which may further enhance the contrast ratio.

The removable panel110includes a front side150, a back side152, a protrusion162(shown in more detail inFIG. 5) extending from a top side154, and a receiving rim164(shown in more detail inFIG. 5) along a bottom side156. Also shown inFIGS. 1A and 1Bare a right side protrusion158and a left side protrusion160extending from the front side150of the removable panel110toward the back side152of the removable panel110. Spacers185may be disposed on the back side152, which may be used to create an offset of a circuit board relative to the back side152of the removable panel110as is explained more fully below with respect toFIGS. 6A-6D.

For attachment, the representative embodiment of the removable panel110illustrated inFIGS. 1A,1B, and1C includes four coupler holes180formed through the removable panel110. These coupler holes180are configured for receiving coupling devices (not shown) that may be used for coupling the removable panel110to frame members of a full display apparatus. Of course, the other embodiments of the removable panel110may include less than, or more than, the four coupler holes180illustrated inFIGS. 1A-1C.

FIG. 1Cillustrates a front view of the removable panel110according to the representative embodiment of the present invention illustrated inFIGS. 1A and 1B.FIG. 1Cmore clearly illustrates a representative placement of pixels arrangements along the pixel rows120and the three apertures135for each pixel arrangement130.FIG. 1Calso illustrates the coupler holes180in the removable panel110configured for receiving coupling devices190, which may be used to attach the removable panel110to a frame. The coupling devices190and attachment of the removable panel110to a frame are shown inFIGS. 4A and 4Band are explained more fully below in the discussion of those figures. Also shown are recesses170, wherein each recess170encompasses the three apertures135comprising a pixel arrangement130. The recesses170may be seen in more detail inFIGS. 6A-6Dand are explained more fully below in the discussion ofFIGS. 6A-6D.

Of course, those of ordinary skill in the art will recognize that other pixel arrangements130are contemplated within the scope of the present invention. For example, a pixel arrangement130may include a single hole for a single light element or two holes for two light elements such as, for example, LEDs. Such a configuration of one or two LEDs may be used for a monochrome display, or may be configured with multi-color LEDs for each pixel, such that a multi-color display may be achieved even from a single LED for each pixel. In the representative embodiments illustrated herein, three holes are used for a pixel arrangement130such that the light from a red LED, a green LED, and a blue LED may be combined to generate any possible color for a full color spectrum video display capable of showing still images and video images using conventional computer color maps. In addition, in some cases it may be desirable to include different colors of LEDs, or include more than one LED of the same color. As a result, pixel arrangements130may also include four or more apertures135for including a variety of LED colors.

FIG. 2illustrates a plurality of display modules100arranged in a matrix organization to comprise a display apparatus200. These modules may be arranged in a variety of configurations for different applications. For example, the matrix organization may include a single row of removable panels110(or a single column of removable panels110) for creating a narrow yet long display, which may be suitable for displaying messages in a traveling ticker-tape type of arrangement. A small number of removable panels110may be used to create a relatively small display apparatus200, or a large number of removable panels110may be arranged to create a relatively large display apparatus200. By way of example, and not limitation, a relatively large billboard size display apparatus200may include a matrix organization of 1100 or more removable panels110in a rectangular configuration.

FIG. 3illustrates an exploded view of display modules100for attachment to frame members210as part of the display apparatus200. In the presently described embodiment, the frame members210extend vertically and each removable panel110may be placed in a removable panel position205such that it abuts a neighboring display module100horizontally. The display modules100also may be stacked vertically to form the overall display apparatus200for presenting the adaptable image. The overall display apparatus200may be configured to display an adaptable image, such as, for example, a series of still images, or a video image. In many embodiments, which include many display modules100, each display module100may be configured to form only a relatively small portion of the overall adaptable image. As a result, alignment and registration of the various display modules100relative to each other may be important to present a large, coherent image. Features of representative embodiments of the present invention include means for enabling this alignment and registration as the display modules100are attached to the frame members210at the various removable panel positions205of the display apparatus200.

FIG. 4Aillustrates a cross-sectional view of a frame member210and two removable panels (110L and110R) prior to attachment andFIG. 4Billustrates a cross-sectional view of the frame member210and two removable panels (110L and110R) after attachment to the frame member210. The frame member210includes a vertical channel220that runs along substantially the length of the frame member210. The frame member210is shown in a cross-sectional view, therefore, the vertical direction of the channel220refers to its running the vertical length of the frame member210as it is oriented vertically as part of the display apparatus200, rather than the vertical direction of the cross-sectional figure. The frame member210illustrated inFIGS. 4A and 4Bis illustrated generally as an I-beam type configuration. However, those of ordinary skill in the art will recognize that many other configurations and cross-sections for the frame member210are possible and are contemplated within the scope of the present invention.

