Fueling station electronic pricing sign

Single digit Light Emitting Diode (LED) modules for replacing plastic numerals in a gas station pricing sign. Three or four LED modules represent one fuel price. The LED modules are mounted to a transparent face present on existing signs, and may be mounted on an exterior or interior surface of the face. In one embodiment, first LED modules mechanically cooperate with backing plates, thereby sandwiching the face, in another embodiment, second LED modules attach to posts glued to the face. When mounted externally, the LED modules fit into tracks provided for the plastic numerals which are being replaced. An RF, infrared, or hard wired control signal may be used to change prices, and a photocell may be used to control LED intensity in response to ambient light. Additional low power consumption LEDs are provided inside the sign to back illuminate information provided on the face.

BACKGROUND OF THE INVENTION

The present invention relates to signs for exhibiting prices at gasoline stations, and more particularly to single digit electronic sign elements suitable for using with existing signs.

During a business day, events may motivate one or more price changes at gasoline stations. For example, fuel costs may change or a competitor may change prices. The station operator may observe that sales are low due to too high of a price, or that long lines are developing at pumps are due to too low of a price. Additionally, station operators may wish to adjust prices at predetermined times during the day based on predictable changes in demand. For example, some stations are contractually obligated to remain open 24 hours of the day. Lower prices may add to sales (and thus profits) outside commuting hours, and both operating cost and market prices may increase between late night and early morning hours.

Gasoline stations are often operated by a single individual responsible for a variety of tasks including receiving payments for fuel and other purchases, resolving any problems that might arise, monitoring activity around the station, and adjusting fuel prices. Generally, gasoline stations are required to post fuel prices which are in agreement with actual prices on gasoline pumps. Although changing actual prices on the pumps may be fairly easy, changing prices on signs may be difficult and time consuming. Because the operator does not have time available to manually changes prices on signs posted for passing motorists, the station operator is not free to make desired price changes on the pumps. As a result, profits are reduced.

Known gasoline station signs use replaceable numerals comprising rectangular transparent plastic sheets bearing numerals, which replaceable numerals are changed to reflect new fuel prices. The replaceable plastic numerals reside over a transparent window (or face) which passes light radiated from light sources inside the sign. Generally, the replaceable plastic numerals slide into tracks or holders on the faces. Because of the expense of replacing the entire gasoline station sign, there is a need for an apparatus and method for replacing existing replaceable numerals with controllable electronic numerals.

Some replacement Light Emitting Diode (LED) numerals have been proposed, which numerals comprise a single LED panel displaying a three or four digit price of fuel. Unfortunately, such panels are heavy and are not effectively adaptable to signs with curved fronts. The large multi-digit panels may not match the curvature of sign fronts, and thus are not suitable for mounting outside the face, and when the large multi-digit panels are mounted inside the face, a gap between the curved face and the flat panel results in defusion of light and thus blurring of the prices.

Known sign faces are generally acrylic or poly carbonate. The acrylic faces are most common, and may crack if holes are drilled to mount LED panels. The poly carbonate faces may be drilled but are less frequent.

What is needed is a method and apparatus for replacing the existing plastic numerals with individual single digit LED modules, which method preferably does not require drilling mounting holes in acrylic faces of signs.

BRIEF SUMMARY OF THE INVENTION

The present invention addresses the above and other needs by providing single digit Light Emitting Diode (LED) modules for replacing plastic numerals in a gas station pricing sign. Three or four single digit LED modules represent one fuel price. The LED modules are mounted to a transparent face present on existing signs, and may be mounted on an exterior or interior surface of the face.

In one embodiment, first LED modules mechanically cooperate with backing plates, thereby sandwiching the face, in another embodiment, second LED modules attach to posts glued to the face. When mounted externally, the LED modules fit into tracks provided for the plastic numerals which are being replaced. An RF, infrared, or hard wired control signal may be used to change prices, and a photocell may be used to control LED intensity in response to ambient light. Additional low power consumption LEDs are provided inside the sign to back illuminate information provided on the face.

In accordance with one aspect of the invention, there is provided a pricing sign including LED numerals. The sign comprises at least one sign face and a multiplicity of single digit LED modules. Each LED module has a multiplicity of LEDs, wherein a subset of the LEDs may be energized to represent a selectable one of ten Arabic numerals. The LED modules are mounted to the face in an arrangement allowing representation of a price.

