Abstract:
A lightweight display includes a plurality of display modules having a plurality of pixels carried by a display mounting frame. A support frame integral with the display mounting frame provides support. An electronic support member carries electrical components electrically communicating with the plurality of display modules for controlling the display of an image. Wherein the depth of the plurality of display modules, display mounting frame, support frame and electronic support member is less than four inches when defining a display assembly. Also wherein the display assembly has a screen size measured diagonally in a range of 114 inches to 224 inches and a weight in the range of 90 pounds to 120 pounds and wherein the display assembly has an aspect ratio ranging from 1.67 to 1.82.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This non-provisional utility application is a continuation of and claims priority to utility application Ser. No. 13/231,950, filed on Sep. 13, 2011. Application Ser. No. 13/231,950 is a continuation-in-part of and claimed priority to utility application Ser. No. 12/348,158 entitled Flexible Display, filed on Jan. 2, 2009. Application Ser. No. 12/348,158 claimed priority to U.S. Provisional Patent Application No. 61/109,144 filed on Jan. 4, 2008. Application Ser. Nos. 13/231,950, 12/348,158, and 61/109,144 are incorporated herein by reference. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     DESCRIPTION OF ATTACHED APPENDIX 
     Not Applicable. 
     FIELD OF INVENTION 
     The present invention relates to display devices. More particularly, the present invention relates to a modular display assembly having easily accessible and removable panels of pixel assemblies positioned along a true plane for providing a lightweight, mobile display which reduces off-axis distortion. 
     BACKGROUND 
     The electronic signage industry incorporates a wide range of design configurations. Each sign utilizes some aspect of lighting incorporated into a frame housing and typically is constructed for is intended environment. For instance certain designs include outdoor billboards and signage utilized in stadiums. These designs are primarily constructed to be very heavy and secure and to project large images without necessarily taking into consideration certain attributes of the projected image such as off-axis viewing. Presently, large scale displays tend to be heavy, expensive, not easily transported and set up, and power hungry. 
     For interior purposes it is known to utilize typically square modules having LED&#39;s and the like which are stacked in various configurations to create the desired design. Such modules are provide by Daktronics of South Dakota and identified as mobile and modular products at ww.daktronics.com/productsservices/products/video/mobilemodular/pages/default.asp. While suitable for their intended purpose and portable, these modules are intended for use at concerts, auto shows, or sporting events and are large. 
     U.S. Pat. No. 7,694,444 entitled Electronic Sign having a formed metal cabinet and assigned to Daktronics identifies a metal cabinet for housing a plurality of modules wherein the cabinet and associated support structure for the modules may be rapidly assembled. Such construction also provides for rear access enabling the light modules to be accessed from the rear should maintenance and the like be required. Furthermore, this patent discloses that the respective display modules are attached to a mounting panel as described in U.S. Pat. No. 7,055,271 entitled Electronic Display Module having a Four-Point Latching System for Incorporation Into an Electronic Sign and Process. This latching system includes a four-point latching system having gears and actuating arms to position latch arms outwardly over a mounting panel assembly followed by a pivotal latch positioning to rotationally engage the latching arms against the mounting panel assembly to secure the display module to the mounting panel assembly. Such a latching system would be necessary for large scale systems or for hostile ambient environments. However, such a construction does not lend itself to a light weight, or mobile display suitable for indoor purposes. Additionally the cabinets are intended to be matched with other such cabinets in a modular fashion for creating an overall display comprised of multiple cabinets. Such construction of multiple cabinets is incapable of providing a flat planar construction in all planes thereby minimizing distortion of off-axis viewing. 
     Accordingly, there is a need for a lightweight design which is easy to assemble and is mobile. 
     SUMMARY OF THE INVENTION 
     A lightweight display includes a plurality of display modules having a plurality of pixels carried by a display mounting frame. A support frame integral with the display mounting frame provides support. An electronic support member carries electrical components electrically communicating with the plurality of display modules for controlling the display of an image. Wherein the depth of the plurality of display modules, display mounting frame, support frame and electronic support member is less than four inches when defining a display assembly. Also wherein the display assembly has a screen size measured diagonally in a range of 114 inches to 224 inches and a weight in the range of 90 pounds to 120 pounds and wherein the display assembly has an aspect ratio ranging from 1.67 to 1.82. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a flexible display in accordance with one embodiment of the invention. 
         FIG. 2  shows an enlarged view of a portion of the display of  FIG. 1  along cut line  2 - 2 . 
         FIGS. 3A-3B  show a side view of a flexible chixel display in accordance with one embodiment of the invention. 
         FIG. 4  shows a chixel in accordance with one embodiment of the invention. 
         FIG. 5  shows a flexible display which incorporates square-shaped chixels in accordance with one embodiment of the invention. 
         FIG. 6  shows a flexible display which incorporates square-shaped chixels of  FIG. 5 . 
         FIG. 7  shows an elongated chixel in accordance with one embodiment of the invention. 
         FIG. 8  shows a flexible display incorporating the elongated chixels of  FIG. 7 . 
         FIG. 9  shows a chixel-based display in accordance with one embodiment of the invention. 
         FIG. 10  shows an enlarged portion of the chixel-based arrangement of  FIG. 9 . 
         FIG. 11  shows an LED wafer in accordance with one embodiment of the invention. 
         FIG. 12  shows a side view of the wafer of  FIG. 11 . 
         FIG. 13  shows an LED stack of the wafer of  FIG. 11 . 
         FIG. 14  shows a side view of an LED of a chixel in accordance with one embodiment of the invention. 
         FIG. 15  shows a top view of the LED of  FIG. 14 . 
         FIG. 16  shows a white light emitting LED of a chixel in accordance with one embodiment of the invention. 
         FIG. 17  shows an alternative embodiment of a chixel LED. 
         FIG. 18A  shows a top view of an LED wafer in accordance with an exemplary embodiment of the invention. 
         FIG. 18B  shows an enlarged portion of the LED wafer of  FIG. 18A . 
         FIG. 19  shows a chixel separated from the LED wafer of  FIG. 18A  in accordance with an exemplary embodiment of the invention. 
         FIG. 20  shows the chixel of  FIG. 19  incorporated into a display. 
         FIG. 21  shows an enlarged portion of the display of  FIG. 20 . 
         FIG. 22  shows a display substrate in accordance with one embodiment of the invention. 
         FIG. 23  shows a side view of a chixel-based display. 
         FIG. 24  shows a flexible chixel-based display in accordance with one exemplary embodiment of the invention. 
         FIG. 25  shows a flexible chixel-based display having dedicated controllers for each chixel. 
