Patent Publication Number: US-2019180654-A1

Title: Module for a video wall having a film

Description:
TECHNICAL FIELD 
     This disclosure relates to a module for a video wall comprising a film. 
     BACKGROUND 
     Video walls comprising a multiplicity of LED devices, wherein one LED device is provided for one pixel are known. The LED device comprises a housing and at least one or more, in particular three, LED chips. For better visibility of the LEDs or protection against incident sunlight, shading elements may be provided above the LED chips. Furthermore, the individual LED housings may comprise lenses to improve the emission properties of the LED chip. 
     There is nonetheless a need to provide an improved module for a video wall. 
     SUMMARY 
     We provide a module for a video wall, wherein at least one device including at least one light-emitting component is arranged on a carrier, a film is arranged on the device, the film includes an optical element, the optical element is configured to influence light irradiation onto the devices and/or light emission of the devices, the devices are arranged in a grid, interspaces in the form of a lattice structure are provided between the devices, the film includes a covering structure, the covering structure includes at least one part of the lattice structure of the interspaces, the covering structure is arranged above the interspaces and covers the interspaces from above, and the film is laminated thereon. 
     We also provide a module for a video wall, wherein at least one device including at least one light-emitting component is arranged on a carrier, a film is arranged on the device, the film includes an optical element, the optical element is configured to influence light irradiation onto the devices and/or light emission of the devices, the devices are arranged in a grid, interspaces in the form of a lattice structure are provided between the devices, the film includes a covering structure, the covering structure includes at least one part of the lattice structure of the interspaces, and the covering structure is arranged above the interspaces and covers the interspaces from above. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a schematic plan view of an excerpt from a video wall. 
         FIG. 2  shows a schematic partial cross section through the video wall. 
         FIG. 3  shows one example of a device comprising a plurality of light-emitting components. 
         FIG. 4  shows a partial cross section through the video wall comprising a film. 
         FIG. 5  shows a partial cross section through a video wall comprising a film, wherein a covering structure is formed in the film. 
         FIG. 6  shows a partial cross section through a further example of a video wall, wherein the optical element is formed in the form of a roughened film or a Fresnel structure. 
         FIG. 7  shows a partial cross section through one example of a video wall comprising a film comprising a roughened surface. 
         FIG. 8  shows a schematic illustration of a partial cross section through a further example of a video wall comprising a film comprising a Fresnel structure. 
         FIG. 9  shows a schematic partial cross section through a further example of a video wall comprising a film comprising shading elements. 
         FIG. 10  shows an enlarged illustration of a partial excerpt from the film comprising the shading elements from  FIG. 9 . 
         FIG. 11  shows a plan view of an enlarged partial excerpt from the video wall from  FIG. 9 . 
         FIG. 12  shows a plan view of a partial excerpt from a film comprising shading elements and comprising Fresnel structures. 
         FIG. 13  shows a schematic illustration of a partial excerpt from a film comprising shading elements and a Fresnel structure. 
     
    
    
     LIST OF REFERENCE SIGNS 
     
         
         
           
               1  Video wall 
               2  Device 
               3  Trench 
               4  Mounting base 
               5  Module base 
               6  Circuit board 
               7  Electrical line 
               8  Electrical/electronic circuit 
               9  Optical element 
               10  Film 
               11  Adhesive layer 
               12  Lower functional layer 
               13  Carrier film 
               14  Upper functional layer 
               15  Covering structure 
               16  Roughened surface 
               17  Radiation-guiding element 
               18  Shading element 
               19  Recess 
               20  Shading material 
               26  Component 
               31  Light-emitting element 
           
         
       
