Abstract:
The present invention relates to an enclosure for electronic displays including a frame, at least one coupling assembly coupled to the frame, wherein one of the coupling assembly and the frame includes a plurality of recesses and the other of the body and the frame includes a plurality of protrusions configured for mating alignment with the recesses, a display module disposed within the frame, a front panel coupled to the frame, and a rear panel coupled to the frame. The present invention further relates to a method of manufacturing the enclosure including providing at least one side wall, providing a corner assembly, wherein the side wall has a plurality of recesses and the corner assembly has a plurality of corresponding protrusions for mating engagement with the plurality of recesses, and sliding the protrusions into the recesses to form a secure fit, whereby secondary operations, such as drilling holes or punching holes, in the side wall are unnecessary to complete the mating engagement.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to the field of display enclosures for indoor and outdoor applications. More particularly, the invention relates to an improved enclosure for electronic displays that greatly reduces material and assembly costs without compromising the enclosure&#39;s function or aesthetics. The invention also relates to a method for making the improved message center. 
     BACKGROUND OF THE INVENTION 
     Enclosures for electronic displays having ventilation fans are known. These enclosures typically include side walls, a rear equipment panel, a front window, one or more fans and display modules mounted within the enclosures. Two methods are primarily used for manufacture of enclosures for electronic displays. The first manufacturing method involves forming a sheet metal enclosure, which involves the steps of shearing a flat piece of sheet metal, punching the required holes into the sheet metal, forming additional metal parts, and welding or fastening the sheet metal and the parts together. This method requires expensive and time-consuming operations such as machine set-up, welding and metal finishing, and is typically only cost effective for large production volumes. The second manufacturing method utilizes an aluminum extrusion. In this method the case is extruded in the desired shape, and, therefore, most of the machine set-up time and costs are eliminated. Although this method is better suited for an enclosure for electronic displays, this method still requires costly secondary operations, such as drilling, tapping and punching holes, for the mounting of additional components such as a fans, power supplies, circuit boards, mounting brackets, panels, etc. Secondary operations can significantly increase the manufacturing cost of an extrusion design. 
     Larger enclosures for electronic displays typically include one or more fans for ventilating the enclosure. The mounting of such fans typically requires additional secondary operations and additional bracketing or other means to support the fan or fans in the enclosure. The location of the fan or fans within the enclosure can negatively affect the aesthetics of an enclosure or reduce the mounting alternatives for the enclosure. A fan mounted to the front of an enclosure can reduce the available front display area of the enclosure and make the enclosure visually less appealing. An enclosure with a rear mounted fan may not be able to be directly mounted to a wall or ceiling without hindering the operation of the fan. 
     Accordingly, it would be advantageous to provide an enclosure for electronic displays that overcomes these disadvantages and other disadvantages. In particular, it would be advantageous to provide an enclosure that is less expensive to manufacture. What is needed is an enclosure that eliminates most secondary operations such as the drilling, tapping and punching of holes. What is also needed is an enclosure with fans that does not require the installation of additional supports, does not reduce the aesthetics or mounting options of the enclosure, and can be assembled without secondary operations. It would be beneficial to provide an enclosure design that is readily adaptable to most indoor and outdoor applications. It would be advantageous to provide a method of making an enclosure that is less expensive, quicker, cleaner, and safer. 
     SUMMARY OF THE INVENTION 
     The present invention relates to an enclosure for electronic displays. The enclosure includes a frame and at least one coupling assembly coupled to the frame, wherein one of the coupling assembly and the frame includes a plurality of recesses and the other of the coupling assembly and the frame includes a plurality of protrusions configured for mating alignment with the recesses. The enclosure further includes a display module disposed within the frame, a front panel coupled to the frame, and a rear panel coupled to the frame. 
     The present invention also relates to an enclosure for electronic displays, wherein the enclosure includes a plurality of side walls, each side wall having a plurality of recesses, and at least one corner assembly. The enclosure further includes a means for coupling two side walls to each corner assembly, a front panel coupled to at least one side wall, a rear panel coupled to at least one side wall, and a display module disposed in the enclosure. 