         FIG. 26  shows a chixel and filter arrangement for a chixel-based display in accordance with an one embodiment of the invention. 
         FIG. 27  a chixel-based display incorporating the chixel and filter of  FIG. 26 . 
         FIG. 28  shows one embodiment of a chixel having additional edge light emitters. 
         FIG. 29  shows a color flexible chixel-based display incorporating the chixel of  FIG. 28 . 
         FIG. 30  shows an enlarged portion of the display of  FIG. 29 . 
         FIG. 31  shows one embodiment of filter pattern. 
         FIG. 32  shows one chixel and filter arrangement. 
         FIG. 33  is a perspective view of a light weight electronic sign according to an additional embodiment of the present invention. 
         FIG. 34  is a front exploded assembly view of an electronic sign according to an additional embodiment of the present invention. 
         FIG. 35  is a view illustrating the various display modules for a kit assembly for manufacturing an electronic sign according to an additional embodiment of the present invention. 
         FIG. 36  is a view illustrating two display modules of the same pitch adjacent to one another illustrating the pixel gap according to an additional embodiment of the present invention. 
         FIG. 37  is a rear view of a display module according to an additional embodiment of the present invention. 
         FIG. 38  is an exploded rear view of a light weight sign illustrating the assembly of components. 
         FIG. 39  is a perspective view illustrating the assembly of the frame components of an additional embodiment of the present invention. 
         FIG. 40  is a cross-sectional view illustrating the mating relationships of the components of the electronic sign of an additional embodiment of the present invention from a top-down view. 
         FIG. 41  is a cross-sectional illustrating the mating relationships of the components of the electronic sign of an additional embodiment of the present invention from a side view. 
         FIGS. 42 and 42A  illustrate the mounting system of an additional embodiment of the present invention. 
         FIG. 43  is an exploded view of an electronic sign having an alternative display configuration according to an additional embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     As required, exemplary embodiments of the present invention are disclosed herein. These embodiments are meant to be examples of various ways of implementing the invention and it will be understood that the invention may be embodied in alternative forms. The figures are not to scale and some features may be exaggerated or minimized to show details of particular elements, while related elements may have been eliminated to prevent obscuring novel aspects. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. 
     For purposes of teaching and not limitation, the exemplary embodiments disclosed herein are discussed mainly in the context of LED light emitter technologies. However, the present invention is applicable to other light emitting technologies as well, such as, by way of example and not limitation, backlit LCDs, electroluminescence, or plasma tubes or cells. 
     Turning to the figures where like elements have like reference numbers throughout the several views,  FIG. 1  shows an exemplary embodiment of a flexible display  100 . As shown in  FIG. 2 , the flexible display  100  is comprised of a plurality of pixel chips  202 , referred to herein as chixels  202 , that are arranged in a chixel arrangement  200 . The chixels  202  may be rigid self-contained components that include a plurality of pixels  204 , formed of subpixels  206 . The chixels  202  are of a sufficiently small size and attached to a flexible display substrate  208  in such a manner that the space between the chixels, referred to herein as a chixel gap  304 , allows the flexible display substrate  208  to have a bending radius to provide a desired flexibility to the display  100 . 
     For example, as shown in  FIG. 3A , chixels  202  are provided on a flexible display substrate  208  with a chixel gap  304  of a size so that the side edges of the chixels are parallel when the substrate  208  is flat. As shown in  FIG. 3B , as the substrate  208  flexes, the chixels  202  move at angles with respect to one another due to the bending of the substrate  208  at the chixel gaps  304 . Although shown as square chixels  202  with sharp upper corners, the chixels  202  could have rounded corners or other shapes to prevent contact between adjacent chixels  202  during bending of the substrate  208 . Furthermore, the chixels  202  could be shaped so as to limit or prevent flexing of the substrate in a particular direction. For example, the chixels could have extensions (not shown) that contact each other to limit movement when the display is flexed in a particular direction. The size of the chixels and spacing between the chixels could also be varied to provide desired flexibility. For example, smaller chixels could be used on portions of the display which require more flexibility and larger chixels used on portions with lower flexibility requirements. 
     The chixels  202  are of a predetermined shape and arranged in a desired pattern on a flexible substrate  208  to form a flexible display  100 . The size, shape, and arrangement of the chixels  202  may be selected to provide a desired bend radius to the flexible substrate  208  to which the chixels  202  are incorporated. 
     As shown in an exemplary embodiment in  FIG. 4 , a chixel  202  may be generally square in shape. For example, the chixel may comprise a 4 by 4 array of 16 pixels  204 , each pixel having three subpixels  206 . As shown in  FIG. 5 , this square shape allows a chixel-based display  500  in which the chixels  206  are incorporated to flex easily both horizontally and vertically between the chixels  202  as the ratio of vertical and horizontal chixels gaps  304  is the same.  FIG. 6  shows a chixel display having chixels  202  on a flexible substrate with sufficient bend radius to be rolled up into a tube. 
     Chixels  202  may be provided in other shapes and arranged to provide a chixel gap  304  of an appropriate size to provide the display  100  with a desired amount of flexibility. Generally, the smaller the chixel  202 , the greater the number of chixel gaps  304  in the display in which the chixels are incorporated and the greater the number of bending points that can be provided and, therefore, the greater the flexibility of the display. For example, if it is desirable to provide a greater amount of flexibility in one direction of the substrate than another then the chixels can be shaped to provide such flexibility by arranging a larger number of flexible gaps in the one direction than the other. 
     The chixel  702  shown in  FIG. 7  includes a 4 by 8 pixel arrangement. As shown in  FIG. 8 , this allows for greater lateral bending because there are approximately twice as many vertical bending points  804  in the display than horizontal bending  806  points. Although the smaller the chixel, the greater the number of chixel gaps and the greater the flexibility of the display, the fewer the number of pixels that can be provided on the chixel and/or the smaller the pixels. Thus, while having smaller chixels increases flexibility, having larger chixels increases the size and/or number of pixels that can be provided on each chixel and decreases the number of chixels that must be attached to the flexible substrate. Thus, smaller chixels could be used in areas of the display with higher flexibility requirements. 
