Vented LED display and method of manufacturing

A vented LED display is described including an LED display panel having a plurality of LEDs disposed thereon and defining a plurality of vent slots between the plurality of LEDs, each of the plurality of vent slots having a vent height. The vented LED display also includes a unitary injection-molded vent having a plurality of louvers and coupled to the LED display panel such that each louver corresponds to at least one vent slot and includes a louver length extending downwardly to at least 75% of the vent height of the corresponding vent slot.

FIELD OF THE INVENTION

The present invention relates generally to LED displays, and, more particularly, relates to a vented LED display and method of manufacturing the same.

BACKGROUND OF THE INVENTION

Outdoor light-emitting diode (LED) signs are known for various purposes, such as for traffic signage, advertisement billboards, outdoor sporting events, etc. Outdoor LED signs have many challenges, such as ruggedization to withstand outdoor environmental conditions (e.g., wind, rain, dust/debris, and other weather and temperature conditions), power requirements and heat dissipation for the multitude of LEDs required to display outdoor viewable messages and content, accessibility to internal components for maintenance purposes, brilliance and contrast in the LED pixels, and costs associated with manufacturing such often large structures, to name a few.

Often, improvements in one area will result in drawbacks associated with another area. For example, one problem with outdoor LED signs is increasing the brilliance and contrast of the LED pixels, while not also increasing power consumption of the LED sign and heat generation. Further, increased power consumption and heat generation will often result in the need to construct heavier, more complicated systems, which in-turn increases manufacturing costs. U.S. Pat. No. 6,169,632 (Kurtenbach et al.) attempted to at least solve some of these problems by creating a modular display system in which each modular display panel included a circuit board with various LED pixels mounted in a housing. Further, the modular display panels in Kurtenbach et al. includes louver panels interspersed with the LED pixels to shade the LED pixels from ambient light, thereby improving the view contrast and viewability. In addition, each modular display panel in Kurtenbach et al. is secured to one or more modular support members by quick connect latches and includes a driver board and a power supply securable to the modular display by twist-on fasteners. Accessibility is provided on both sides of the Kurtenbach et al. display system through the quick connect latches and ready removability of the circuit boards and louver panels.

Unfortunately, the modular display system in Kurtenback et al. suffered from at least one major drawback. For outdoor LED signs, there is a problem of high wind resistance due to their solid surfaces and their considerable size, which is often required in order for the LED pixels to be visible from long distances. Further, outdoor LED signs are often placed at higher altitudes for greater visibility, which increases the wind resistance even more because wind resistance tends to increase at higher altitudes.

U.S. Pat. No. 7,407,306 (DeMarb et al.) addressed this problem by providing an aerodynamic display panel with a plurality of stacked layers wings with space between the layers to allow air, rain, and other elements to pass through. Unfortunately, the DeMarb et al. aerodynamic display panel suffers from a multitude of drawbacks. Initially, the layers have a wing-shaped cross-section which, as wind flows through the wing layers, results in a lifting force caused by the pressure difference above the wing as compared to the pressure below the wing. Accordingly, such lifting forces will create a strain on the aerodynamic display panel. In addition, the risk of wind forces knocking down the display panel of DeMarb et al. is increased as a result of both horizontal wind forces and vertical lifting forces acting on the display panel simultaneously. In addition, each layer in DeMarb et al. is a separate enclosure for an LED to provide protection to the electrical components from environmental hazards. Unfortunately, such design results in a rather complicated and difficult to assemble and manufacture display panel including horizontal support receivers and vertical support receivers built into each layer and corresponding vertical and horizontal support beams to be routed through such receivers in order to assemble the display and support the layer enclosures thereon. Accordingly, the manufacturing and assembling the DeMarb et al. aerodynamic display panel would be rather costly and time-consuming. Furthermore, the DeMarb et al. aerodynamic display panel is not readily accessible for maintenance purposes. If even one of the layers requirement repair or replacement, it would be rather time consuming to disassemble the display panel in order to perform the repair or replacement. Also, it would be difficult to selectively program the DeMarb et al. sign to display varying messages and/or content on-the-fly as each layer is a separate enclosure shielding its electrical components from environmental hazards.

SUMMARY OF THE INVENTION

The invention provides a vented LED display and method of manufacturing that overcomes the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type.