     The invention further relates to an enclosure for electronic displays including at least two side walls, at least one side wall having a plurality of recesses, and at least two corner assemblies, each corner assembly connecting two side walls to form a frame. The enclosure further includes a front panel slidably coupled to the side walls, a rear panel slidably coupled to the side walls, a module panel slidably coupled to the side walls and at least one display module coupled to the module panel. 
     The present invention further relates to a method of manufacturing an enclosure for electronic displays. The method includes providing at least one side wall, providing a corner assembly, wherein the side wall has a plurality of recesses and the corner assembly has a plurality of corresponding protrusions for mating engagement with the plurality of recesses, and sliding the protrusions into the recesses to form a secure fit, whereby secondary operations, such as drilling holes or punching holes, in the side wall are substantially unnecessary to complete the mating engagement except for mounting the parts together. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts, in which: 
     FIG. 1 is a front perspective view of an enclosure for electronic displays in accordance with an exemplary embodiment of the present invention; 
     FIG. 2 is a front perspective view of the enclosure of FIG. 1 with the window removed and the hinged module rack in an extended position; 
     FIG. 3 is a partial cut-away view of the side wall extrusion of FIG. 1; 
     FIG. 4 is a cross-sectional assembly view of the upper side wall, the rear panel and the hinged module rack of FIG. 2; 
     FIG. 5 is a cross-sectional assembly view of the lower side wall, the rear panel, and the hinged module rack of FIG. 2; 
     FIG. 6 is a front view of the enclosure of FIG. 1 with the window and the equipment, including display modules, removed; 
     FIG. 7 is a perspective assembly view of a corner assembly of FIG. 1; 
     FIG. 8 is a perspective view of the inner surface of a corner assembly of FIG. 1; 
     FIG. 9 is a perspective view of the inner surface of a corner assembly with a cooling fan of FIG. 1; 
     FIG. 10 is a front perspective view of the enclosure of FIG. 1 with the window and the hinged module rack removed; 
     FIG. 11 is an exploded perspective view of the window from the enclosure of FIG. 1; and 
     FIG. 12 is an exploded front perspective view of a enclosure according to a second embodiment of the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIG. 1, an enclosure  10  for electronic displays is shown. Enclosure  10  includes four side walls  12  slidably connected to four corner assemblies  14  to form a frame  16 . Side walls  12  include upper side wall  30 , right side wall  31 , left side wall  33 , and lower side wall  36 . It is understood that enclosure  10  may have more or less than four side walls  12  in alternative shapes of enclosure  10  (e.g., triangle, hexagon, circle, etc.). According to an exemplary embodiment, enclosure  10  further includes a front panel  17 , shown in FIG. 1 as a generally translucent window  18 , secured to the frame  16  by a set of clips  20 . According to an exemplary embodiment, window  18  is a polycarbonate material. Each corner assembly  14  includes a louver  22  coupled to each corner assembly  14  (e.g., by a snap-tight fit). Each side wall  12  is an extrusion and an aluminum extrusion in an exemplary embodiment. According to an exemplary embodiment, enclosure  10  can satisfy indoor, outdoor and National Electrical Manufacturers Association (“NEMA”)  12  applications. A NEMA  12  application provides protection against incidental contact, falling dirt, circulating lint, fibers, and light splashing of liquids. 
     Referring to FIG. 2, enclosure  10  further includes a rear panel  24  coupled to side walls  12 , a hinged module rack  26  coupled to upper side wall  30 . In a closed position, hinged module rack  26  is aligned parallel to and between front panel  17  and rear panel  24 . Hinged module rack  26  rotates forwardly about an axis  29  longitudinally extending along upper side wall  30  to an open position. A plurality of display modules  32  (e.g., seven-segment light-emitting diodes, light-emitting diodes, lamps, bulbs, etc.) are mounted to hinged module rack  26  by fasteners (not shown). A safety bar  34  extends from the rear face of hinged module rack  26  to couple hinged module rack  26  to a mounting rail bracket  124  mounted to lower side wall  36 , thereby holding hinged module rack  26  in an open position. A fan  38  is mounted to corner assembly  14  for ventilating enclosure  10 . Safety bar  34  allows hinged module rack  26  to be maintained in an open position thereby allowing front access to rear panel  24  and equipment sub-panel  206 . Front access eliminates the need to remove enclosure  10  from, for example, a wall in order to access equipment on rear panel  24  or equipment sub-panel  206 . 