In accordance with another aspect of the invention, there is provided a first method for converting a pricing sign to use single digit LED modules. The first method comprising mounting at least one single digit LED module to the sign, connecting a data cable between a controller and the LED module, and connecting a power cable between a power supply and the LED module. Mounting the LED module to the sign comprising the steps of removing a plastic numeral, drilling mounting holes in a sign face at pre-defined locations, placing the LED module into tracks on an outside surface of the face, positioning a backing plate opposite the LED module against an inside surface of the face, and sandwiching the face between the LED module and the backing plate using fasteners passing through the backing plate, through the face, and into the LED module.

In accordance with yet another aspect of the invention, there is provided a second method for converting a pricing sign to use single digit LED modules. The second method comprises mounting at least one second single digit LED module to a face of the sign, connecting a data cable between a controller and the LED module, and connecting a power cable between a power supply and the LED module. Mounting the second LED module comprises the steps of, removing a plastic number from tracks on the face, gluing enclosure posts to the sign face, placing the second LED module into the tracks, and attaching the LED module to the enclosure posts;

DETAILED DESCRIPTION OF THE INVENTION

A known pricing sign10as might be used at a gasoline station is shown inFIG. 1. The sign10is constructed to allow plastic numerals12to be swapped in and out to change a fuel price. Additional fractional numerals14reflect typical fuel pricing.

The numerals12generally residing between horizontal upper track20and lower track22on a sign face (or window)15as shown inFIG. 2A, or in vertical tracks21and the lower track22as shown inFIG. 2B. The sign face15is generally transparent which allows light radiated inside the sign10to back illuminate the plastic numerals12and other information on the sign face15, for example, fuel types.

A single digit Light Emitting Diode (LED) module42according to the present invention is shown residing in the upper track20and the lower track22inFIG. 3A. The LED module42is preferably sized to be inserted into the tracks20,22by first sliding the top of the LED module42into the top track20, and then lowering the LED module42into the bottom track22. The LED module42is shown residing in the tracks21,22inFIG. 3B.

A side view of the LED module42is shown residing in the tracks20,22inFIG. 3C. In a preferred embodiment, the LED module42including shield posts39provided to facilitate attachment of a transparent shield43is shown inFIG. 3D. The shield43is advantageous when the LED module42is located within reach from the ground, and may be vandalized by spray paint and the like, wherein the shield43may easily be cleaned or replaced at low cost.

The LED module42comprises a louver board31, an LED Printed Circuit Board (PCB)28, and an enclosure24as shown inFIG. 4. The LED module42is assembled as indicated by arrows25. The elements of a second LED module42acomprise the louver board31, the LED Printed Circuit Board (PCB)28, and a second LED enclosure24aas shown inFIG. 4a.

A front view of a louver board31is shown inFIG. 5A, and a side view of the louver board31is shown inFIG. 5B. The louver board includes a multiplicity of LED holes33corresponding to a multiplicity of LEDs27(seeFIG. 6A). When the LED module42is assembled, the LEDs27are aligned with the LED holes33wherein the LEDs27pass through the LED holes33, protrude into the LED holes33, or are visible through the LED holes33. The louver board31includes louvers32which vertically shade the LEDs27. One of the louvers32preferably resides between each pair of vertically adjacent LED holes33. The louvers32extend a thickness T1from the louver board31, which thickness T1is preferably between approximately 0.25 inches to approximately 0.5 inches, and more preferably approximately 0.25 inches. The louver board31is mounted to the enclosure24using fasteners passing through first mounting holes23ain the louver board31and into second mounting posts37b(seeFIG. 7A) projecting from the enclosure24. Post holes23bare provided in the LED PCB28(seeFIG. 6A), thereby allowing the mounting posts37bto pass through the LED PCB28. The mounting holes23ain the louver board31may be somewhat different in number and location depending on which LED enclosure24,24athe louver board31is mounted on.