With the foregoing and other objects in view, there is provided, in accordance with the invention, a vented LED display including an LED display panel having a plurality of LEDs disposed thereon and defining a plurality of vent slots between the plurality of LEDs, each of the plurality of vent slots having a vent height; and a unitary injection-molded vent having a plurality of louvers and coupled to the LED display panel such that each louver corresponds to at least one vent slot and includes a louver length extending downwardly to at least 75% of the vent height of the corresponding at least one vent slot.

In accordance with yet another feature of the present invention, each louver of the unitary injection-molded vent and each corresponding at least one vent slot of the LED display panel together defining a fluid pathway shaped and configured to allow fluid to flow through the vented LED display from a front face thereof through a rear face thereof.

In accordance with another feature of the present invention, the LED display panel is a borderless panel.

In accordance with an additional feature of the present invention, the LED display panel is a unitary injection-molded structure.

In accordance with a further feature of the present invention, the LED display panel and the unitary injection-molded vent together form a housing for one or more electronic components associated with the plurality of LEDs disposed on the LED display panel.

In accordance with another feature of the present invention, the plurality of LEDs disposed on the LED display panel is arranged as a plurality of horizontal LED rows disposed between the plurality of vent slots.

In accordance with yet another feature of the present invention, each of the plurality of louvers is disposed rearward of the at least one corresponding vent slot.

In accordance with yet another feature, for each vent slot, the corresponding louver includes an opaque surface disposed rearward of the vent slot and positioned to block light from passing through a substantial portion thereof.

In accordance with a further feature of the present invention, the LED display panel is a unitary injection-molded structure including a plurality of LED shades positioned above each of the plurality of LEDs disposed on the LED display panel so as to block light emitting from the plurality of LEDs in a vertical direction.

In accordance with another feature of the present invention, each of the plurality of louvers includes a cross-section with a first convex portion disposed forward of and transitioning into a second convex portion when viewed from a rear face of the unitary injection-molded vent.

In accordance with yet another feature of the present invention, the first convex portion forms at least a portion of an electrical component housing for the plurality of LEDs disposed on the LED display panel; and the second convex portion forms the louver length extending downwardly to at least 75% of the vent height of the corresponding at least one vent slot.

In accordance with another feature of the present invention, the plurality of LEDs disposed on the LED display panel is arranged as a plurality of LED rows disposed between the plurality of vent slots; and each of the plurality of LED rows extends from edge-to-edge on the LED display panel such that when an adjacent vented LED display is coupled thereto to form an outdoor LED sign each of the LED rows forms a continuous LED row with one or more horizontally adjacent vented LED displays coupled thereto.

In accordance with another feature, an embodiment of the present invention also includes a vented LED display having a monolithic LED display panel having LEDs disposed thereon in a matrix arrangement of rows and columns separated by one or more vent slots between the rows; and a vent formed as a unitary structure, coupled to the monolithic LED display panel, and having a plurality of louvers, each of the plurality of louvers corresponding to at least one of the one or more vent slots so as to define a fluid pathway shaped and configured to allow fluid to flow through the vented LED display from a front face thereof through a rear face thereof.

In accordance with another feature of the present invention, each of the monolithic LED display panel and the vent are at least one of an injection molded structure and a die-cast structure.

In accordance with another feature of the present invention, each of the plurality of louvers is disposed rearward of the monolithic LED display panel.

In accordance with yet another feature, an embodiment of the present invention includes a method of manufacturing a vented LED display, the method including steps of providing a first three-dimensional pattern formed on a molding surface of a first mold; and injecting a polymeric fluid material into the first mold and curing the polymeric fluid material in the first mold so as to form a first injection-molded member including an LED display panel surface defining one or more vent slots, each vent slot including a vent height. Further, the method may also include providing a second three-dimensional pattern formed on a molding surface of a second mold; and injecting a polymeric fluid material into the second mold and curing the polymeric fluid material in the second mold so as to form a second injection-molded member including a plurality of louver surfaces arranged so that each louver surface includes a louver length that extends downwardly to at least 75% of the vent height.

In accordance with a further feature of the present invention, the method includes coupling LEDs to a printed circuit board (PCB) so that the LEDs are in a matrix arrangement of rows and columns.

In accordance with another feature of the present invention, the method includes after the step of coupling LEDs to the PCB, positing the PCB between the first and second injection-molded members and coupling the first injection-molded member to the second injection-molded member to form the vented LED display with the one or more vent slots between the rows of LEDs.

