Split flap display

A split flap display is provided. The display includes a wall frame mounted on a wall. The wall frame includes a plurality of panel guides extending outwardly therefrom, a breakout board mounted thereon, and a plurality of cantilevered snap locks extending outwardly therefrom. An array of carousel modules is mounted in a cabinet. The array includes a single row and a plurality of columns. The cabinet includes a locking slot adapted to releasably receive a free end of one of the plurality of cantilevered snap locks and a slide lock configured for longitudinal translation engagement with the free end of one of the plurality of cantilevered snap locks, such that translation of the slide lock displaces the free end of the cantilevered snap lock out of engagement with the locking slot. When the free end of the cantilevered snap lock is out of engagement with the locking slot, the array can be removed from the wall frame.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to electro-mechanical flip chart display boards.

Description of the Related Art

Split flap displays were well known devices used in train and bus stations to update departure and arrival times of trains and busses. Each letter on the board is comprised of a rotating wheel with a plurality of flaps that roll over as the wheel rotates. The wheel stops at a desired position, displaying the desired letter. This process repeats for all of the letters on the board. However, when the rotating mechanism for one of the letters malfunctions, the process to repair the mechanism is quite tedious, requiring the display to be disassembled to repair or replace the malfunctioning mechanism.

It would be beneficial to provide an improved split flap display that allows the repair or replacement of a single module without having to disassemble a large portion of the display.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, the present invention is a split flap display that includes a wall frame mounted on a wall. The wall frame includes a plurality of panel guides extending outwardly therefrom, a breakout board mounted thereon, and a plurality of cantilevered snap locks extending outwardly therefrom. An array of carousel modules is mounted in a cabinet. The array includes a single row and a plurality of columns. The cabinet includes a locking slot adapted to releasably receive a free end of one of the plurality of cantilevered snap locks and a slide lock configured for longitudinal translation engagement with the free end of one of the plurality of cantilevered snap locks, such that translation of the slide lock displaces the free end of the cantilevered snap lock out of engagement with the locking slot. When the free end of the cantilevered snap lock is out of engagement with the locking slot, the array can be removed from the wall frame.

In another embodiment, a split flap display includes a cabinet and a plurality of modules located in the cabinet in a first array. Each of the plurality of modules comprises a plurality of motor driven carousels. Each of the carousels includes a plurality of flaps.

DETAILED DESCRIPTION OF THE INVENTION

In the drawings, like numerals indicate like elements throughout. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. The terminology includes the words specifically mentioned, derivatives thereof and words of similar import. The embodiments illustrated below are not intended to be exhaustive or to limit the invention to the precise form disclosed. These embodiments are chosen and described to best explain the principle of the invention and its application and practical use and to enable others skilled in the art to best utilize the invention.

As shown in the Figures, the present invention is a split flap display100(“display”100) that uses a plurality of independently operated modules110that rotate to display a predetermined indicia112on one of a plurality of flaps114mounted on each module110. Indicia112can be alphanumeric characters, symbols, or other indicia. Modules110are typically operated such that, after all modules110display their particular indicia, the indicia112spell a word or provide some other type of readable message to a viewer.

FIG. 1shows an exemplary display100that has three rows and fifteen columns of modules110mounted in an array in a rectangular frame120. Those skilled in the art, however, will recognize that other sizes of module arrays can be provided.

Referring toFIG. 2, frame120has a back panel122onto which modules110are mounted. Back panel122provides a plurality of mounting holes123for card guides140,142(shown inFIG. 3) that provide slots for modules110. Frame120can be constructed from sheet metal and can be stamped and bent according to size requirements and the number of modules110to be installed in display100.

Back panel122can be integrated with a top surface124and a bottom surface126. Top surface124includes a well127that receives power input as well as Ethernet and USB hardwired connectors, if required for a particular display100. A header129is removably affixed over top surface124to protect any electrical components or connections, as well as to provide a facing131that can receive printing or other indicia as desired by the user.