A front view of the LED PCB28is shown inFIG. 6A, and a side view is shown inFIG. 6B. The LEDs27are attached to the LED PCB28, and the LEDs27are selectively electrically connected by electrical connections30to minimize the number of separate LED circuits required to form the desired numerals, thereby forming LED segments. The number of LED segments is preferably between seven segment (least expensive) and forty segments (for large signs). More preferably, twenty three LED segments are used. The actual number of LEDs27depends on the size of the LED module42and details of the numerals desired to be depicted, and larger LED modules42will generally have a greater number of LEDs. Preferably, the LEDs27comprise a column of fifteen LEDs on each edge of the LED PCB28, and columns of sixteen LEDs next to the columns of 15 LEDs. Two rows of four LEDs27each fit between the columns at the top, center, and bottom of the LED PCB28. Thus composed, the LEDs27form a square cornered “8”.

The LED PCB28further includes mounting holes23aprovided to mount the LED PCB28to the enclosure24using fasteners passing through the mounting holes23aand into first mounting posts37a(seeFIG. 7A) projecting from the enclosure24. The LED PCB28also includes second mounting holes23bfor allowing the second mount posts37bto pass through the LED PCB28. The LEDs27extend a thickness T2from the LED PCB28, wherein T2is preferably approximately 0.1 inches. A connector29extends from the rear of the LED PCB28. The mounting holes23bin the LED PCB28may be somewhat different in number and location depending on which LED enclosure24,24athe LED PCB28is mounted on.

A front view of an enclosure24is shown inFIG. 7Aand a side view of the enclosure24is shown inFIG. 7B. The enclosure24includes first mounting posts37afor mounting the LED PCB28to the enclosure24, and second mounting posts37bfor mounting the louver board31to the enclosure24. A rim38has an interior suitable for accepting the LED PCB29and/or the louver board31. The rim38extends a third thickness T3from the surface of the enclosure24, which thickness T3is preferably approximately 0.75 inches. A multiplicity of board supports41are spaced apart around the interior of the rim38, which board supports41are adapted to support the edge of the LED PCB29and/or the louver board31. An access hole36is provided to allow the connector29to pass through the enclosure24. A multiplicity of fastening features34are provided around the edge of the enclosure24for facilitating mounting the LED module42to the sign face15. Preferably, the fastening features include captive nuts, thereby allowing the LED module42and backing plate46(seeFIGS. 3C and 3D) to be mounted to the sign face15using fasteners inserted from inside the sign10. Generally, the sign face15comprises hinged segments, wherein the segments pivot open, providing access to a back side of the sign face15. Such access allows the LED module42to be mounted using fasteners inserted from the inside of the sign10.

A rear view of the enclosure24is shown inFIG. 7C. Fastener holes35align with fastening features34. A gasket40is provided, which resides on a back mounting surface of the enclosure24and has sufficient thickness to compensate for curvature or irregularities in the sign face15, which gasket thickness is preferably approximately 0.02 inches. The gasket40is preferably a double moisture gasket.

A backing plate46for cooperating with the LED module42to sandwich the sign face15is shown inFIG. 7D. The backing plate46includes second fastener holes44positioned to cooperate with fastener holes35in the enclosure24.

A top view of several of the LED modules42mounted on an outwardly facing side (or outer surface) of the sign face15is shown inFIG. 8A, and a top view of several of the LED modules42mounted inside the sign face15is shown inFIG. 8B. The LED modules42are preferably mounted outside the sign face15to allow better heat dissipation, but because the LED modules42are constructed as single numeral segment, the LED modules may be mounted inside the sign face15without creating a substantial gap between the LEDs and the sign face (or window) and thereby avoid diffusion of the light radiated by the LEDs.

In some cases, the sign face15may have some degree of curvature. A detailed top view of a curved segment of a sign face15residing between the LED module15and the backing plate46is shown inFIG. 8C. A second detailed top view of the previously curved segment of a sign face15now sandwiched between an LED module42and backing plate46is shown inFIG. 8D. The backing plate46has been tightened against the LED module42and the segment of the sign face15between the backing plate46and LED module42is thereby straightened. Straightening of the curved sign face15also results when the LED module42is inside the sign10and the backing plate46is on an outside surface of the sign face15.