As used herein, the terms “about” or “approximately” apply to all numeric values, whether or not explicitly indicated. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure. In this document, the term “longitudinal” should be understood to mean in a direction corresponding to an elongated direction of the LED display panel. The terms “program,” “software application,” and the like as used herein, are defined as a sequence of instructions designed for execution on a computer system. A “program,” “computer program,” or “software application” may include a subroutine, a function, a procedure, an object method, an object implementation, an executable application, an applet, a servlet, a source code, an object code, a shared library/dynamic load library and/or other sequence of instructions designed for execution on a computer system.

DETAILED DESCRIPTION

The present invention provides a novel and efficient vented LED display module that is particularly suitable for outdoor usage as an outdoor LED sign. Embodiments of the invention provide a vented LED display module with a front face having a plurality of LEDs disposed thereon in a matrix arrangement of LED rows and columns, the front face defining a plurality of vent slots disposed between LED rows to reduce the wind resistance of the LED sign. In addition, embodiments of the invention provide a rear face formed as a unitary vent having a plurality of louvers that, when the unitary vent is coupled to the front face, defines a plurality of fluid pathways that allows air to flow completely through the vented LED display module. In a further embodiment, the vented LED display module is operably configured to allow air to flow through the vent slots and be directed downward by the corresponding louver. Stated another way, embodiments of the present invention allow air to flow through a matrix arrangement of vent slots defined by the front face and out through the rear face through the plurality of louvers. In addition, embodiments of the present invention provide for the louvers to extend downwardly past a substantial height of the corresponding vent slot so as to provide a contrasting opaque surface for the sign, enhancing viewability thereof by viewers viewing from the sign from the front face.

Referring now toFIG. 1, one embodiment of the present invention is shown in a front, perspective view.FIG. 1shows several advantageous features of the present invention, but, as will be described below, the invention can be provided in several shapes, sizes, combinations of features and components, and varying numbers and functions of the components. The first example of a vented LED display100, as shown inFIG. 1, includes an LED display panel102having a plurality of LEDs104disposed thereon.

The LED display panel102can be considered a structure on which the LEDs104are disposed and that forms a front, viewing side of the vented LED display100. Such front, viewing side of the LED display panel102can be considered a front face106of the vented LED display panel102. As used herein, the term “front face” is intended to indicate one or more surface(s) on the front side of the LED display panel102that are viewable by a user viewing the vented LED display100from the front side, where the LEDs104are disposed. In a preferred embodiment, the front face106is an opaque surface of a dark color (e.g., black) so as to provide a contrasting surface for the lights emitting from the LEDs104. In another embodiment, the front face106is the same color as the louvers so as to provide a uniform appearance (discussed herein in more detail below). As used herein, unless otherwise expressly indicated herein, any discussion of orientation, direction, disposition, position, or other configuration of elements of the vented LED display100and any components thereof pertains to the display100in its operational configuration, in an upright orientation, perpendicular to a planar ground surface. Further, terms such as, “front,” “back,” “rear,” “forward,” “rearward,” “top,” “bottom,” “up,” “down,” “downwardly,” “left and right sides,” and the like, are indicated from the reference point of a viewer viewing the LED display100from its front face106, where the LEDs104are disposed.

In a preferred embodiment, the LED display panel102is a unitary structure. Advantageously, this provides a significant advantage over prior art LED displays that are more complicated to manufacture, assemble, repair, and access for maintenance purposes, as discussed above. In one preferred embodiment, the LED display panel102is a unitary injection-molded structure. As used herein, the term “molded” may be used without the term “injection,” yet it is understood that the term “molded” refers to a structure that has been formed from an injection-molding manufacturing process, as is known in the art. In an alternative embodiment, the LED display panel102may be formed as a unitary metallic structure through a die casting manufacturing process, rather than as a unitary polymer-based structure, as with the injection-molding process. In other embodiments, the LED display panel102may be formed with other types of manufacturing processes.

In one embodiment, the front face106is formed with a generally planar surface. In a further embodiment, the front face106may include miniscule ridges and/or grooves not readily visible by viewers from a far distance. In other embodiments, the front face106may be provided as other shapes and configurations, such as a slightly curved surface, for example. In yet other embodiments, the front face106may include a plurality of shades108(see alsoFIG. 8for an enlarged view of the shades108). The shades108may be disposed directly above the LEDs104for various purposes, such as, for example, to block light emitting in a vertical direction from rows of LEDs above and below for greater visual clarity, to shield the LEDs104from environmental elements, and the like. In a preferred embodiment, the shades108are integral to the front face106of the LED display panel102for ease of assembly. For example, the LED display panel102may be a unitary injection-molded structure with the plurality of shades108. In another embodiment, the LED display panel102may be a unitary die cast structure with the plurality of shades108. In an alternative embodiment, the shades108may be coupled to the LED display panel102during the manufacturing process, after the body providing the primary structure for the LED display panel102is formed. In yet other embodiments, the front face106may be provided with other components and features.