As mentioned previously, the removable panels (110L and110R) include a right side protrusion158and a left side protrusion160at the sides of the removable panels (110L and110R). The right side protrusion158and the left side protrusion160are configured such that they can abut against each other and both protrusions158,160can fit at least partially inside of the vertical channel220. This abutting arrangement, and the disposition inside the vertical channel220substantially aligns multiple removable panels110in the vertical direction of the overall display apparatus200, as well as the depth of placement relative to the face of the frame member210(i.e., vertically in the cross-sectional drawing). In addition, the abutting arrangement and disposition in the vertical channel220creates a seal that provides substantial protection from encroachment of water, air, and other contaminants along the left sides and right sides of the removable panels110.

To form an enhanced seal, a gasket225may be disposed in the vertical channel220prior to disposing the right side protrusion158and left side protrusion160in the vertical channel220. This gasket225may be formed of any partially deformable material suitable for accepting the right side and left side protrusions (158and160) and making a substantially watertight seal, such as, for example, any suitable sealant, caulking, foam, rubber gasket, or other gasket-type material.

Also illustrated inFIGS. 4A and 4Bare attachment holes215formed through the front face of the frame member210and the coupling devices190attached to the removable panels110.FIG. 4Billustrates the frame member210and the two removable panels (110L and110R) after attachment using the coupling devices190. The coupling devices190are configured such that when they are attached to the removable panel110they can be operated from the front of the removable panel110or from the back of the removable panel110for attachment of the removable panel110to the frame member210. The coupling devices190may be any suitable attachment device, such as a screw, bolt, fastener, retainer, and the like.

The representative embodiment of the coupling devices190illustrated inFIGS. 4A and 4Balso illustrates a front adjustment adaptor193on a front face of the coupling device190and a rear adjustment adaptor198on the rear face of the coupling device190. These adjustment adaptors may be any adaptor suitable for operating the coupling devices190. By way of example, and not limitation, if the coupling devices190are operated by rotation, the front and rear adjustment adaptors193,198may be a screwdriver slot, a Phillips head slot, a square key, a hex key, a star key, a hex head, a square head, a wing-nut, and the like.

Furthermore, the representative embodiment of the coupling devices190illustrated inFIGS. 4A and 4Bis configured with flanges192on opposite sides of a substantially cylindrical coupling device190. In attaching the removable panels (110L and110R) to the frame members210, the flanges192may be aligned with key slots218(as shown in cut-away bottom view216) in the attachment holes215of the frame member210. After aligning the flanges192with the key slots and placing the coupling devices190inside the attachment holes215, the flanges192protrude through to the back side of the frame member210such that about a quarter turn of the coupling device190in a first direction will fasten the removable panel110to the frame member210by the flanges192being seated against the back side of the frame member210. After attachment, about a quarter turn of the coupling device190in a second direction will align the flanges192on the coupling device190with the key slots in the attachment holes215such that the coupling device190may slide through the attachment hole215and the removable panel110is enabled for removal. With the coupling devices190operated for removal, the removable panel110may be pulled free from the frame member210. Due to an overlap mechanism, described more fully below with respect toFIG. 5, the removable panel110may need to be rotated slightly such that the lower portion of the removable panel110is pulled free from the frame member210first to enable the protrusion162(FIG. 1C) at the top of the removable panel110to be pulled free from under the removable panel110that is positioned above the removable panel110that is being removed.

FIG. 5shows one removable panel above another removable panel to illustrate the overlap mechanism and how the removable panels adjoin to provide further protection from environmental elements. A lower removable panel110L illustrates the protrusion162extending from the top of the lower removable panel110L. An upper removable panel110U illustrates a rabbet-type configuration formed in the bottom side of the upper removable panel110U for receiving the protrusion162from the lower removable panel110L. The rabbet-type configuration includes a receiving rim164, such that when the lower removable panel110L and upper removable panel110U are joined, the receiving rim164of the upper removable panel110U overlaps and cooperatively engages the protrusion162of the lower removable panel110L in a shingle-type arrangement.

In a dry fit configuration, this shingle-type arrangement creates a seal that provides substantial protection from water, air, and contaminant encroachment along the top sides and bottom sides of the removable panels110. For additional protection, a sealant (not shown) may be applied between the upper removable panel110U and the lower removable panel110L, or between the protrusion162and the receiving rim164, to provide a more robust seal. The sealant may be any suitable sealant, caulking, foam, or gasket type material that can form a substantially watertight seal.

FIG. 6Aillustrates a representative embodiment of a representative pixel arrangement130in the removable panel110. In this embodiment, each pixel arrangement130includes three apertures135and is encompassed by a recess170.