     As shown in  FIG. 4 , a chixel  202  may include pixels  204  that are comprised of subpixels  206 . The subpixels  206  may have different properties in order to provide desired properties for the pixel  204  of which they form a part. For example, the pixels  204  may comprise red  206 A, green  206 B, and blue  206 C subpixels that together form an RGB pixel. The intensity of the individual subpixels  206 A,  206 B,  206 B can be manipulated to provide light having desired characteristics, such as a desired light color or brightness. The subpixels  206  may have a rectangular shape so that together they form a square-shaped pixel  204 . The pixels  204  may be provided in a 4 times 4 array on a rigid substrate  220  to form a chixel of about 4 mm. The substrate  220  may be transparent to allow light emission through the substrate. For example, the substrate may be rigid glass or sapphire as discussed in more detail below. The pixels  204  may be provided at a distance apart from one another, the distance referred to as a “pixel gap”  304 . In an exemplary embodiment of a chixel, a plurality of light emitters is provided on a rigid substrate and serves as subpixels of a display. The subpixels may be divided into groupings, such as groupings of three subpixels, to form pixels. For example, subpixels that emit red, green and blue light may be grouped together to form an RGB pixel. Other arrangements, such as by way of example and not limitation, include a monocolor display in which all subpixels or pixels emit the same color light. Additionally, the light emitted by the pixels or subpixels may be converted or filtered to provide the desired light output; for example, the pixels could be formed of blue LEDs that are filtered or are color converted and filtered. 
     The subpixels may be of rectangular shape so that when combined with other subpixels they form a square pixel. The pixels may be arranged on the substrate such that the space between adjacent pixels, referred to herein as a “pixel gap,” is of a desired distance d 1 . Because there are no pixels to produce light at the pixel gap, the gap may appear as a darkened area of a display, referred to as a “pixel gap line.” Similarly, the subpixels may be uniformly spaced so that space between subpixels, the “subpixel gap”, is of a desired size. 
     In one aspect of the invention, the pixels are of a size relative to the pixel gap to make the pixel gap line less noticeable to a viewer. For example, the pixels may be of a size relative to the size of the pixel gap so as to provide a display of a desired resolution in which the pixel gap is not as pronounced or distracting to the viewer. This relationship and sizing may depend on a number of factors, including, but not limited to, viewing distance, contrast ratio, brightness, and viewing environment. 
     The size of the pixel gap  304  may vary depending upon the particular light emitting technology used for the subpixel  206 . For example, some light emitters may require conductors that extend around the edge of the emitter, which prevents the light emitters from directly abutting each other, thereby resulting in large subpixel and pixel gaps. For example, Organic Light Emitting Diodes (OLEDS) generally require that current be provided through the front of the display and a contact is commonly arranged to extend around the edge of the OLED, thereby preventing OLEDs from being tightly packed in a display. 
     One problem with prior art displays is that the pixel gap  304  is of such size that gap lines are visible in the resulting display which is distracting to a viewer and renders an image of poorer quality. This led to prior art attempts to provide front conductors for the pixels. This front conductor approach raises additional problems in producing flexible displays, however, due to the limited flexibility and high resistance values of known transparent front electrodes. 
     In one aspect of the present invention, the pixels  204  are sized relative to the pixel gap  306  between the pixels  204  such that the pixel gap  306  is less noticeable to an observer. For example, in a prior art OLED device the gaps between pixels that are required for the wraparound electrodes can result in a pixel gap to pixel area ratio that is readily noticeable to a viewer of the display. 
     In the present invention, pixels  204  are sized relative to the pixel gap  306  so that the gap line is less noticeable while still providing a desired resolution. One advantage of the present invention is that if a 4 mm chixel  202  which includes 16 pixels in a 4 by 4 array is used to provide the pixels for the display, the number of operations to provide the pixels  204  to the display is 1/16 of that of a technique that attempts to attach individual pixels to a display because multiple pixels are added with a single chixel. As discussed in more detail below, minimizing the effect of the gap line allows for the use of manufacturing techniques and resulting structures that were previously avoided due to concerns over gap lines. For example, by adjusting the pixel size to the pixel gap to minimize the effect of a gap line allows for electrodes to extend around the side of a pixel and allow a display to be driven at the rear, thereby eliminating some of the problems with prior art devices that are front driven. 
     As shown in  FIG. 9 , chixels  202  may be coupled to a flexible display substrate  208  by an adhesive or other coupling means. The pixels  204  can be arranged on the chixel  202  with uniform pixel spacing of a pitch or pixel gap d 2 . The chixels  202  can be arranged on the flexible display substrate  208 , to maintain the uniform pixel gap  304  d 2  between adjacent chixels  202 A,  202 B. For example, the pixels  202  may be located near the edges  910 A-B of the chixels  202  and adjacent chixels  202 A-B arranged so that the pixel gap  306  is uniform between pixels  204  even across adjacent chixels  202 A,  202 B. As discussed above, the chixel gap  304  between the chixels  202  provides a desired bend radius to the flexible substrate  208  that allows the display  100  to flex. Thus, a uniform pixel gap and a desired flexibility can be obtained; in other words the pixel pitch is consistent in both the rows and columns, even between pixels on the edges of two adjacent chixels. In one exemplary embodiment the pixel gap may be 320 micron, the chixel gap 320 micron and the pixel size 1600 micron. 
     As discussed in more detail below, the flexible substrate  208  may comprise a variety of layers, such as by way of example and not limitation, a contrast layer, a diffusion layer, a filter layer, and an anti-reflection layer. Each of these layers may be of a flexible plastic type. Thus, even though the chixels  202  themselves may be rigid, a sufficient number of chixel gaps  304  are provided in an appropriate arrangement that a desired bend radius of the flexible substrate  208  is obtained. 
     Chixels  202  may employ different light emitting technologies, such as LED, electroluminescence, plasma tubes or cells, and backlit LCD.  FIGS. 11 and 12  show an exemplary method of manufacturing an LED-based chixel. An LED is formed by depositing an n-doped semiconductor and a p-doped semiconductor layer on a substrate. Light is formed at the p-n junction when it is excited by electrical current. As shown in  FIG. 11  an LED wafer  1100  may be produced that includes a plurality of spaced apart LED stacks  1104  that, as discussed in more detail below, may serve as light emitters for a flexible display. As shown in  FIG. 12  the LED wafer  1100  may comprise a rigid substrate  1102  having a plurality of LED stacks  1104  thereon. For example, as shown in  FIG. 13  an LED stack  1104  may include a p-doped layer  1106  and an n-doped layer  1108  that are provided atop a sapphire substrate  1102  and have the appropriate properties to emit light when supplied with an appropriate charge (current). Various techniques can be used to create the LED stacks with great accuracy. Portions of the layers  1106 ,  1108  may be removed to create separate LED stacks on the rigid substrate separated from one another by a gap  1110  that generally corresponds to a subpixel or pixel gap of a completed display. For example, a mask may be applied and etching techniques used to etch channels through the upper layers  1106 ,  1108  down to the substrate to produce stacks that share a common substrate  1102 . In an exemplary embodiment LED stacks may be generally square having a length of about 320 .mu.m and a width of about 320.mu.m and a gap between the LED stacks  1104  of about 50.mu.m. Applicant has found that a layer of n-GaN of about 0.2.mu.m thickness and a p-GaN layer of about a 0.2.mu.m thickness on a sapphire substrate of a thickness of about 350.mu.m can be used to produce LEDs that emit blue light having a wavelength of about 450 nm. Different layers may be used or additional layers added to the LED stacks to obtain LEDs that emit light with desired characteristics. Furthermore, as discussed in more detail below, filters, photoconverters, and other apparatus may be used to manipulate the light emitted from the LEDs. 