Importantly, the LED display panel102is a vented display panel, defining a plurality of vent slots110between the LEDs104. As used herein, the term “vent slot” is intended to indicate a through-opening that allows fluid, such as air and liquid, to pass through from one side and out through the other opposing side. Although the term “slot” is used in the term “vent slot,” the invention is not intended to be limited to a particular shaped opening, and is intended in its most broad sense to be inclusive of any shape of through-opening that that allows fluid to pass through from one side and out through the other opposing side of the LED display panel102. The vent slots110may be, for example, rectilinear shaped, as shown in the exemplary embodiment. In another embodiment, the vent slots110may be circular, or oval-shaped. In yet another embodiment, the vent slots110may be elongated and narrow, or, alternatively, may be short and wide. In yet another embodiment, the plurality of vent slots110may each be the same shape. In an alternative embodiment, the plurality of vent slots110may be provided in shapes that vary from one to another.

In one embodiment, one or more vent slots110are defined by the LED display panel102between LED rows114. In a further embodiment, one or more vent slots110are defined by the LED display panel102between horizontal rows of LEDs114. Stated another way, the LEDs104may be disposed on the LED display panel102arranged as a plurality of horizontal rows of LEDs114disposed between one or more vent slots110. There may be provided a single vent slot110between LED rows114, or more than one vent slots110between LED rows114as in the exemplary embodiment. In such embodiment, the one or more vent slots110may be horizontally aligned to form a row of vent slots110between LED rows114. In one embodiment, there may be more than one LED row114disposed between rows of vent slots110. For example, in order to increase the number of LED pixels provided on the LED display panel102, there can be provided a pair of horizontal LED rows114disposed between each row of vent slots110, as in the exemplary embodiment. In other embodiments, there may be provided less than or more than two rows of LEDs114between rows of vent slots110.

In one embodiment, the LED display panel102can be considered a monolithic LED display panel102with LEDs disposed thereon in a matrix arrangement of rows114and columns116of LEDs104separated by one or more vent slots110between the rows114. In another embodiment, the plurality of LEDs104may be disposed on the LED display panel102in other patterns and configurations. For example, in one embodiment, the plurality of LEDs104may be arranged in diagonal lines. In another embodiment, the plurality of LEDs104may be arranged as a circular-shaped matrix, rather than a rectangular matrix arrangement, as depicted in the exemplary embodiment. There are many arrangements of LEDs104that can be provided in various embodiments of the present invention and a multitude of interspersed vent slot110arrangements to provide for venting of outdoor wind and elements through the LED display100, in accordance with the present invention.

Moreover, the LEDs104can be any type of lighting element, such as, for example, miniature LEDs, RGB LEDs, white LEDs, blue LEDs, red LEDs, green LEDs, OLEDs, and the like. In yet other embodiments, the lighting element may be a DIP (dual in-line package) or an SMT (surface mount technology) LED. The DIP is commonly known in the art to be operable to emit a single color (either red, green, or blue). On the other hand, SMT provides a wider range of variable color combinations, as SMT LEDs include red, green, and blue LEDs in a single SMT LED. As is known in the art, SMT may also be referred to as SMD (surface mounted device) LED. In one embodiment, the LEDs104are disposed external to the vented LED display100(seeFIG. 8for a close-up view of the LED104). In another embodiment, the LED display panel102defines a plurality of apertures with at least a portion of each LED104disposed in one of the plurality of apertures. Preferably, the aperture and the corresponding LED104disposed therein form a water-tight seal so as to prevent environmental elements from reaching any of the other electrical components that may be housed within the vented LED display100.

Referring now toFIG. 2, an enlarged, partial front view of the LED display100is depicted illustrating one embodiment of the vent slot110. Each of the vent slots110may include a vent height200. In a further embodiment, each of the vent slots110may also include a top edge202and a bottom edge204and the vent height200may extend from the top edge202to the bottom edge204. In other words, in one embodiment, the vent height200is defined as a vertical distance between the top edge202to the bottom edge204. As used herein, the term “edge” is intended to indicate an outside limit of an object, area, or surface.