Side panels128,130are removably mounted onto back panel122. Each side panel128,130includes a mesh screen132formed therein to allow for ventilation of display100. Ventilation fans134, shown inFIG. 3, are located adjacent each mesh screen132and screens132are provided with openings sufficiently small to prevent inadvertent insertion of a finger thereinto.

Referring toFIG. 3, rail boards136are provided for each row. Rail boards136are mounted on back panel122and provide electrical connections for each module110. Additionally, card guides140,142are mounted to back panel122. Modules110are supported by card guides140,142. For modules110that are to be mounted on a top or bottom row of display100, card guides140are used. For modules110that will not be on the top or bottom row (in this example, in the center row), card guides142are used.

Card guides140,142can be commercially available guides that are used to mount printed circuit boards. An exemplary provider of such guides is Richco. For circuit boards, a card guide140,142is required for each of the top and the bottom of the board with a single board mounted between two vertically adjacent card guides140,142. For display100, however, two modules110are releasably connected to a single card guide140, while four modules110are connected to a single card guide142. Additionally, two modules110can be mounted between two vertically adjacent card guides140,142.

Referring toFIGS. 4-6, modules110each includes a carousel150comprised of a plurality of flaps152. In an exemplary embodiment,50flaps152are provided per carousel150. Each flap152has a front face154with the top half of an indicia printed thereon and a rear face156with the bottom half of a different indicia printed thereon such that, when the top face154of one flap152and the bottom face156of an adjacent flap152are exposed, top face154of one flap152and bottom face156of the adjacent flap152form a complete indicia112, as shown inFIG. 4. Each side of flap152includes a side tab158extending outwardly therefrom. Side tab158engages slot159in carousel wheels160,161(shown inFIG. 5), in which flap152pivots.

FIG. 5shows a housing162for module110. Housing162is constructed from stamped and bent sheet metal and has a front face164, left and right sides166,168, and an open rear170. Front face164includes an opening172that allows flaps152to rotate and to be visible.

Left side166is generally solid, with openings174for motor mounting screws176to extend through. A driver board178is mounted to an inner face of left side166. Driver board178is used to control operation of module110, including a Hall Effect sensor179, as will be discussed in detail below. Driver board178includes a male insert177that fits into a female card edge module connector240that is fixed to signal rail board136. Card edge module connector240receives and transmits signals from the controller to operate module110.

A sound enhancing rod180is secured to left side166with a nut182and screw184. As flaps152rotate, flaps152“slap” sound enhancing rod180, generating a sound to let people in the vicinity of display100hear the operation of display100. Additionally, sound enhancing rod180also serves to prevent the swaying of flaps152after turning over during operation of module110.

Left side166also includes top and bottom through holes181(only top through hole181shown inFIG. 5) for releasable connection to card guides140,142.

Right side168includes an opening186formed therein to allow for connection of a flap188rotating assembly therein. An anti-rollback flap190is provided on an inner face of right side168and is used to make contact with the free end of each flap152as flaps152rotate during operation and provide a hard stop, preventing carousel150from rolling backward.

Right side168also includes top and bottom through holes181for releasable connection to card guides140,142.

A plurality of nylon motor mounts192are provided, each motor mount192sliding over a retaining screw176. Motor mounts192are arranged in a “square” pattern such that a motor194is supported within the square. Motor194includes an output shaft196that is connected to a motor hub198. Motor hub198is keyed to a right carousel wheel161and secured by a plurality of screws200. Motor194is electronically connected to driver board178such that driver board178operates motor194.

Right carousel wheel161includes plurality of slots159spaced therearound to retain one side of each flap152, as well as through holes202sized to allow screws204to extend therethrough, as well as through nylon spacers204and left carousel wheel160for retention by threaded inserts206that are press fit through through-openings208in left carousel wheel160.