     In order to make the LED stacks  1104  into workable LEDs, a p-contact  1120  and an n-contact  1122  may be provided to the stacks  1104  as shown in  FIG. 14  to form an LED  1400 . The p-contact  1120  may be provided in a cutout area  1130  of the p-doped layer  1108 . For example, an etching process may be used to remove a portion of the p-doped layer to allow the n-contact  1122  to be placed directly on top of the n-doped layer  1106 . This allows the p-contact to be placed directly atop of the n-doped layer  1106  and conductors  1140  to extend upward from the LED to a rear mounted display driver when the LEDs are incorporated into a display. This obviates the need of providing a large space between the light emitters for providing a pathway for conductors running along the edge and side of the light emitter and thereby allows the LEDs to be tightly packed. The wafer may be processed by etching, ablation, or other known techniques to form LEDs of various shapes, such as the LED  1700  shown in  FIG. 17  and arranged in a desired arrangement. 
     Additional layers can also be added to the LEDs  1400 . For example, as shown in an exemplary LED  1600  in  FIG. 16  a luminescent phosphor layer  1610 , typically a powder phosphor formulated based on the light output of the LED to provide the best conversion, may be provided for color conversion, to convert the emitted blue light to white. The color conversion layer  1610  may be added by known techniques. As shown in  FIGS. 14 and 16  when an appropriate current is applied, light is transmitted downwardly from the LED  1400 ,  1600 . Thus, in these embodiments the substrate  1102  is transmissive. 
     The wafer  1100  may include different layers on different LED stacks to provide different light characteristics. For example, different layers could be used to produce red, blue, and green light from different LED stacks  1104 . The wafer  1100  could also be made of uniform LED stacks  1104  having the same or similar properties. For example, the LED stacks  1104  could be constructed to emit white light or blue light which could then be filtered to produce light with desired characteristics. In the exemplary embodiment shown in  FIG. 14  in which GaN layers are used, blue light is emitted. Filters may also be used to provide red, green and blue LEDs which could define red, green and blue subpixels of an RGB pixel display. As seen in  FIG. 16  a white phosphor photoconversion layer  1610  can be applied so that the light emitted from the LED  1600  is white which is more efficiently filtered than blue light. 
     As shown in  FIGS. 18A-B  an LED wafer  1800  may include an array of uniformly spaced rectangular-shaped LEDs  1802 . The LEDs  1802  define subpixels  1803  that may be incorporated into a flexible display. The subpixels  1803  are spaced apart a horizontal distance hi that forms a subpixel gap  1808 . A group of LEDs, such as three LEDs, may be used to define an addressable pixel  1804  for a display. A larger array of LEDs may define a chixel  1806  which may include multiple subpixels and pixels. In the exemplary embodiment shown in  FIG. 19  the chixel  1806  includes 8 rows of 12 LEDs which define 96 subpixels and 32 three-LED pixels  1804  of the chixel  1806  to provide a 4.times.8 pixel arrangement. Commands/instructions from a driver may be directed to the LEDs of the pixel grouping to manipulate the individual LEDs  1802  as subpixels so that the overall light produced by the pixel  1804  is of desired characteristics, such as a desired color and brightness. 
     Multiple chixels  1806  may be coupled to a flexible substrate  208  to form a flexible display  2000 . For example, as shown in  FIG. 20  chixels  1806  may be coupled to a flexible substrate  208  in an arrangement  2202 . The arrangement of the subpixels  1803  on the individual chixel  1806  in conjunction with the arrangement of the chixels  1806  on the substrate  208  may be such as to provide uniform LED spacing and hence uniform subpixel and pixel spacing across the display  100 . In addition, the pixel gap  306  may be uniform across the display and may be set equal to the pixel gap  308 . By providing the subpixels  1802  about the edge of the chixel  1806 , and removing a predetermined amount of the substrate  208  in the dicing process, the chixel gap  304  may be such that the pixel gap  306  between pixels on adjacent chixels  202  is the same as the pixel gap between pixels on the same chixel and the pixel gap is equal to the subpixel gap. This provides for a uniform display with minimal gap lines. While discussed primarily in terms of the lateral spacing of the subpixels, pixels, and chixels, the same principles apply to the spacing of the subpixels, pixels, and chixels in other directions, such as the vertical gaps. 
     The size of the pixels  1804  can be varied depending upon the desired resolution and use of the display. For example, the size of the subpixels and pixels  1804  within a chixel  1806  incorporated into a display intended for use at a viewing distance of 10 feet may be smaller than a display meant to be used at a viewing distance of 100 feet, even though the displays have the same resolution. 
     As discussed above, the chixels  202  may be coupled to a flexible substrate  208  to form a flexible display  100 . In addition to providing support to the chixels  202  the substrate  208  may also provide additional functions, such as filtering, light diffusion, contrast enhancement, etc., and may be comprised of multiple layers. An exemplary flexible substrate  2200  shown in  FIG. 22  comprises a diffusion layer  2202 , a contrast enhancement layer  2204 , and an outer protective layer  2206 . The flexible substrate  2200  may also include an adhesive layer  2208  for coupling chixels  202  to the flexible substrate  2200  and one or more filters  2210 , as well as an antireflective layer  2212  (not shown). 
     The chixels  1600  may be placed light-emitting end down on the substrate  208  as shown in  FIG. 23  so as to emit light through the flexible substrate  2200 . The exposed p  1120  and n  1122  contacts allow the display to be driven from the rear by a drive system  2402  as shown in  FIG. 23 , thereby avoiding the complications of providing transparent front electrodes to the LED subpixels. As discussed above with reference to  FIGS. 3A-3B  the chixels  1600  are arranged on the substrate  2200  so that the resulting chixel gaps  304  provide sufficient bending areas to give the substrate  2200  a desired amount of flexibility. The drive means may address the subpixels in predetermined pixel groupings. 
     As shown in  FIG. 22  the substrate may be provided with one or more filters  2210  to manipulate the light emitted from the LED light emitters. For example, an array of color filters can be printed, sprayed or otherwise provided to the substrate  2200 . As seen in  FIG. 26  a red-green-blue filter arrangement  2602  having filter portions  2604 A,  2604 B,  2604 C of red R, green G and blue B may be added to the substrate assembly  2200  to form a filtered substrate  2702  with filter portions  2604  that correspond with the different LED light emitters  1600 A,  1600 B,  1600 C of a chixel  1600 . The chixel  1600  is coupled to the filtered substrate to form a color display  2700  so that the light emitters  1600  align with the filtered portions  2604  to form RGB pixels  2702 A,  2702 B,  2702 C as shown in  FIG. 27 . 