Referring now toFIGS. 3-4, the vented LED display100may also include a vent300couplable to the LED display panel102(not shown). The vent300, advantageously, allows fluid to flow through to the other side from the vent slots110, in order to reduce wind resistance for the outdoor LED sign, while simultaneously providing an opaque surface spanning at least a portion of the openings of the vent slots110so as to provide a contrasting surface for the lights.

In a preferred embodiment, the vent300is a unitary structure. Advantageously, this provides a significant advantage over prior art LED displays that are more complicated to manufacture, assemble, repair, and access for maintenance purposes, as discussed above. In one preferred embodiment, the vent300is a unitary injection-molded structure. In an alternative embodiment, the vent300may be formed as a unitary metallic structure through a die casting manufacturing process. In other embodiments, the vent300may be formed with other types of manufacturing processes.

The vent300may include a plurality of louvers302. In a preferred embodiment, the plurality of louvers302are formed on the vent300through an injection-molding process so that the vent300can be easily coupled to the vented LED display panel102to form the vented LED display100. As used herein, the term “louver” is intended to indicate each of a set of angled slats and/or flaps arranged so that at least a portion of the louver allows fluid to pass through. In one embodiment, the plurality of louvers302are arranged at regular intervals on the vent300. Stated another way, each of the plurality of louvers302are vertically equidistant from one another. In an alternative embodiment, the plurality of louvers302may be arranged at non-regular intervals on the vent300.

Referring briefly toFIG. 5, an exemplary embodiment of the louver302is illustrated in a cross-sectional, side view of one of the plurality of louvers302. The louver302may be provided in many shapes and configuration in various embodiments. For example, the louver302may be shaped with a curved surface, or may be provided with a substantially planar (90%+/−10 of the surface of the louver is planar) angled surface. Preferably, the louver302is shaped so as to maximize the reduction of wind resistance. In a preferred embodiment, the louver302includes a cross-section with a first convex portion500and a second convex portion502when viewed from a rear face400(FIG. 4) of the vent300. As used herein, the term “rear face” is intended to indicate surface(s) on the rear side of the vent300that are viewable by a user viewing the rear side of the vented LED display100, opposite the front side where the LEDs104are disposed. In one embodiment, the first convex portion500can be considered disposed forward of the second convex portion502. In other words, the first convex portion500may be disposed closer to the front face106than the second convex portion502. In a further embodiment, the first convex portion500may be continuous with the second convex portion502. Stated another way, the first convex portion500may transition into the second convex portion502. In one embodiment, the louver302may be considered to include two adjacent curves or arcs. In another embodiment, the first convex portion500may form at least a portion of an electrical component housing for electrical components of the LEDs104(seeFIG. 1) disposed on the LED display panel102(seeFIG. 1). In yet another embodiment, the second convex portion502provides the opaque surface that spans at least a portion of the openings of the vent slots110(seeFIG. 2) so as to provide a contrasting surface for the lights.

Referring again toFIG. 2, with brief reference toFIGS. 1 and 4, when the vent300and the LED display panel102are coupled together to form the LED display100, each of the plurality of louvers302may correspond to at least one vent slot110. In other words, each of the plurality of louvers302is arranged or positioned to align with at least one vent slot110when the vent300and panel102are coupled together in an operational configuration. More specifically, in some embodiments, each of the plurality of louvers302is disposed rearward of the corresponding vent slot110. Such arrangement forms a fluid pathway206shaped and configured to allow fluid to flow through the vented LED display100from the front face106through the rear face400for reducing wind resistance. As used herein and for the sake of brevity, the fluid pathway206is described herein as allowing fluid to flow from the front face through the rear face; however, it is understood that the shape and configuration of the fluid pathway206also allows fluid to flow through the vented LED display100in the other direction, from the rear face400through the front face106. As is known in the art, the direction of fluid flow (e.g., wind) will depend on the direction that such environmental elements are traveling as they encounter the vented LED100in an outdoor environment. In addition, the fluid pathway206may allow rain and other elements through and may also assist with dissipating heat generated by the LEDs104. In a further embodiment, each of the plurality of louvers302is considered to extend rearwardly and downwardly from the top edge202of the corresponding vent slot110. In another embodiment, each of the plurality of louvers302is disposed rearward of the LED display panel102.