     Referring to FIG. 3, a cross-sectional view of one of side walls  12  is shown, each of side walls  12  being of similar construction. Side wall  12  is an extrusion that is symmetrical about a longitudinal center line  39 . Side wall  12  includes an outer sheet  40  with opposing first and second hooked ends  42 ,  44 . First and second hooked ends  42 ,  44  extend inwardly in a generally perpendicular direction from outer sheet  40  and then extend toward one another. Side wall  12  further includes a longitudinally extending platform  46  spaced inwardly and generally parallel to outer sheet  40 . Platform  46  includes opposing first and second edges  48 ,  50  extending outwardly generally perpendicular from platform  46  to integrally connect to outer sheet  40 . Platform  46 , including first and second edges  48 ,  50 , and outer sheet  40  form a channel  52 . First hooked end  42 , outer sheet  40 , and first edge  48  of platform  46  form a front channel  54 . Second hooked end  44 , outer sheet  40 , and second edge  50  of platform  46  form a rear channel  56 . Platform  46  further includes an outwardly extending platform recess  60 ,  61  adjacent to each first and second edges  48 ,  50 . First and second inwardly extending and opposing stepped members  62 ,  64 , each having a free end  66 ,  67 , extend inwardly generally perpendicular to platform  46  and then extend away from one another generally parallel to platform  46  toward free end  66 ,  67 . Each free end  66 ,  67  includes a stepped member recess  68 ,  69  positioned opposite platform recess  60 ,  61  and a bracing member  70 ,  71  positioned generally perpendicular to outer sheet  40 . Platform  46 , including platform recess  60 ,  61  and first and second stepped members  62 ,  64 , including stepped member recess  68 ,  69 , form first and second t-shaped channels  72 ,  74 , respectively. Platform  46  further includes longitudinally extending first and second circular slots  76 ,  78  positioned adjacent to first and second stepped members  62 ,  64 , respectively, toward the longitudinal centerline  39  of side wall  12 . First and second circular slots  76 ,  78  open inwardly and are disposed parallel to one another. Platform  46  further includes two inwardly extending and opposing right angled protrusions  80 ,  81 . Inwardly extending and opposing right angled protrusions  80 ,  81  are positioned adjacent to one another and spaced apart to form a center groove  82  aligned with the longitudinal centerline  39  of platform  46 . Platform  46  further includes inwardly extending first and second extensions  84 ,  86  positioned adjacent to first and second circular slots  76 ,  78 , respectively. First and second extensions  84 ,  86  each include a stub  90 ,  91  extending perpendicular from first and second extensions  84 ,  86  toward the longitudinal centerline of side wall  12 . First and second extensions  84 ,  86  platform  46  and right angled protrusions  80 ,  81  forming two longitudinally extending mounting slots  92 ,  93 . According to an exemplary embodiment, side walls  12  are 4.25 inches in depth and approximately 0.09 inches in thickness. 
     Referring to FIG. 4, the attachment of rear panel  24  to upper side wall  30  is shown. Rear panel  24  is connected to upper side wall  30  by clips  20 . Each clip  20  has an aperture  94  and an inwardly extending mounting surface  96 . Rear panel  24  is placed against bracing member  71  of second stepped member  64 . A nut  98 , one for each clip  20 , is slid into second t-shaped channel  74 . A fastener, shown as a screw  100 , is inserted through aperture  94  of each clip  20  and into nut  98 . When assembled, clip  20  braces against second hooked end  44  of upper side wall  30  and rear panel  24  is secured to upper side wall  30  between mounting surface  96  of clip  20  and bracing member  71 . Second t-shaped channel  74  serves as screw relief for screw  100 . Other fastening arrangements, such as resilient members, snap-tight assemblies, etc., are contemplated. Referring to FIG. 1, front panel  17  connects to side walls  12  at first hooked end  42  in a similar manner that rear panel  24  connects to upper side wall  30 . Rear panel  24  also connects to remaining side walls  12  in a similar manner as rear panel  24  connects to upper side wall  30 . Each clip  20  is pivotable about screw  100  to allow for easy removal and re-installation of front panel  17  or rear panel  24 . Mounting of rear panel  24  and front panel  17  to side walls  12 , in the manner described above, eliminates secondary operations such as drilling or punching, followed by tapping, of holes into side walls  12 , rear panel  24  or front panel  17  to accommodate fasteners. 