An inner face of left carousel wheel160also includes a magnet210. Magnet interfaces with the Hall effect sensor179on driver board178to self-calibrate module110each time module110rotates such that magnet passes the Hall Effect sensor179. Magnet210provides location information about carousel150by generating a signal at the Hall Effect sensor179that is transmitted to the controller for display100.

FIGS. 7-9show an exemplary embodiment of a 2×2 array of modules110with card guides140,142. A card guide142is shown inFIG. 10. Card guide142is symmetric about a central horizontal plane. Therefore, only a description of card guide142above the plane is provided, with the portion of card guide142below the plane being identical.

Card guide142includes an elongate rod220having a fixed end222that is secured to back panel122and a free end224into which left and right sides166,168of adjacent modules110are inserted. A groove226extends the length of rod220. Groove226is wide enough for left and right sides166,168of adjacent modules110to fit therein, as shown inFIGS. 11 and 12.

A securing pin230includes a locking portion232and a release portion234. Securing pin230is slidable between a locking portion (shown inFIG. 12) and an unlocking position (shown inFIG. 11). Locking portion232is sized to extend through holes181in two adjacent modules110to releasably secure the two modules110to card guide142above the plane. Similarly, a second locking portion232is sized to extend through holes181in two adjacent modules110to releasably secure the two modules110to card guide142below the plane, such that four modules110are retained within card guide142.

To lock four modules110to card guide142, the four modules110are aligned as shown inFIGS. 7-9 and 11, with securing pin230in the unlocking position. Securing pin230is then pushed to the position shown inFIG. 12. To unlock modules110, release portion234is pushed from the position shown inFIG. 12to the position shown inFIG. 11.

Referring now toFIG. 13, rail board136is shown in detail. Rail board136is an eight module long controller, although those skilled in the art will recognize that more or less than eight module connectors240can be included. An unlimited number of rail boards136can be connected together in series, which allows for infinite expandability of display100. Each module connector240accepts a driver board178from one of eight modules110connected to driver board136. As shown inFIG. 14, each module connector240is located vertically below a corresponding card guide142for proper alignment and ease of installation of modules110to rail board136.

Each rail board136includes a board controller242that is in turn connected to a master controller244attached to back panel122. Rail boards136form part of a closed loop control system in which the master controller sends out an electrical signal to operate each motor194. An exemplary master controller244can be an Arduino, which is well known in the art.

When an electrical signal is transmitted to motor194, motor194rotates until the “home” position is detected, the home position is detected when Hall Effect sensor179detects magnet210and board136sends back a ‘home’ ping to master controller244. This feature allows for recalibration of module110on every rotation.

Optionally, display100can be communicated with wirelessly, such as via Rasberry Pi246which then transmits a signal to the main controller to operate modules110. Alternatively, display100can be communicated with using a hardwired Ethernet connection (not shown), which transmits to the main controller244.

To power display100, each rail board136receives a 24 VDC power supply248that is electrically connected to board controller242for powering motor194on each module110. The data has a 24V-5V converter250that distributes electrical power to each board controller242.

Display100has the capability to be set as a “client” (similar to how a web user is a client when using a browser to navigate to a web page) and to set the refresh or call frequency for display100to maintain or change the indicia112on modules110from a specified server/website location. So, if a user wants to integrate display100with live data the user points display100as a client to that source.

Display100can be controlled via a web app that is wireless or wired, with the capability of building out messages containing different screens, playlists containing different messages, and scheduling playlists based on time of day, or other parameters. Also, display100allows for instantaneous messaging or changing of indicia112on display100using what is shown on a PC/mobile/tablet interface that is electronically connected to display100. Display100can be used to display current weather, stock quotes, or other such information. Master controller244also allows for changes of time delay between screens in any one message, which can be used to “animate” display100.