In addition, in one embodiment, the louver302includes a louver length208that extends downwardly to at least 75% of the vent height200of the corresponding vent slot110. Advantageously, this may provide a surface which, when the vented LED display100is viewed from certain angles, provides for a display that appears to viewers to be of solid construction, without any through-openings or vents. Referring briefly now toFIG. 6, in one embodiment, the louvers302are shaped and oriented such that when viewed by a viewer from an upward-looking angle, as inFIG. 6, the louvers302provide a sufficient louver length208that the vented LED display100appears to be of a solid construction. As is known in the art, outdoor signs are often positioned relatively high to maximize visibility in an outdoor environment and, therefore, are often viewed by viewers from an upward-looking angle. Accordingly, embodiments of the vented LED display100provide the advantage of a venting construction with the appearance of a solid panel body when viewed from certain angles. In one embodiment, the LED display102and the louvers302are of the same color (e.g., black) and/or the same material (e.g., polymer-based) so as to further provide a solid uniform appearance to viewers. In addition, preferred embodiments of the vented LED display100are provided with injection-molded members that are easily coupled together for ease of manufacturing, reducing costs and complexity associated therewith.

Referring again toFIG. 2, with brief reference toFIGS. 1 and 4, in one embodiment, the louver302is of an opaque material so as to provide an opaque surface, blocking light from passing through a substantial portion of the vent slot110. Stated another way, the louver302may include an opaque surface disposed rearward of the vent slot110and positioned to block light from passing through a substantial portion of the vent slot110. As used herein, the term “substantial portion” is intended to indicate at least 75% of the vent slot110. In other embodiments, the louver302may also include surfaces that are transparent or semi-transparent. More specifically, in some embodiments, the second convex portion502(FIG. 5) provides the louver length208that extends downwardly to at least 75% of the vent height200of the corresponding vent slot110. In other embodiments, the louver length208extends downwardly to at least 80% of the vent height200. In yet other embodiments, the louver length208extends downwardly to at least 90% of the vent height200. In yet further embodiments, the louver length208extends downwardly to more than 90% of the vent height200. Advantageously, the louver302may provide an opaque surface such that vented LED display100appears to be of solid construction, while the vent slots110allow the vented LED display100to be vented and to reduce wind resistance for the outdoor sign.

Referring now toFIGS. 7-8, the vented LED display100is illustrated in a side view and an enlarged partial side view, respectively, showing the LED display panel102and the vent300coupled together in an operational configuration. In one embodiment, each of the LED display panel102and the vent300may be a unitary structure, such as an injection-molded member, that can be relatively easily coupled together. The LED display panel102and the vent300may be coupled together in a multitude of ways, such as, for example, with various types of fasteners (e.g., screws, bolts, snaps, friction-fit fasteners, adhesives, hook-and-loop fasteners, dowel fasteners, and the like). In one embodiment, the LED display panel102and the vent300together form a housing for one or more electronic components associated with the LEDs104disposed on the LED display panel102. In another embodiment, only one of the LED display panel102and the vent300is a unitary structure. In yet another embodiment, the vented LED display100may be formed as a single unitary structure, rather than, for example, two separate injection-molded members. In yet other embodiments, the LED display panel102and the vent300may be shaped, formed, and/or configured in other ways. In one embodiment, the electronic components include a printed circuit board (PCB)700. The PCB700may mechanically support and electrically connect the LEDs104by, for example, a pattern of conductive tracks etched onto a non-conductive substrate. The LED display panel102may be considered a “mask.” The mask may be formed as a relatively thin panel defining the plurality of apertures for the LEDs104and a plurality of vent slots110between rows of apertures. Such mask functions as the front face106for the vented LED display100to conceal and protect the PCB700and form at least a portion of the housing.

Referring toFIGS. 5 and 9, in one embodiment, the LED display panel102may be formed as a borderless panel. Advantageously, this improves the seamless appearance of a modular embodiment of the vented LED display100. In other words, and with specific reference toFIG. 9, an outdoor LED sign900may be formed by coupling a plurality of vented LED displays100a-ntogether to form a continuous pattern of LED pixels spanning across the surface area of the outdoor LED sign900. As used herein, the number of vented LED displays between “a” through “n” can be any number. This is an improvement over prior art LED panels that include borders outlining a periphery of the LED panel such that if such LED panels were coupled together to form a larger sign, the borders would interfere with the uniform appearance of the sign. Stated another way, in one embodiment, the LED rows114disposed on each of the plurality of vented LED displays100a-nextends from edge-to-edge such that when the LED display panel100is coupled to adjacent LED display panels100to form the outdoor LED sign900each of the LED rows114forms a continuous LED row114with adjacent vented LED displays100coupled thereto.