     As shown in  FIG. 24  drive means  2402  may be provided to the chixels to provide the necessary power and commands to make the light emitters of the chixels emit light in a desired manner. The drive means  2402  may include drive electronics as known in the art. In the exemplary embodiment shown in  FIG. 25 , a controller  2502  is provided for each chixel. The controller  2502  may comprise a data line and a power line that controls the emission of light from each of the light emitters on a particular chixel  1600 . By providing individual chixels with a controller  2502 , chixel units can be provided which can be premade and ready to install in a display. 
     Other filter arrangements may be provided in lieu of the standard RGB filter arrangement discussed above, in which each filter covers a single light emitter. For example, in the exemplary embodiment shown in  FIGS. 28-30  edge filters  2804  are arranged horizontally to cover portions of more than one light emitter. These edge filters further minimize the effect of the chixel gaps  304 . In addition, the chixels may be sized to include edge light emitters in addition to standard three-subpixel multiples. 
     Chixel gaps may to be more noticeable when the display  100  is flexed into a non-flat condition. As shown in  FIG. 28  in addition to the standard lateral RGB filter arrangement of the filter arrangement  2602  in  FIG. 26 , the filters that correspond to light emitters  1600  at the outer edge of a chixel  2802  referred to as edge emitters  2810  may be sized and shaped to cover edge emitters of two adjacent chixels  2802 . For example, edge filters  2804  may be provided to bridge the chixel gap  304  between adjacent chixels  2802  and cover edge light emitters  2810  on each chixel  2802 . These edge filters  2804  may be oriented horizontally and may be of a size as to together cover an edge light emitter  2810  on adjacent chixels  2802  in a vertical RGB arrangement. For example, as shown in  FIG. 28  a row of 14 light emitters  1600  on a chixel  2802  include 12 center light emitters and two edge emitters  2810 . The chixel  2802  may be arranged on a filtered substrate  2906  having vertical filter portions  2604  and edge filters  2804  so that the center 12 light emitters  1600  correspond with a row of 12 vertically oriented red  2604 A, green  2604 B or blue  2604 C filters and the two edge light emitters  2810  correspond with colored edge filters  2804 A-C. 
     Instead of covering a single light emitter on one chixel, the edge filter are sized and oriented to cover an edge light emitter  2810  on each chixel thereby bridging the chixel gap. In addition, the edge filters may be of a size such that multiple edge filters cover the adjacent light emitters. For example, red, green and blue edge filters may be arranged to cover adjacent edge light emitters in a vertical RGB pattern. The same may be done along the upper and lower edges of adjacent chixels. In addition to having the 12 RGB filters which correspond to 4 RGB pixels, an extra light emitter may be provided at each edge of the chixel to form a row of 14 light emitters. Thus, when two chixels are placed next to one another two edge pixels/light emitters are adjacent one another. It should be noted that while the subpixels and filters are generally discussed as corresponding with a single light emitter, filters may cover multiple light emitters. For example, a subpixel of a chixel could include three vertically aligned light emitters which could be cover by a red filter to define a red subpixel. 
       FIG. 31  shows another exemplary filter pattern  3102  that may be used in conjunction with a chixel  2802  in which upper and lower end filters  3104  are elongated to filter adjacent upper and lower light emitters  2820  across the chixel gap  304  in  FIG. 32 . Although each upper edge filter  3104  is shown as a single color filter that covers two adjacent light emitters from adjacent chixels  2802 A-B, the filters could be sized so that each light emitter is covered by a red, green, and blue filter. 
       FIG. 33  is a front isometric view of a lightweight electronic sign  1000 . Electronic sign  1000  consists of a plurality of display modules  1100  carried by a mounting frame  1110  which is designed to provide optimum off-axis viewing. The lightweight electronic sign  1000  may be mounted from a ceiling or a wall. In the preferred embodiment, lightweight electronic sign  1000  is intended for use within a facility such as a conference room, hotel lobby, or the like. The lightweight structure is integrated into a single unit for easy portability. 
       FIGS. 34 and 35  illustrate the components of lightweight electronic sign  1000 . A module display mounting frame  1120  carries a plurality of display modules  1130 . A display mounting support frame  1140  is carried by a rear surface of display mounting frame  1120 . An electronic support member  1150  is disposed preferably disposed rearwardly of support frame  1140 . The display mounting frame, display mounting support frame, and electronic support frame are carried by an externally positioned outward frame  1160 . In the preferred embodiment, outward frame  1160  consists of upper and lower horizontal frame members  1162  and  1164 , left and right vertical frame members  1166  and  1168 , and respective frame corner pieces  1170 . 
     In the preferred embodiment, display mounting frame  1120  is formed by one or more methods including, punching, or laser cutting or combination thereof with very precise cuts of close tolerance. Mounting frame  1120  is preferably manufactured from a single piece of aluminum forming a grid-like structure having a plurality of vertical and horizontal display module mounting surfaces  1122  and  1124  which are offset defining a plurality of display module receptacles  1126 . In the preferred embodiment, the precision cutting of the mounting frame  1120  provides for a singular plane which touches the outer vertical display module mounting surfaces in both the vertical and horizontal planes. In essence, the profile of the mounting frame is completely flat. A display module is received within a respective display module. Each display module carries a plurality of optical display sources such as pixel devices which may consist of LEDs or similar light emitting source which are presented to the face of the display module for working in conjunction with additional displays for transmitting an overall image. For ease of assembly and operational utilization, magnets  1172  are carried by display mounting frame  1120  for releaseable attachment with respective display modules for mounting the display modules with the display mounting frame. 
     In the preferred embodiment, the manufacturing of the electronic sign is done in a manner to enable the fast and efficient assembly of requested signs. The respective display receiving apertures  1126  are of a uniform size throughout mounting frame  1120 . Assembly preferably includes a kit of distinct display modules of similar shapes but of different density of pixels. For instance as shown in  FIG. 35  display modules  1130  may consist of different pixel spacings. For instance, display module  1130  may consist of display module  1131  which has an eight millimeter spacing of pixel placements,  1133  which has a six millimeter spacing of pixel placements or  1135  which has three millimeter spacing of pixels. In the preferred embodiment, display module  1130  is a square tile preferably two hundred and fifty millimeters in both the length and width direction. By providing different pixel spacings, different resolutions of the overall display may be obtained depending on the ultimate intended purpose of the display. Additionally by providing a consistent size, a plurality of displays may be manufactured via a kit arrangement depending on the requirements of the end user. 