In an alternative embodiment, shown inFIGS. 15-17, a split flap display300is shown. Instead of a housing that is custom designed and built based on customer requirements (i.e., a specified number of rows and a specified number of columns), Display300is modular, with prefabricated housing backplates302that are a single row and eight (8) columns wide. Multiple housing backplates302can be connected together to provide a display300of any size, with the number of columns being a whole number multiple of the number of columns in the housing302. As shown inFIG. 15, display300is an exemplary three rows with three back plates302(24 columns). While eight (8) columns are used, those skilled in the art will recognize that more or less than eight (8) columns can be used.

Display300includes a cabinet301constructed from a master header304that is located in the top left corner of a multi-backplate assembly300. Master header304is a generally inverted “L-shaped” panel constructed from sheet metal. Power and data enter display300through a cutout306in master header304and connect to a controller308mounted on master header304.

If display is more than eight columns wide, repeat headers310are added in series next to master header304to pattern out the desired number of columns in display300. Similar to master header304, repeat headers310are generally inverted “L-shaped” panels constructed from sheet metal. As shown inFIG. 15, two repeat headers310are provided, although those skilled in the art will recognize that more or less than two repeat headers310can be used.

The repeat headers310form a header row, which serves to house extra power supplies and other electronics (not shown) necessary for larger signs. Master header304and repeat headers310are covered by a removable header panel312, which is easily removed via thumbscrews (not shown) in the top of display300. Header panel312is custom built, depending on the number of columns for display300.

Bottom panels314provide a back plate302, along with a bottom plate316. A gusset318located about half way between the end of bottom plate316and is attached to its respective back plate302to provide support. If display300is only a single row display, then bottom panel314is used and is connected directly to master header304or a repeat header310.

Header side panels320are provided to cap the ends of the headers304,306, and spacer plates322are provided at the top and bottom of the rightmost part of display300. Header side panels320are vented to provide for air circulation to cool controller308.

All back plates302, headers304,310, and bottom panels314have jog bends315that lap over the pieces to the right and below them. Where the lapping of sheet metal between adjacent back plates302, headers304,310, and bottom panels314occurs, connectors, such as screws or rivets, are installed via concentric holes in both pieces. In this way, these panels pattern out in width and height in standard dimensions to construct cabinet301. Side walls324are also modular, and are secured together to make up the height of the sides of display300. Side walls324are then secured to the left and right most back plates302and bottom panels314to complete cabinet301.

Referring toFIG. 16, split flap modules330are locked into the back plates302(if used) and bottom panels314via lance features332punched into the back of the sheet metal panels forming back plates302and bottom panels314. Lance features332accept a hook334in the back of each module330, dropping down into place and resting on each hook334. Each module330includes a cable (not shown) that releasably connects a module board336in each module330to a shifter rail338mounted on each back plate302and bottom panel314. Each lance feature332holds hook334of each of two adjacent modules330, allowing the array of modules330to hang securely within cabinet301.

In the event of a malfunctioning module330, to remove that module330from cabinet301header panel312is first removed from cabinet301. Removing header panel312provides necessary clearance above the top row of modules330to lift hooks334up and out of lances332. To remove a module330from a row other than the top row, the modules330above the desired module330are first raised up in this manner, allowing vertical space for the desired module330to be lifted out of its respective hooks334and removed from cabinet301. A replacement module330can be re-inserted into cabinet301by raising any modules330above the area where the replacement module330is to be inserted, inserting the new module330, lowering the modules330above the new module330, and replacing header panel312.

In an alternative embodiment, shown inFIGS. 17-19, a split flap display assembly400includes at least one stand-alone wall mounted display400′ having a single row of eight (8) modules430of split flap characters. Assembly400can accept additional displays400′, either horizontally (to add columns), vertically (to add rows), or both (to add columns and rows) to expand the network and size of assembly400. The additional displays400′ can be added when the first display400′ is mounted or, alternatively, displays400′ can be added later on to expand display400, allowing for a modular and retroactive expansion of display400.