Referring now toFIG. 10, the outdoor LED sign900may include a support frame1000on which the vented LED displays100are mounted. The outdoor LED sign900may also include a housing1002for a main board1004communicatively coupled to and operably configured to power and/or control the LEDs104(not shown). In one embodiment, the main board1004is a programmable board that allows users to selectively program a message to be displayed on the outdoor LED sign900. In another embodiment, the housing1002may include a hinged or pivotable door1006that can be easily opened and closed to access the main board1004for selective programming and/or repair and replacement of the same. The main board1004can be provided as a printed circuit board for data processing that includes at least a portion that is programmable. In other embodiments, the main board1004may be considered a “motherboard” that includes one or more CPUs (central processing units). In one embodiment, the main board1004may be provided with a port that allows service technicians to plug-in an electronic device that interfaces with the main board1004and allows the service technician to selectively program messages. In other embodiments, the main board1004does not allow for selective programmability of messages to be displayed on the outdoor LED sign900. In such embodiments, the main board1004may be programmed or manufactured with a pre-set message at the manufacturing site for the board.

Referring now toFIGS. 11-16, various views an exemplary embodiment of the outdoor LED sign900are illustrated.FIG. 11is an elevational rear view of the outdoor LED sign900showing the vent300and louvers302. In the exemplary embodiment, the outdoor LED sign900includes 8 (eight) vented LED displays100coupled together (more specifically, 4 (four) vented LED displays100coupled together, one above the other, on each opposing side of the housing1002). In other embodiments, there may be provided other numbers and configurations of vented LED displays100coupled together to form the outdoor LED sign900. In yet other embodiments, the outdoor LED sign900may be yet another modular element of yet a larger LED sign, such as an LED billboard. In such embodiments, a multitude of the outdoor LED signs900, which may also be referred to as cabinets, are coupled together to form a larger outdoor sign. In an exemplary embodiment, an LED billboard may be made up of a 4×19 array of modular outdoor LED signs900coupled together to provide a single sign.

FIGS. 12 and 16show elevational side views of opposing sides of the outdoor LED sign900. As can be seen, in the exemplary embodiment, the louvers302(not shown) do not extend beyond the sidewalls so as to provide a modular and compact design.FIGS. 13 and 15shows a top plan view and bottom view, respectively, of the outdoor LED sign900.FIG. 14shows an elevational front view of the outdoor LED sign900showing the LED display panels102defining the plurality of vent slots110to allow fluid to pass therethrough. For the sake of clarity of the arrangements of the vent slots110, the LEDs104and the louvers302are not shown inFIG. 14. Although not readily apparent fromFIG. 14, in a preferred embodiment, the louvers302are formed with an opaque surface that extends downwardly covering a substantial portion of the vent height200to provide the outdoor LED sign900with an appearance of solid construction, when viewed at certain standard viewing angles.

An exemplary embodiment of a manufacturing process will be described with reference to the process flow chart ofFIG. 17in conjunction withFIGS. 1-4andFIG. 7. Although the process flow chart ofFIG. 17shows a specific order of executing the process steps, the order of executing the steps may be changed relative to the order shown in certain embodiments. Also, two or more blocks shown in succession may be executed concurrently or with partial concurrence in some embodiments. Certain steps may also be omitted inFIG. 17for the sake of brevity.

It is understood that that any molds and/or three-dimensional patterns discussed with reference to the process flow chart ofFIG. 17are for manufacturing embodiments of the LED display panel102and vent300described herein above and depicted inFIGS. 1-16. Accordingly, it would be understood by persons of ordinary skill in the art that the molds are formed with three-dimensional patterns that would produce the surfaces of the panel102and vent300, as described herein above. Therefore, for the sake of brevity, descriptions of such molding surfaces are not repeated in the following section. Rather, the following section focuses primarily on the manufacturing process steps.