     As shown in  FIG. 36 , when two display modules  1131 ( a ) and  1131 ( b ) are integrated within the display mounting frame, the two display modules have a pixel spacing such that the gap  1133  which extends from the last vertical row of pixels to the edge of the respective display module is one half of the pixel gap. Accordingly, the gap which extends from the edge of the adjacent display module to the first vertical row of pixels  1134  in combination with the gap from last vertical row of the adjacent display module is equal to the pixel gap between adjacent pixels on a respective display module. This configuration assists in providing for off-axis viewing such that no differentiation between display modules may be perceived from an ordinary observer viewing the overall displayed design. By utilizing a uniform sized display module, the various horizontal rows of pixels align when adjacent tiles are positioned in the display mounting frame. The same pixel gap configuration also exists for display modules which are adjacent in a vertical orientation. 
     As shown in  FIG. 37 , the display module  1131  has a rear surface which is utilized for enabling the display module  1131  to be carried by display mounting frame  1120 . In the preferred embodiment, the rear surface carries an attachment frame  1180  for interfacing with display mounting frame  1120 . In the preferred embodiment, attachment frame  1180  carries a metallic portion  1171  for magnetically mating with magnets  1172  carried by display mounting frame  1120 . Multiple configurations of this magnetic mating arrangement may be achieved. For instance, attachment frame  1180  may be metallic, or the magnets could be positioned on the attachment frame with a corresponding set of metallic slugs carried by the display mounting frame. In either circumstance, the magnets provide sufficient support for the display module. 
     The display module also includes an alignment device  1182 . In the preferred embodiment, alignment device  1182  consists of a plurality of posts which are matingly received by alignment post receptacles  1184  located within display mounting frame  1120 . The alignment device  1182  of each display module is positioned in the same manner and the alignment post receptacles  1184  are located in the same position with respect to each display module receptacle  1126  such that each display module  1131  may be positioned anywhere within the display mount frame. Also, the relationship of the alignment device and the magnetic attachment devices are such that the display modules are each positioned with respect to the display attachment frame such that a flat plane is established in both the horizontal and vertical directions. 
     Display modules  1131  also include a plurality of connectors  1184  for attaching to various electrical components of the lightweight display. Connectors  1184  are positioned within the profile defined by the alignment device and magnetic attachment devices such that the connectors will extend into the display receptacles defined within display mounting frame  1120 . 
       FIG. 38  is an exploded view of the lightweight display illustrating the relationships of the various components of the display. Display module  1131  is aligned with display mount frame  1120  such that alignment device  1182  is received via alignment receptacles  1172  enabling magnetic attachment device  1171  to secure the display module with the display mount frame. The electrical connectors  1184  pervade through the display mount receptacle  1126 . 
     A display mounting support frame  1140  is positioned rearwardly of display mount frame  1120 . Display mounting support frame  1140  consists of a plurality of horizontal support beams  1194  and vertical support beams  1196 . Depending on the ultimate size of the lightweight display, various configurations of horizontal and vertical support beams may be utilized. One embodiment as shown in  FIG. 34  consists of four horizontal and four vertical support beams. These beams also define an open receptacle enabling access to the electrical connectors of the display module. 
     Electronic support member  1150  is preferably a rigid board which is structurally sufficient for supporting a plurality of electrical devices. Such devices preferably include power supplies  1190 , and display circuit boards  1192 . The electrical devices are interconnected with the display modules via wiring, ribbon cable  2004  and the like. Preferably, each display module is connected with a separate display module such that each display module is ultimately connected with a display circuit board. In this manner each display module may be provided electrical control signals. Additionally, by having a system wherein a plurality of display modules are interconnected, these display modules are able to provide a reference to each other enabling the sign to ultimately display the desired display. Preferably, wires are tied together and positioned along the support beams to reduce congestion. 
     In addition to the support beams, spacing beams  2002  are carried by display mounting support frame  1140 . In the preferred embodiment, electrical support member  1150  abuts spacing beams  2002  defining a rearward enclosure. In the preferred In the preferred embodiment, preferably the entire depth of the display is less than four inches from the front of the display to the rear portion of the display. This compact construction is enabled by facilitating the placement of the electrical components within the periphery defined by the display mounting support frame and the display mounting frame. 
       FIGS. 39-41  illustrate the mating relationship of the external frame members with the additional components of the lightweight display for establishing a secure, solid and compact display. As shown in  FIG. 39 , upper horizontal frame member  1162  is matingly adapted for receiving corner piece  1170 . Additionally, vertical frame member  1166  is matingly adapted for receiving corner piece  1170 . Preferably both horizontal and vertical frame members are manufactured from extruded aluminum. The extrusion establishes a corner piece receptacle interior  1171  for receiving a connecting barb  1173  of corner piece  1170 . Both the horizontal and vertical frame members include corner piece receiving interior  1171  for receiving the respective connecting barbs  1173  of corner piece  1170 . Of course the construction may be had where the barbs are contained on the respective frame members and the corner piece has a receptacle for receiving the barbs. Or alternatively the barbs may be constructed as individual pieces for mating engagement with interiors of the extruded frame members and an extruded corner piece. However, in the preferred embodiment, it is desired that the vertical and horizontal frame members are constructed from extruded frame members which are cut to the desired length. In this manner, the manufacturing process would be best served having the barbs integral with the corner pieces. 