    
     DETAILED DESCRIPTION 
     One advantage of our module is that the optical properties of the module are improved. Moreover, the module comprises a small structural height. The advantage is achieved by virtue of the fact that a film is arranged on the devices, wherein the film comprises an optical element, and the optical element is configured to influence light irradiation onto the devices and/or light emission of the devices. 
     By applying a film, for example, with the aid of a single laminating process, it is possible to realize a multiplicity of functions. In particular, a laminating process is able to be carried out more simply than a potting process or a spraying process for a film. 
     The film may comprise a covering structure arranged above the lattice structure of the interspaces of the devices. The covering structure comprises a low reflectance for visible light. The low reflectance may be achieved, for example, by way of the choice of the material of the covering structure. In particular, the covering structure may be produced from a dark, in particular black, material such as plastic, for example. As a result, optically visible disturbing effects such as e.g. reflections by the interspaces are reduced for an observer. The film affords the possibility of arranging the covering structure very close above the interspaces and precisely above the lattice structure of the interspaces. 
     The film may comprise an adhesive layer and an upper functional layer. The optical element is formed in the upper functional layer. A secure connection between the film and the devices may be achieved with the aid of the adhesive layer. 
     A carrier film may be provided between the adhesive layer and the upper functional layer. The carrier film enables the film to be formed more stably. Moreover, providing the carrier film makes it possible for the upper functional layer to be controlled to the function of the optical element in terms of structure and in terms of chemical composition, without having to carry out carrier functions. 
     A lower functional layer may be formed between the adhesive layer and the carrier film. The lower functional layer may comprise, for example, the covering structure for the interspaces. It is thus possible to provide a film for which two functional layers are provided, wherein the two functional layers carry out different optical functions. 
     The carrier may comprise a circuit board comprising electrical lines and/or circuits, wherein the devices are arranged on the circuit board. The devices electrically conductively connect to the lines and the electrical circuits of the circuit board. As a result, it is possible to achieve simple and secure line routing without significantly influencing the optical properties of the video wall. The electrical lines are formed, for example, such that the devices are individually drivable. 
     The optical element may be formed as a radiation-guiding element for the electromagnetic radiation of the at least one device. In this way, it is possible to improve color rendering and image reproduction, for example, with regard to an emission space. In particular, the emission direction of the video wall may be delimited upward and downward. Moreover, the lateral emission of the video wall may be extended. In this way, the video wall may be viewed better from a larger field of view. 
     The optical element may be formed as a Fresnel structure. The optical element may be formed as a roughened surface. The roughened surface ensures that reflections at the video wall are reduced. The surface of the video wall thus appears matte. A higher contrast during image reproduction is achieved as a result. 
     The optical element may be formed as a shading element for at least one device. As a result, disturbing light irradiations, for example, as a result of the sun may be kept away from the devices. Consequently, color falsifications as a result of light irradiation are reduced, in particular avoided. 
     The shading element may be introduced in a recess of a structured film. Consequently, the shading element may be formed on the film in the form of a metal structure. 
     The shading element may be arranged at a predefined angle with respect to a plane of the component or else comprise predefined shapes for improved shading of the device. 
     The devices may comprise a lateral distance from one another which is less than 0.8 mm, in particular less than 0.3 mm. Particularly in such small distances, it may become difficult to fill the interspaces with a potting material. Consequently, covering the interspaces with the aid of the covering structure in the film offers a simpler and secure covering of the interspaces. 
     The above-described properties, features and advantages and the way in which they are achieved will become clearer and more clearly understood in association with the following description of examples explained in greater detail in association with the drawings. 
       FIG. 1  shows, in a schematic plan view, a partial excerpt from a video wall  1  comprising a module comprising a plurality of devices  2 . A video wall  1  may comprise one or more modules. In the example illustrated, the devices  2  are formed in square fashion and arranged in a uniform grid. Each device  2  comprises at least one light-emitting component. The light-emitting component may be formed e.g. as a light-emitting diode or as a laser diode. Between the components  2 , trenches  3  are provided, which are filled, for example, with a filling material in particular with a dark in particular black, plastic. The term “light” is understood to mean any type of electromagnetic radiation, in particular visible light or infrared light. 