A front view of a second LED enclosure24awhich is part of the second LED module42a(seeFIG. 4A) is shown inFIG. 9A, a side view inFIG. 9B, and a top view inFIG. 9C. The LED enclosure24aincludes four shield posts for facilitating mounting a shield43(seeFIG. 3D) over the second LED module42a, six first mounting posts37afor mounting an LED PCB28(seeFIG. 6A), and six second mounting posts37bfor mounting a louver board31(seeFIG. 5A) to the LED enclosure24a. The shield43, LED PCB28, and louver board31are attached to the LED enclosure24ain a similar manner as they are attached to the LED enclosure24, however the position and number of mounting holes23a,23bare adapted to match the mounting posts37a,37blocation and number shown for the LED enclosure24a. The LED PCB28resides against a seat80on the LED enclosure24a. The number of shield posts, mounting posts may be changed for convenience, and an LED module having a different number of shield posts or mounting posts is intended to come within the scope of the present invention.

Four openings81in the LED enclosure24, residing behind the LED PCB28mounting position, open approximately 85 percent of the area behind the LED PCB28. The openings81are similar in shape, and reside in two rows of two openings81. Bottom (or first) openings88near the bottom of the LED enclosure24aallow air to enter the second LED module42a, and top (or second) openings90near the top of the LED enclosure24aallow hot air to escape the LED module42a. The top openings90are preferably on sides of the LED module42anear the top of the LED module42a. Wire passages86are provided in each side of the LED enclosure24ato allow wiring to pass between second LED modules42ato thus avoid creating holes in the sign face15(seeFIG. 1).

A top piece84is attached to the top of the LED enclosure24a. The top piece84is preferably snapped into place, and is removable, but may be held by screws or similar fasteners, pop rivets, glue, or the like. The top piece84is provided so that a small number of LED modules may be adapted to fit the vertical space provided by a variety of existing signs. The Top pieces81are preferably provided in approximately ¼ inch increments of height.

A rear view of the LED enclosure24ais shown inFIG. 9D. Latches94attached to the top piece84extend through notches95in the LED enclosure24ato attach the top piece84to the LED enclosure24a. Four bottom openings88allow an air flow92to enter the second LED module42a. A portion of the air flow92enters bottom openings88near the bottom corners of the LED enclosure24aand flows upward through channels93, and out though the side openings90near the top of the LED enclosure24a. Another portion of the air flow92flows upward through a main center portion of the second LED module42ato cool the LEDs27(seeFIGS. 6A,6B), and out though the side openings90near the top of the LED enclosure24a. Baffles87at the tops of the channels93prevent water from entering the LED enclosure24athrough the side openings90, wherein the water drains through the channels93.

A cross-sectional view of a portion of the channel93of the LED enclosure24ataken along line9E-9E ofFIG. 9Dis shown inFIG. 9E. Side openings90are separated by the baffle87, thereby preventing water from entering the interior of the second LED module42a. A second cross-sectional view of a portion of the channel93of the LED enclosure24ataken along line9F-9F ofFIG. 9Dis shown inFIG. 9F, showing the channel93and the seat80. A third cross-sectional view of a portion of a bottom end portion of the channel93of the LED enclosure24ataken along line9G-9G ofFIG. 9Dis shown inFIG. 9G, showing a cross-section of the bottom opening88.

A side view of an enclosure post82used to mount the LED enclosure24ato the sign face15is shown inFIG. 9H, and a front view of the enclosure post82is shown inFIG. 9I. The enclosure post82has a square base82awhich may be glued to the sign face15, and a cylindrical portion82bwhich extends away from the sign face15. The LED enclosure24ain mounted by aligning the channels93with the enclosure posts82, and inserting screws through the LED enclosure into the enclosures posts. The cylindrical portions82bare smaller than the width of the channels93, thereby allowing the air flow92, or a water flow, to pass the cylindrical portions82bwhen the LED enclosure24ais attached to the sign face15. The enclosure posts82are preferably made from an acrylic material. Other methods of attaching the LED module24ato the sign face15may include hooks, catches, and the like, and an LED module attached to a sign face using any of these types of fasteners in intended to come within the scope of the present invention. It is preferred that the mounting method does not require breeching the sign face15.