FIG. 6Billustrates a side view of the representative pixel arrangement130in the removable panel110showing the apertures135and the recess170. Also shown inFIG. 6Bis a circuit board300bearing three LEDs310prior to the circuit board300being coupled to the removable panel110. As stated earlier, using three LEDs310to form a pixel is one possible embodiment of a pixel wherein the LEDs310may comprise a red LED, a green LED and a blue LED.

In many conventional display boards using LEDs310, the circuit board300bearing the LEDs310is covered with a potting material to cover the circuit board300and the lower portions of the LEDs310. This potting material may act to protect the LEDs310and circuit board300from environmental elements. However, potting material on the circuit board, around the ICs, components and the leads of the LEDs increases thermal resistance, impeding heat transfer away into the air. Furthermore, when LEDs310are soldered into a circuit board300, there may be misalignment between neighboring LEDs310and the LEDs310may be mounted at a slight angle. This angle and misalignment may be noticeable to a viewer and may create patterning in an overall image. Finally, potting materials generally have a relatively low durometer value. As a result, the potting material may not be stiff enough to hold the LEDs firmly in place to prevent additional misalignment from fabrication and handling processes.

Representative embodiments of the present invention use the more precise placement of the apertures135in the removable panel110for precise positioning and placement of the LEDs310installed on the circuit board300.FIG. 6Cshows the circuit board300portion and removable panel110portion ofFIG. 6Bassembled together with the LEDs310penetrating through the apertures135and extending partially into the recess170. As the circuit board300and removable panel110are brought together, relatively small misalignment in the LEDs310or angled placement of the LEDs310may be corrected by the LEDs310fitting in to the more precise placement of the apertures135. Recall fromFIG. 1Bthat the back side152of the removable panel110may include spacers185disposed at various places. These spacers185(not shown inFIGS. 6A-6D) may be used to ensure a proper depth of penetration of the LEDs310into the apertures135.

Finally,FIG. 6Dshows the assembly ofFIG. 6Cwith a sealant175disposed in at least a portion of the recess170of the removable panel110. The sealant175is disposed in the recess170to form a seal around the sides of the LEDs310while still leaving the top portion of the LEDs310exposed for efficient transmission of the light generated by the LEDs310, as well as leaving the leads of the LEDs310exposed to circulating air below the removable panel110, which enhances cooling and prevents hot spots. The sealant175may be any suitable sealant, caulking, foam, or gasket-type material that can form a substantially watertight seal to protect a large portion of the LEDs310from exposure to the elements and prevent water and other contaminants from encroaching behind the removable panel110and affecting the base of the LEDs310, the circuit board300, and other components that may be attached to the circuit board300. The depth of sealant175may be adjusted depending on such factors as the desired amount of LEDs310exposed above the sealant175, height of the LEDs310, and spacing between the removable panel110and the circuit board300.

In one representative embodiment, a silicon sealant is disposed in the recess170. The silicon sealant, as well as other suitable sealants, may also provide some adhering characteristics to assist in holding the circuit board300in place relative to the removable panel110. Some representative embodiments may use the sealant175as a means for holding the circuit board300in place against the removable panel110. With these embodiments, a simple punch device may be used to push on the fronts of the LEDs310to separate the circuit board300from the removable panel110such that the circuit board300may be easily repaired or replaced.

Keeping the LEDs310cool provides additional life to the LEDs310and enables the LEDs310to retain their color characteristics with less degradation of color hue and intensity. By leaving the base of the LEDs310, the leads of the LEDs310, the circuit board300and components exposed to ambient air, heat may be more readily drawn away from the LEDs310to keep them relatively cool.

InFIGS. 6A-6D, the recess170is illustrated to encompass a pixel including three LEDs310. However, other recesses170are contemplated within the scope of the present invention. By way of example, and not limitation, a recess170may be formed around each LED, a recess170may be formed to encompass more than one pixel arrangement130, and a recess170may be formed to encompass an entire pixel row.

While not illustrated, it will be understood by those of ordinary skill in the art that the removable panels110will be operably wired together and coupled to a controller configured for operating each of the removable panels110, each of the pixels on each removable panel110, and each color element LED within each pixel. Many wiring options may be possible, such as, for example, a serial connection between all of the panels such that the panels are essentially daisy-chained together. Furthermore, many controller configurations are possible for controlling the LEDs310and defining what adaptable images, in the form of still images or video, may be displayed on the display apparatus.

Although this invention has been described with reference to particular embodiments, the invention is not limited to these described embodiments. Rather, the invention is limited only by the appended claims, which include within their scope all equivalent devices or methods that operate according to the principles of the invention as described.