       FIG. 2  shows a schematic illustration of an enlarged partial cross section through the video wall  1  from  FIG. 1 . The module of the video wall  1  comprises a mounting base  4  on which a module base  5  is arranged. The mounting base  4  may comprise holding means to secure the video wall  1  e.g. to a building. The module base  5  may comprise mechanical securing elements and connectors to electrically connect the devices  2 , in particular the light-emitting components. A circuit board  6  is arranged on the module base  5 . The circuit board  6  may comprise electrical lines  7  and/or electrical circuits  8  to drive the devices  2 . The devices  2  are secured on the circuit board  6 . The devices  2  may be adhesively bonded, soldered or secured to the circuit board  6  by other means. The trenches  3  are formed between the devices  2 . The trenches  3  may comprise a width of 1 mm or less, in particular a width of less than 0.8 mm, in particular less than 0.3 mm. The small distance between the devices  2  provides for a high device density and thus a high luminosity of the video wall. The circuit board  6 , the module base  5  and the mounting base  4  constitute a carrier. The carrier may be formed only by the circuit board  6  and the mounting base  4  or the module base  5  may be dispensed with. Moreover, a circuit board  6  comprising no electrical lines  7  and/or no electrical circuits  8  may also be provided. 
       FIG. 3  shows a plan view of a device  2  in a schematic illustration. In the example illustrated, the device  2  comprises a multiplicity of components  26 . The components  26  are formed in square fashion and arranged in a 16×16 grid. One component  26  constitutes one image pixel. A component  26  comprises three light-emitting elements  31  arranged in a row. The component  26  may also comprise more or fewer light-emitting elements  31 . The light-emitting elements may be formed e.g. as light-emitting diodes or as laser diodes. 
     The device  2  constitutes a 16×16 multipixel LED housing. The device  2  comprises electrical lines and/or electrical circuits that make it possible for each image pixel, that is to say each component  26 , to be driven individually. The device  2  may also comprise more or fewer components  26 . By way of example, the device  2  may be formed in the form of a 4×4 multipixel LED housing or in the form of a 32×32 multipixel LED housing. In the smallest example, the device  2  comprises a single component  26  comprising a single light-emitting element  31 . 
       FIG. 4  shows a schematic partial cross section through a video wall constructed in accordance with  FIG. 2 , wherein a film  10  is applied on the video wall  1 . The film  10  may be applied by adhesive bonding, laminating or by other methods. The film  10  comprises an adhesive layer  11  that adheres on the devices  2 . A lower functional layer  12  is applied on the adhesive layer  11 . A carrier film  13  is provided on the lower functional layer  12 . An upper functional layer  14  is arranged on the carrier film  13 . The lower functional layer  12  and/or the carrier film  13  may be dispensed with. The lower and upper functional layers  12 ,  14  and the carrier film  13  may be formed, for example, from plastic, silicone, epoxy material, glass or thermoplastics. The individual layers of the film  10  may be produced with the aid of photo patterning methods, printing methods, jet methods or embossing methods. 
     The film  10  is, for example, provided as a completed film and adhesively bonded onto the devices  2  with the aid of a laminating process. In this case, the film may be applied with the aid of a roll laminating process or a vacuum laminating process. Depending on the example of the video wall  1  and the film  10 , it may be necessary to adjust the film  10  in relation to the structures and arrangements of the components  2  or the image pixels of the video wall. Both the lower functional layer  12  and the upper functional layer  14  may carry out optical functions. A module for a video wall comprises at least one device comprising at least one light-emitting component arranged on a carrier, wherein a film is arranged on the device, the film comprises an optical element  9 , and the optical element  9  is configured to influence light irradiation onto the device and/or light emission of the device. 
       FIG. 5  shows a schematic partial cross section through a video wall  1  comprising a film  10 , wherein a covering structure  15  is formed as optical element in the lower functional layer  12 . The covering structure  15  optically covers interspaces, that is to say trenches  3 , between the devices  2 . To that end, the covering structure  15  is arranged above the trenches  3 . The covering structure  15  may be formed from an optically black material. Moreover, the material of the lower functional layer  12  may be correspondingly colored with a black color to form the covering structure  15 . Moreover, the covering structure  15  may be formed from a different material than the rest of the lower functional layer  12 . By way of example, the covering structure  15  may be produced from a black plastic. 
       FIG. 6  shows a partial cross section through the lower functional layer  12 , wherein the covering structure  15  is formed in a lattice-shaped fashion. This lattice shape corresponds to the lattice shape of the trenches  3  of the arrangement of devices  2 , as evident with reference to  FIG. 1 . As a result of formation of the covering structure  15  in the lower functional layer  12 , the distance between the covering structure  15  and the trenches  3  is very small, with the result that a good optical covering of the trenches  3  is achieved. A negative optical influencing of the image of the video wall by the trenches  3  is reduced, in particular prevented, with the aid of the covering structure  15 . The carrier film  13  and the upper functional layer  14  may also be dispensed with in  FIG. 4 . 