     Referring further to FIGS. 4 and 5, hinged module rack  26  connects to mounting slots  92 ,  93  of upper side wall  30 . A set of fasteners, shown as bolt  102 , are inserted into mounting slot  92 ,  93  of upper and lower side walls  30 ,  36 . A hinge bracket  104  couples a plurality of mounting rails  106  to upper side wall  30 . According to an exemplary embodiment, hinge bracket  104  is made of Type  304  stainless steel. Hinge bracket  104  includes a top arm  110  positioned parallel to upper side wall  30  and a forward arm  112  positioned generally perpendicular to upper side wall  30 , when forward arm  112  in the closed position. Forward arm  112  and top arm  110  each include a plurality of apertures (not shown) for coupling mounting rails  106  to upper side wall  30 . Each bolt  102  extends through top arm  110  into a module rack nut  114 . Each mounting rail  106  is connected to forward arm  112  of hinge bracket  104  by a fastener, shown as a rail screw  116 . Rail screw  116  is inserted through forward arm  112  and a spacer  118 , that is inserted through mounting rail  106 , to connect with a mounting rail nut  126 . A plurality of spaced apart secondary mounting rails  120  are placed generally perpendicular to mounting rails  106  and are coupled to mounting rails  106  by fasteners, shown as rivet  122 . Each mounting rail  106  couples to lower side wall  36  through bolt  102  extending through mounting rail bracket  124  into a mounting rail nut  126 . A fastener, shown as lower mounting screw  128 , is inserted through mounting rail  106  and connects mounting rail  106  to mounting rail bracket  124 . The mounting of hinge bracket  104  and mounting rail bracket  124  to upper and lower side walls  30 ,  36 , respectively, through mounting slots  92 ,  93  eliminates secondary operations such as drilling or punching, followed by tapping, of holes into side wall  12  to accommodate fasteners. 
     Referring to FIG. 6, spaced apart mounting rails  106  of hinged module rack  26  extend from upper side wall  30  to lower side wall  36 , though in alternative arrangements, module rack  26  may occupy only a portion of the space between upper side wall  30  and lower side wall  36 . Spaced apart secondary mounting rails  120  extend transversely across and are coupled to mounting rails  106 . Mounting rails  106  and secondary mounting rails  120  are configured for the mounting of display modules  32  and other equipment. Upon disconnection of lower mounting screws  128 , hinged module rack  26  can be forwardly rotated about the longitudinal axis of hinge bracket  104  to provide front access to rear panel  24 . 
     Referring to FIGS. 7 and 8, corner assembly  14  includes a corner body  130 , preferably an aluminum casting, having an inner surface  132  (not shown in FIG. 7) and an outer surface  134 . Body  130  includes a base plate  136  that is formed to first and second side plates  156 ,  158 . Base plate  136  having opposing mounting edges  144  and a circular void  146  disposed between first and second side plates  156 ,  158  and mounting edges  144 . A shaft  150  is disposed within circular void  146  and is coupled to base plate  136  by at least three trusses  152  extending radially from shaft  150 . In an exemplary embodiment, four trusses couple shaft  150  to base plate  136 . Shaft  150  includes a bore  154  axially extending through shaft  150 . First and second side plates  156 ,  158  extend generally perpendicular from base plate  136  and each side plate  156 ,  158  includes an outwardly projecting corner  160  that substantially covers either side of body  130 . A mounting member  162  obliquely extends from base plate  136  at each mounting edge  144 . Mounting member  162  includes two adjacent tongues  164 , each tongue  164  having a tongue aperture  166 . Corner assemblies  14  coupled to upper side plate  30 , further include a corner support bracket  168  placed over tongues  164  and one mounting edge  144  of base plate  136 . Corner support bracket  168  includes a mounting end  170  connected to mounting edge  144  and a tang  172  formed generally perpendicular to mounting end  170  and