A rear view of the second embodiment of the LED enclosure24awith a back cover96in place is shown inFIG. 9J, and the back cover alone is shown inFIG. 9K. The back cover96is attached to the LED enclosure24ausing back cover screws98passing through screw holes99into cover attachment points97(seeFIG. 9D). The back cover96may be removed to adjust the LED brightness and to make electrical connections. The screws98are preferably recessed into the back cover96.

A preferred tongue and groove54cooperation of adjacent LED modules42is shown inFIG. 10. Because a light source preferably resides inside the sign10, light leaks between adjacent LED modules42might result from the absence of an overlap of the LED modules42. The LED enclosures24,24apreferably include a tongue on one side, and a cooperating groove on the opposite side.

A front view of the LED module42alone, and a front view of the LED module42attached to a sign face15is shown for comparison inFIGS. 11 and 11A.

The preferred arrangement of LEDs27with the LEDs off is shown inFIG. 12. LED numerals26a-26jrepresenting ten Arabic numerals “1”, “2”, “3”, “4”, “5”, “6”, “7”, “8”, “9”, and “0” are shown inFIGS. 12A-12J. Generally, fuel prices also include a fractional amount “ 9/10” which may be represented by an LED fractional numeral26kas shown inFIG. 12K. In cases where a decimal point is desired or required by law, a narrow decimal point module26I may be used to provide an LED decimal point as shown inFIG. 13. A sign10having prices represented by LED numerals according to the present invention is shown inFIG. 14.

An interior view of the sign10having LED modules42according to the present invention is shown inFIG. 15A. Power cables66provide a power signal to a power supply64, and distribute power to the connectors29on the LED modules42, LED light sources74, a fan76connected to the power supply64by a fan cable77, and/or to a heater78connected to the power supply64by a heater cable79. Data cables62provide price (or other) data to a controller60, and from the controller60to the connectors29on the LED modules42. The power cables64and the data cables62are preferably connected daisy chain fashion between the connectors29. A dimmer sensor58senses ambient light, and sends a dimmer signal over a dimmer cable56to the controller60. Preferably, four LED intensity levels are provided to adjust the LED intensity to ambient light levels, and the light sources74may be turned on or off based on the sensor58data. An input sensor68receives price (or other) information from a Radio Frequency (RF), infrared, or any wireless signal type, and provides a data signal to the controller60through a second data cable70. A preferred data cable for carrying data signals to the sign10is a phone wire.

A side view of the sign10converted to an LED sign using the second LED modules42ais shown inFIG. 15B. The second LED modules42aare mounted to the sign face15using the enclosure posts82(seeFIGS. 9H,9I), and the sign face15is not breached. Further, the data cable62and the power cable66exit the sign at a cable exit67preferably on the side of the sign and do not breach the sigh face15(seeFIG. 14). The cable62,66thus do not breach the sign face15. Other aspects of a converted sign using the second LED modules42ais similar to a sign converted using the first LED modules42.

A first method for converting a known sign to an LED sign is described inFIG. 16. The method comprises the steps of mounting at least one LED module to the sign, comprising the steps of removing a plastic number at100, drilling mounting holes in a face at pre-defined locations at102, placing an LED module into tracks on an outside surface of the face at104, positioning a backing plate opposite the LED module against an inside surface of the face at106, and sandwiching the face between the LED module and the backing plate using fasteners passing through the backing plate, through the face, and into the LED module at108. Steps100-108are repeated for each LED module. Data is provided to each LED module by connecting a data cable between a controller and the LED module at step110, and power is provided to the LED modules by connecting a power cable between a power supply and the LED module at step112. The method may further include connecting the data cable between a controller and the LED modules in a daisy chain fashion. Drilling the mounting holes may be facilitated by using a template to determine where to drill the holes.

A second method for converting a known sign to an LED sign is described inFIG. 17. The method comprises the steps of mounting at least one second LED module42ato the sign, comprising the steps of removing a plastic number at100, gluing enclosure posts to the sign face at step120, placing an LED module into the tracks at step122, and attaching the LED module to the enclosure posts at step124. Steps100,120-124are repeated for each LED module. A data cable is connected between a controller inside the sign and the second LED module42aby running the data cable out of a side of the sign near the top of the sign, and down the outside of the sign, without breaching the sign face15, at step110. A power cable is connected between a power supply and the second LED module42ain the same manner as the data cable is connects, at step112.