       FIG. 7  shows a cross section through a further example of a video wall  1  comprising a film  10  in a schematic illustration, wherein only an upper functional layer  14  is provided in this example, the upper functional layer being connected to the devices  2  by the adhesive layer  11 . The upper functional layer  14  is formed with a roughened surface  16 . As a result, a matte surface is produced and specular reflections and reflections at the top side of the film  10  are avoided. The surface  16  may be roughened by chemical or mechanical methods. Moreover, the roughened surface  16  may be realized by a corresponding structure. However, the roughened surface  16  may also be produced, for example, with the aid of a photo patterning method, printing method or embossing method. The example of the film  10  in  FIG. 7  may also be combined with the example in  FIG. 5 , wherein the covering structure  15  is formed in the lower functional layer  12 . A carrier film  13  and a lower functional layer  12  are additionally provided in this case. The carrier film  13  may also be dispensed with in this example. 
       FIG. 8  shows a schematic illustration of a partial cross section through a further example of a video wall  1  comprising a film  10 , wherein the upper functional layer  14  comprises a Fresnel structure  17 . The upper functional layer  14  may connect to the devices  2  either by an adhesive layer  11 , as illustrated. Moreover, a lower functional layer  12  and a carrier film  13 , as illustrated in  FIG. 5 , may also be provided. The Fresnel structure  17  of the upper functional layer  14  provides for better light guiding in a predefined direction, in particular toward observers. The brightness and/or the contrast of the image information emitted by the video wall  1  are/is significantly improved as a result. 
       FIG. 9  shows a schematic partial cross section through a further example of a video wall  1  comprising a film  10 , wherein the upper functional layer  14  comprises covering elements  18 . The shading elements  18  form a shading structure for the devices  2 , in particular the components  26 . The upper functional layer  14  is applied directly on the lower functional layer  12  such that the carrier film  13  was dispensed with. A carrier film  13  may be provided. In addition, however, the lower functional layer  12  may also be dispensed with. 
       FIG. 10  shows an enlarged partial cross section through the arrangement from  FIG. 9 . The upper functional layer  14  comprises recesses  19 , the recesses  19  being filled with a shading material  20 , in particular metal. The shading material may be moreover dark, in particular black, plastic or colored transparent material, colored, for example, with black ink such as plastic, silicone, epoxy material or thermoplastics. Moreover, the shading material  20  may also be formed from a reflective material such as, for example, metal or dielectric material in the form of layer stacks. The shading material  20  may also be formed in the form of an absorbent material. The arrangement of the shading elements  18  is aligned in accordance with the arrangement of the devices  2  or the components  26  such that, for example, a row of devices  2  is shaded by a shading element  18 . Consequently, a plurality of shading elements  18  arranged in parallel are provided for the shading of the video wall  1 . To produce the shading elements  18 , the upper functional layer  14  may be photopatterned by the recesses  19  being introduced into the upper functional layer  14 . Afterward, the recesses  19  are filled with the shading material  20 , in particular the metal. 
       FIG. 11  shows, in a schematic plan view of the video wall from  FIG. 9 , the arrangement of the shading elements  18  of the film  10  relative to the components  26 . In this way, for each row of components  26  it is possible to achieve a shading from above, that is to say with respect to incident sunlight, with the aid of the shading elements  18 . The shading elements  18  are formed e.g. as plate-shaped elements. 
       FIG. 12  shows, in a schematic plan view, a further example of a film  10  applied on a video wall  1 . The film  10  comprises shading elements  18  and a radiation-guiding element  17  for the light of the components  26 . Consequently, the function of the radiation-guiding elements  17  is combined with the shading function of the shading elements  18 . The radiation-guiding elements may be formed e.g. in the form of Fresnel structures or in the form of lenses. The radiation-guiding elements  17  are aligned e.g. in each case with one device  2  or a group of devices  2 . The lenses may be aligned centrally with components and/or devices. 
       FIG. 13  shows a further example of a video wall  1 , a plan view of the film  10  being illustrated. The film  10  comprises shading elements  18  and a roughened surface  16 . Consequently, the function of the shading elements  18  and the function of the roughened surface  16  may be combined. 
     Although our modules have been more specifically illustrated and described in detail by preferred examples, this disclosure is not restricted by the examples disclosed and other variations may be derived therefrom by those skilled in the art, without departing from the scope of protection of the appended claims. 
     This application claims priority of DE 10 2016 109 040.9, the subject matter of which is incorporated herein by reference.