The process may begin, at step1700, and may immediately proceed to step1702, where a manufacturer may provide a first three-dimensional (3-D) pattern formed on a molding surface of a first mold, for forming one or more surfaces of the LED display panel102. In step1704, a first injection-molded member is formed that includes an LED display panel surface, such as the front face106. The LED display panel surface defines one or more vent slots110arranged and configured as described herein above, with reference toFIGS. 1-16. Further, each vent slot110may include the vent height200. More specifically, the manufacturer may inject a polymeric fluid material into the mold such that the polymeric fluid fills in cavities defined by the first three-dimensional pattern. After the polymeric fluid fills in the first three-dimensional pattern, the manufacturer may cure the polymeric fluid so as to harden, forming a rigid first injection-molded member. The manufacturer may use any known type of injection molding machine(s) and any polymeric fluid (e.g., resins, elastomers, thermoplastics, etc.) known in the art.

In step1706, the manufacturer may provide a second three-dimensional pattern formed on a molding surface of a second mold, different from the first mold, for forming one or more surfaces of the vent300and louvers302. In step1708, a second injection-molded member including a plurality of louver surfaces is formed by the manufacturer by injecting the polymeric fluid material into the second mold such that the polymeric fluid fills in cavities defined by the second three-dimensional pattern. After the polymeric fluid fills in the cavities of the second three-dimensional pattern, the manufacturer may cure the polymeric fluid so as to harden the fluid, forming a rigid second injection-molded member including the plurality of louver surfaces. As discussed herein above, in a preferred embodiment, each of the plurality of louver surface includes a louver length208that extends downwardly to at least 75% of the vent height200.

In one embodiment, the first three-dimensional pattern may be formed so as to provide a plurality of apertures on the LED display panel102through which the LEDs104may be coupled to the LED display panel102. Accordingly, in step1710, the manufacturer may couple the LEDs104to the PCB700so that the LEDs104are arranged in the matrix arrangement of rows and columns, described and depicted herein above, separated by the one or more vent slots110between the rows, when fully assembled. More particularly, the LEDs104are physically and electrically coupled to the PCB700to provide the electronic circuitry to control and emit light from the LEDs104.

In step1712, after coupling the LEDs104to the PCB700, the manufacturer may couple the PCB700between the first and second injection-molded members so as to form the vented LED display100in accordance with the present invention. In other words, the PCB is sandwiched between the first-injection-molded member and the second-injection-molded member. In one embodiment, a periphery of the LED display panel102is aligned and coupled to a periphery of the vent300so as to form a seamless structure for the vented LED display100. The first and second injection-molded members may be coupled to one another by any known fastener, such as, for example, screws, nuts, bolts, adhesives, etc. Advantageously, embodiments of the method of manufacturing the vented LED display100provide a more time-efficient, cost-efficient manufacturing process for making vented LED displays100. In alternative embodiments, the vented LED display100may be formed by a die-cast manufacturing process.

In another embodiment, the PCB700(with the LEDs104disposed thereon) may be coupled to the vent300by fasteners, for example. Subsequently, the PCB700may be coupled to the LED display panel102by engaging the PCB700with a rear side of the LED display panel102so that each of the LEDs104can be inserted within a plurality of apertures, the apertures defined by the LED display panel102. This manufacturing step results in the LEDs104being positioned forward of the front side of the LED display panel102so as to be visible to viewers (as can be clearly discerned in at leastFIGS. 7-8). The LED display panel102may then be secured to the vent300by, for example, fasteners, so as to form the vented LED display100. The process may end at step1714.

A novel and efficient vented LED display has been disclosed that is particularly suitable for outdoor usage as an outdoor LED sign. Embodiments of the invention provide a vented LED display module with a front face having a plurality of LEDs disposed thereon in a matrix arrangement of LEDs, the front face defining a plurality of vent slots disposed between LEDs to reduce the wind resistance of the LED sign. In addition, embodiments of the invention provide a rear face formed as a unitary vent having a plurality of louvers that, when the unitary vent is coupled to the front face, defines a plurality of fluid pathways that allows air to flow completely through the vented LED display module. In a further embodiment, the vented LED display module is operably configured to allow air to flow through the vent slots and be directed downward by the corresponding louver. Stated another way, embodiments of the present invention allow air to flow through a matrix arrangement of vent slots defined by the front face and out through the rear face through the plurality of louvers. In addition, embodiments of the present invention provide for the louvers to extend downwardly past a substantial height of the corresponding vent slot so as to provide a contrasting opaque surface for the sign, enhancing viewability thereof by viewers viewing from the sign from the front face.