obliquely extending from base plate  136 . Tang  172  includes two tang apertures  174 , each tang aperture  174  aligns with each tongue aperture  166 . Body  130  further includes a support hole  176  positioned adjacent to mounting edge  144 . Support hole  176  is sized to accommodate an eyebolt or other support means (not shown) for top hanging or mounting of enclosure  10 . Corner assembly  14  slidably couples to side walls  12 . Each tongue  164  slidably connects to mounting slots  92 ,  93  of side wall  12 . For corner assemblies  14  coupled to upper side wall  30 , tang  172  of corner support bracket  168  slidably connects to channel  52  of side wall  30 . Fasteners, shown as circular slot screws  178 , extend through mounting brackets  162  of base plate  136 , and mounting end  170  of corner support bracket  168  for corner assemblies  14  connected to upper side wall  30 , into first and second circular slots  76 ,  78  of upper side wall  30  to connect corner assembly  14  to upper side wall  30 . Corner assembly  14  further includes a cover  188  having a cover aperture  180 , and a ventilation opening  182  positioned generally perpendicular to a cover support hole  184 . Cover  188  is fastened to outer surface  134  of body  130  by a fastener, shown as a cover screw  186 , that extends through cover aperture  180  and attaches to bore  154  of shaft  150 . Referring to FIG. 1, louver  22  is connected to cover  180  over ventilation opening  182 . According to an exemplary embodiment, louver  22  is made of injection molded plastic and includes a filter for filtering incoming air to meet NEMA  12  air quality requirements. The slidable connection of mounting member  162  into side wall  12 , the attachment of corner support bracket  168  into upper side wall  30 , the attachment of circular slot screws  178  into first and second circular slots  76 ,  78  of side wall  12 , and the attachment of cover  188  to shaft  150  of corner assembly  14 , all eliminate secondary operations such as drilling or punching, followed by tapping, of holes into side wall  12  to connect corner assembly  14  or to accommodate fasteners. 
     Referring to FIGS. 8 and 9, adjacent tongues  164  extend from base plate  136 . Mounting bracket tongue fasteners  165  connect tongues  164  to mounting slots  92 ,  93 . Base plate  136  further includes fan apertures  200  on inner surface  132  of body  130 . Fan  38  attaches to inner surface  132  of body  130  of corner assembly  14 . Fasteners, shown as fan screws  202 , extend through fan  38  and connect fan  38  to corner assembly  14  at fan apertures  200 . 
     Referring to FIG. 10, rear panel  24  has an inner surface  204  positioned opposite a back surface (not shown). An equipment sub-panel  206  connected to inner surface  204  of rear panel  24  by fasteners, shown sub-panel mounting studs  220 . Equipment sub-panel  206  is configured for the mounting of equipment such as power supplies and a controller board. Mounting such equipment to equipment sub-panel  206  reduces the number of holes required in rear panel  24 . Wall hanging brackets  222  and spacers  224  for wall mounting of enclosure  10  extend from corner assemblies  14  at rear panel  24 . According to an exemplary embodiment, rear panel  24  is a thin gauge decorative panel with few holes. Also, according to an exemplary embodiment, equipment sub-panel  206  is an aluminum sheet having a thickness of approximately 0.08 inches. 
     Referring to FIG. 11, window  18  includes a transparent front cover  208  extending over and substantially covering a screen  210 . In this exemplary embodiment, front cover  208  is clear or has a red tint. Front cover  208  and screen  210  slidably connect to a sectional window frame  212 , thereby enclosing front cover  208  and screen  210 . Window frame  212  includes frame edge extrusions  214  connected at each corner of window frame  212  by frame corner brackets  216  and frame fasteners  218 . Connecting window frame  212 , in the manner described above, eliminates secondary operations such as drilling or punching, followed by tapping, of holes into side walls  12  or window  18  to accommodate fasteners. 