     The horizontal, vertical and corner pieces are configured for defining receiving positions for the components of the lightweight display. In particular, corner piece  1170  preferably includes a mating receptacle for electronic support member  1150 . In the preferred embodiment, the mating receptacle is a groove  2010  with dimensions for providing a snug fit with the upper surface  2020  of electronic support member  1150 . Additionally, vertical frame member  1166  includes a mating receptacle for electronic support member  1150 . In the preferred embodiment, the mating receptacle is a groove  2011  for providing a snug fit with the side surface  2021  of electronic support member  1150 . In this manner, the electric support member  1150  is securely carried by externally positioned outward frame  1160 . Also, display mounting support frame  1140  having a vertical side edge is constructed to fit within display mounting support frame receptacle  2012  defined along the length of vertical frame member  1166  for providing a snug supporting fit corner piece  1170  has a similar groove or notch  2013  for receiving an upper portion of the display mounting support frame  1150 . 
     A cross-sectional view of the intricate and snug construction of the preferred embodiment is shown in  FIG. 40 . Extruded vertical frame member  1166  extends from the display modules  1131  rearwardly to the electronic support member  1150 . The extruded vertical frame member  1166  carries both the display mounting frame  1120  within display mounting support frame receptacle  2012  which is preferably a groove along the length of the extruded vertical frame member at least as long as the vertical height of display mounting frame  1120 . Preferably this groove is of a width which provides frictional engagement with display mounting frame  1120 . Additionally, electronic support member  1150  is also simultaneously carried by extruded vertical frame member  1166  via groove  2011 . Groove  2011  is preferably of a width which provides frictional engagement with electronic support member  1150 . 
       FIG. 41  illustrates the compact construction of the lightweight display from a side view. In the preferred embodiment, the overall width from the front of the extrusion vertical frame member to the rear is preferably four or less inches. The groove which captures the display mounting frame is approximately point zero eight inches. As seen in  FIG. 41 , horizontal frame members  1162  and  1164  include an electronic support member groove  2030  and  2032 . As with the other grooves, these grooves are sized for frictional engagement with the upper and lower surfaces of electronic support member  1150 . Additionally, horizontal frame members  1162  and  1164  include display mounting frame grooves  2034  and  2036 . Preferably these horizontal frame members have an upper and lower support frame support members  2040  and  2042  for abutting against the horizontal frame members of support frame  1140  for a snug fit preventing upward or downward movement of the support frame.  FIG. 41  also illustrates the flush planar configuration of the display modules  1131  which are mounted on top of each other with their respective alignment pins received within display mounting frame  1120  and the magnetic attachment of the respective display modules with the display mounting frame  1120 . In the preferred embodiment, a clear screen  2050  is configured for extending over the upper and lower profiles of the respective display modules in a “C” cap configuration. Clear screen  2050  abuts the horizontal frame members  1162  and  1164 . 
     As can be seen in  FIGS. 39-41  a slim and structurally sound configuration for a lightweight display may be had according to the invention. Preferably to provide a compact construction the electronic support member is smaller than the display mounting frame, accordingly the horizontal frame members are curved to affix to each structure. Furthermore, in the preferred embodiment, slots are formed within the horizontal frame structure to provide cooling of the electrical components. 
     A thin display mounting frame which is precisely cut provides both a flat vertical and horizontal plane for mounting a plurality of video displays provides initial support for the display modules. A secondary support frame manufactured from extruded aluminum provides lightweight support. A third lightweight board supports the electronics necessary for running the display. A lightweight extruded peripheral frame structurally holds these three components together. By providing for slots or grooves within the horizontal and vertical frame members, the display mounting frame and electronic support frame are supported generally along the entire length of their periphery. This construction provides for a secure assembly. Additional recesses are defined within the vertical frame members for abutting against the vertical members of the support frame while the horizontal upper and lower frame members of the peripheral frame abut against the upper and lower horizontal frame members of the support structure to provide for structural support along the four sides of the support frame. 
     The preferred embodiment of the invention consists of a kit which enables mass production of various displays. As noted, each display module has a predetermined size notwithstanding the pixel displacement for the respective module. The display mounting support frame has display module receptacles for receiving each display module with alignment holes and magnetic attachment devices located consistently throughout the surface area of the display mounting support for consistently receiving, supporting and aligning the display modules to provide an arrangement wherein the pixel gap between adjacent pixels remains constant in both a vertical and horizontal direction within a particular display module and between adjacent display modules. The magnetic attachment enables for easy removal of the respective display modules enabling access to the electronic components carried by the rear electronic support frame. In this manner, various configurations of lightweight displays may be manufactured utilizing a kit of display modules. Only the height and width of the display mounting frame will be variable. 
     To further assist on the manufacturing, the outward frame of the preferred embodiment consists of a singular design of an extruded frame member. This frame member may be extruded to any length and then cut to size. By providing for slots within the extrusion for receiving the display mounting support frame and the rear electronic support frame, the slots can be utilized along a vertical height or a horizontal length. With the consistent cross section and positioning of the grooves, a simple process may be had by providing a singular extrusion. The respective extrusions are connected utilizing a uniform corner piece which may be used for all four corners of a rectangular display design. Of course, while a preferred embodiment consists of a singular extruded design, a possible alternative is utilizing a particular extrusion configuration for horizontal frame members only and a second extrusion configuration for the vertical frame members. 
     In this manner a kit for assembling would consist of a plurality of display modules of various pixel densities which would be chosen depending on the desired resolution of the finished lightweight design, at least a singular extrusion for defining an outward frame member which could be cut to the desired display size, a plurality of similar constructed corner pieces, a rear electrical board which can be cut to size and a plurality of extruded support beams would could be welded to a desired configuration for supporting the desired display. This ease of manufacturing provides for a simple construction of a lightweight display with minimum components. In practice only the display mounting support frame needs to be customized for the respective size of the ultimate display, the remaining components consist of general construction supplies such as the extruded beams which are merely cut to size. 
     Accordingly, with this construction, the depth of various displays maintain the same while the height and width of the various designs may be modified. By providing for a constant pixel gap, off-axis viewing is enabled. 
     In practice the following lightweight constructions were developed: 
     