Each display400′ includes a cabinet401having a front face402, an extruded parallelepiped body404and a back panel406, which provide a fully enclosed cabinet401. Modules430are removably inserted into cabinet401. Referring toFIG. 20, in an exemplary embodiment, each module430includes a plurality of flaps432on a carousel434that rotates on an axis436. In an exemplary embodiment, fifty (50) flaps432are provided, although those skilled in the art will recognize that more or less than fifty (50) flaps432can be provided. Each flap432includes indicia provided thereon such that, when carousel434is stopped from rotating, adjacent flaps display a letter, a number, or some other character to be read on display400′.

Two side walls438,440(shown inFIG. 17) provide rotation points for carousel434, as well as mounts for a drive motor442and drive shaft gear444, mounts for a drive train-gear446, mounting locations for an electronic board448(shown inFIG. 17), which provides motor commands and records positional information of carousel434via a Hall Effect sensor, such as Hall Effect sensor179discussed above, and mounting locations for a sound enhancing rod450. Sound enhancing rod450provides both a stop for falling flaps432as carousel434rotates, which improves visibility of characters on flaps434by halting the falling motion, and amplifies the sound of the falling flaps434. The two side walls438,440and their components are identical, completely reversible parts.

Body404has ridges452on internal top and bottom faces454,456, respectively, which allows each side wall438,440of each module430to slide into, providing equal spacing and rigidity for each module430. Front face402and back panel406are each guided into body404by molded internal lips460. Once the front face402, the body404, and back panel406are in place, screws462are slid in through the rear of back panel406and threaded into inserts464that are friction fit into the inside of front face402.

Each display400′ is attached to a respective wall panel470via wall panel guides480that slide through support cutouts482in back panel406, allowing the full weight of the display400′ to rest on the guides480. Cantilevered snap locks484extend from wall panel470, extend through openings in back panel406, and engage a locking slot486inside display400′.

To install a display400′, a user first mounts wall panel470in a desired location using screws (not shown) inserted through mount holes472in wall panel470.FIG. 18shows an example of six (6) wall panels470mounted in a grid. A master controller474, such as a Raspberry Pi, which is only provided for the first display400′ in the grid (and not for the remaining displays400′), provides a receiver for receiving electronic signals and commands over Wifi. Breakout boards476are also housed in each wall mount panel470; these boards pass along signals from master controller474to its respective display400′ and to the modules430in each display400′. Each breakout board476, is connected to adjacent unit breakout boards476via ribbon cables (not shown) in each cardinal direction via cutouts478in each wall panel470. A network of displays400′ can be built and linked via breakout boards476as large as the user desires.

With the network of wall mount panels installed in the desired grid and locations, wall panel guides480are slid through support cutouts482in the back panel of back panel406. Snap locks484engage locking slot486inside display400′. Locking in this manner allows users to easily mount displays400′ with a simple push toward the wall, and does not allow display400′ to be accidentally dislodged or unlocked.

In order to unlock and remove a display400′ from the wall panel470in the event of a failure of one or more carousels434in a display400′, display400′ can be removed from the wall without affecting any remaining displays400′ on the wall.

To remove display400′, two keys490are provided, one on either side of display400′, proximate to the top of display400′. Key490is used to unlock display400′ from wall panel470by inserting the male end of the key490into a small opening494at the top of the left and rightmost side of display400′. Once inserted, the user pushes both keys490into openings494and toward the wall to apply pressure to slide locks496that are located directly behind each respective opening494. The slide locks496are allowed only 1 degree of freedom by longitudinally sliding along internal channels497along the bottom face of454of body404. This displacement of the slide locks496toward the back of display400′ applies pressure on snap locks484, biasing snap locks484downward and out of locking slot486, thereby allowing display400′ to slide off the wall mount panel guides480.

In an exemplary embodiment, modules430can be the same as modules330described above. Operation of modules330,430can be the same or similar to the operation of modules110described above.