     Referring to FIG. 12, an enclosure  10   a  according to an alternative embodiment is shown. Enclosure  10   a  includes a module rack  28   a  slidably connected to upper and lower side walls  30   a ,  36   a  at a center groove  82   a . Front panel  17   a  and rear panel  24   a  also slidably connect to enclosure  10   a  at front and rear channels  54   a ,  56   a  of upper and lower side walls  30   a ,  36   a , respectively. Front panel  17   a , rear panel  24   a  and module rack  28   a  are inserted into or removed from enclosure  10   a  by removing one side wall  12   a . Access to front panel  17   a , rear panel  24   a  and module rack  28   a  is readily achieved by removing cover screw  186   a  and cover  188   a  from two corner assemblies  14   a  and then removing circular slot screws  178   a  from first and second circular slots  76   a ,  78   a  thereby allowing right side wall  31   a  (or left side wall  33   a ) and two corner assemblies  14   a  to be removed as one piece. Slidably connecting rear panel  24   a , front panel  17   a  and module rack  28   a  to side walls eliminates secondary operations such as drilling or punching, followed by tapping, of holes into side walls  12   a  rear panel  24   a , module rack  28   a  or front panel  17   a  to accommodate fasteners. According to another alternate embodiment front panel, rear panel and module rack slidably couple with a snap-tight fit to side wall. 
     In an exemplary embodiment, air flow through enclosure  10  is provided by fans  38  mounted to each corner assembly  14 . Body  130 , cover  188  and louver  22  of corner assembly  14  form an air plenum allowing for air to pass into and out of enclosure  10 . Two fans  38  are configured to pull air into enclosure  10  and the remaining two fans  38  are configured to discharge air from enclosure  10 . In an alternative embodiment, enclosure  10  contains two fans  38 , one fan  38  drawing air into enclosure  10  and a second fan  38  discharging air. In another alternative embodiment, enclosure includes a single fan  38  for drawing into or discharging air from enclosure  10 . In another alternative embodiment, no fans are used, air flow passes through enclosure  10  by natural circulation or other means through air plenum of corner assemblies  14 . 
     A method of manufacturing the exemplary embodiment of FIG. 1 includes extruding or obtaining side walls  12 . The method further includes cutting side walls  12  to the desired lengths. Side walls  12  can be cut to any length allowing the length and width of enclosure  10  to adapt to a large number of different sizes for varying applications. The method further includes mounting equipment to equipment sub-panel  206 , and mounting equipment sub-panel  206  to rear panel  24 . The method further includes mounting fans  38  to corner assemblies  14 , assembling hinged module rack  26  and assembling front panel  17 . The method further includes sliding bolts  102  into mounting slots  92 ,  93  of upper and lower side walls  30 ,  36 . Then, the method includes connecting hinged module rack  26  to bolts  102  of upper side wall  30  with module rack nuts  114 . The method further includes sliding nuts  98  into the front and rear t-shaped channels  72 ,  74  of side walls  12 . The method further includes sliding side walls  12  on to corner assemblies  14  such that adjacent tongues  164  enter mounting slots  92 ,  93 , and placing circular slot screws  178  into first and second circular slots  76 ,  78  of side walls  12 . The method further includes placing front panel  17  and rear panel  24  on bracing member  70 ,  71  of side walls  12 , respectively. The method further includes placing screw  100 , clip  20  and nut  98  assembly in front and rear t-shaped channels  72 ,  74  securing front panel  17  and rear panel  24  to side walls  12 . 
     According to an exemplary embodiment, mounting brackets for wall mounting or top hanging are attached to the enclosure. According to an exemplary embodiment, side walls  12 , rear panel  24  and corner assembly cover  188  can be provided in a number of different colors to coordinate the enclosure to a decor. 
     While the embodiments illustrated in the FIGURES and described above are presently preferred, it should be understood that these embodiments are offered by way of example only, and various alternatives would be apparent to those of skill in the art. For example, a light box (a box containing fluorescent lights) maybe installed within enclosure  10  in place of display modules  32 . In another alternative embodiment, the equipment is mounted directly to the rear panel without an equipment sub-panel. In another alternative embodiment, the side wall extrusion does not contain the channel, the center groove, or the front and rear channels. In another alternative embodiment, the hinge bracket is connected to side wall in a lower position or a side position and the hinged module rack rotates forward from the top of the enclosure or the side of the enclosure. In another alternative embodiment, the hinged module racket rearwardly rotates allowing rear access to the front panel.