       
         
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                   
               
             
             
               
                 Screen Size 
                 114 
                 Inches 
                 151 
                 Inches 
                 180 
                 Inches 
                 224 
                 Inches 
               
               
                 Brightness 
                 1500 
                 nits 
                 1500 
                 nits 
                 1500 
                 nits 
                 1500 
                 nits 
               
             
          
           
               
                 Contrast Ratio 
                 3000; 1 
                 3000; 1 
                 3000; 1 
                 3000; 1 
               
               
                 Resolution 
                 400 × 240 
                 520 × 280 
                 640 × 360 
                 800 × 440 
               
             
          
           
               
                 Weight 
                 90 
                 lbs 
                 100 
                 lbs 
                 120 
                 lbs 
                 120 
                 lbs 
               
             
          
           
               
                 Power 
                 less than a 
                   
                   
                   
                   
                   
                   
               
               
                   
                 coffeemaker 
               
             
          
           
               
                 Depth 
                 4 
                 inches 
                 4 
                 inches 
                 4 
                 inches 
                 4 
                 inches 
               
             
          
           
               
                 Aspect Ratio 
                 1.67 
                 1.75 
                 1.77 
                 1.82 
               
               
                   
               
             
          
         
       
     
     As shown in  FIGS. 42 and 42A  the lightweight display may be vertically hung or mounted utilizing wall mounts which are generally flush with the rear of electronic support member  1150 . In the preferred embodiment, frontal access to the interior of the display may be achieved by removing the respective display modules from the display mounting frame. This is enabled by the easily detachable magnetic support mechanism utilized for securing the respective display modules to the display mounting support frame. In the preferred embodiment, mounting brackets  2080  are carried by certain support beams of support frame  1140 . In the preferred embodiment the mounting brackets consist of a plurality of receptacles  2082  for receiving bolts. In the preferred embodiment mounting bracket  2080  consists of vertical and horizontal bolt holes for either receiving a horizontally mounted display or a vertically hung display. To facilitate horizontal mounting, upper beam member of outward frame  1160  includes a plurality of apertures  2084  aligned with the respective bolt holes of the mounting brackets. In the preferred embodiment certain apertures have been cut into the electronic support member. By providing for a common mounting structure, the lightweight display may easily be moved to a separate location and mounted utilizing the stationary mounting brackets. 
       FIG. 43  illustrates an alternative to configuration to a rectangular configuration. An oval configuration is illustrated consisting of a non-rectangular display mounting support frame  3000 , a non-rectangular support frame  3100  and an extruded outer frame  3200  having a plurality of grooves for structurally receiving the display mounting support frame  3000  and support frame  3100 . This configuration is similar to the prior examples including alignment holes and magnetic attachment means for receiving display modules  1131 . 
     Accordingly it may be that an advantage of the invention is a easy to manufacture lightweight display which provides for off axis viewing. Utilizing a common display module construction with varying pixel densities, and common extruded frame members both for an internal support frame and an external decorative frame, a plurality of lightweight display units may be constructed each having a depth no greater than 4 inches.