Patent ID: 12190755

DETAILED DESCRIPTION

An illustrative embodiment of the present invention relates to a visual display system creating various visual and audible effects from the motion of light particulate matter, such as beads of expanded polystyrene, comprising a chamber through which variable flows of air are configured to agitate, fluidize, suspend, or float at least some of the beads. The system makes use of a novel variable flow air array generation device that facilitates a variable flow air array within the chamber. The device includes three or more array sections and a controller. The three or more array sections each contribute distinct but coordinated air flows that coalesce with each other into forming the variable flow air array within the chamber. The three or more array sections also have a total combined area that is a substantial portion of a total area of the screened area at the bottom of the chamber through which the variable flow air array passes. The controller controls each of the three or more array sections of the device providing each of the distinct but coordinated air flows. The variable flow air array generated by the device agitates, fluidizes, suspends, or floats at least some of a plurality of beads in the chamber creating a dynamic display of beads within the chamber.

FIG.1throughFIG.21wherein like parts are designated by like reference numerals throughout, illustrate an example embodiment or embodiments of a visual display system, according to the present invention. Although the present invention will be described with reference to the example embodiment or embodiments illustrated in the figures, it should be understood that many alternative forms can embody the present invention. One of skill in the art will additionally appreciate different ways to alter the parameters of the embodiment(s) disclosed, such as the size, shape, or type of elements or materials, in a manner still in keeping with the spirit and scope of the present invention.

The visual display system100includes a base assembly2, a chamber assembly4, and a top assembly6. The base assembly2includes a chamber base20and in certain embodiments, such as shown inFIG.1, a fan base10, and a conduit base30. The base assembly2may be constructed of any suitable solid material such as for example wood, plastic, or metal. The chamber assembly4includes a chamber41, and in certain embodiments, such as shown inFIG.1, a conduit42. The top assembly6includes a top cap50. The top assembly6may be constructed of any suitable solid material such as for example wood, plastic, or metal. In some embodiments, such as shown inFIG.1, the top cap may further include an exhaust port52controlled, at least partially, by a damper51.

The chamber41of the chamber assembly4has a bottom34where it attaches to the chamber base20of the base assembly2, a top36where it attached to the top cap50of the top assembly6, and at least one sidewall38extending between the top36and bottom34and defining an interior volume102of the chamber41. The bottom34has a screened opening44therethrough. The screened opening44can be made of any suitable material such as plastic or metal that can pass air without letting out the particle material or beads43contained in the chamber41. Typically, this screening material will have a hole diameter or opening that is smaller than the diameter of the smallest beads43being used in the visual display system100. The at least one sidewall38has an observation portion providing an internal view of the chamber41from an environment external to the chamber41. In certain embodiments, the observation portion of the at least one sidewall38comprises a substantially transparent or substantially translucent material such as glass, plexiglass, or polycarbonate.

A plurality of beads43is disposed within the interior volume of the chamber41. In certain embodiments, the plurality of beads43comprise lightweight expanded polystyrene plastic beads. Beads43can be any relatively lightweight, small material with a density of less than about 1 gram/centimeter3(gm/cm3) and preferably of spheroid shape. In some embodiments, common expanded polystyrene (EPS) beads such as those used in “bean bag” chairs having a size between 2 and 5 millimeters with a density of about 0.016 to 0.022 gm/cm3. However, for very large displays a larger expanded polystyrene bead size such as up to about 13 mm or larger may be preferred.

The visual display system100further includes a variable flow air array generation device104that facilitates a variable flow air array106. The variable flow air array106generated by the device104agitates, fluidizes, suspends, or floats at least some of the plurality of beads43creating a dynamic display of beads43within the chamber41. Here the variable flow air array generation device104is housed in the chamber base20of the base assembly2. The device104is in fluid communication with the screened opening44in the bottom34of the chamber41. The device104comprises three or more array sections and a controller801.

Each of the three or more array sections contributes distinct but coordinated air flows108within the chamber41that coalesce with each other into forming the variable flow air array106. The three or more array sections have a total combined area that is a substantial portion of a total area of the bottom34having the screened opening44therethrough. In certain embodiments, the three or more array sections have a total combined area that is at least 40% of a total area of the bottom34having the screened opening44therethrough. In some embodiments, the three or more array sections of the variable flow air array generation device104are substantially contiguous. In other embodiments, the three or more array sections of the variable flow air array generation device104are arranged in a grid, one-dimensional array, multiple spaced one-dimensional arrays, or ring-shaped configuration. Examples of such configurations can be seen inFIG.20andFIG.21.

The controller801in electronic communication with and controls each of the three or more array sections of the device104providing each of the distinct but coordinated air flows108. In certain embodiments, the controller801of the variable flow air array generation device104comprises an analog controller, a processor, or a microcontroller. In some embodiments, the controller801of the variable flow air array generation device104provides variable signals to each of the three or more array sections individually. The control can be provided via DMX 512 type digital controls or through any analog, digital, networked, software, microprocessor driven, or other methods known to those skilled in the art of controlling airflows with HVAC and industrial controls.

In some embodiments, the system100further includes a bead transport control subsystem similar to what is disclosed in U.S. Pat. No. 11,017,697 to Sharp comprising at least one conduit42connecting a first region of the chamber41with a second region of the chamber41and having a screened opening45disposed in a wall or end or end of the conduit42. The conduit42may also have one or more screened exhaust openings in the sidewalls as shown in U.S. Pat. No. 11,017,697. In this example, at least one conduit42connects to a first region of the chamber41via a bottom opening46and with a second region of the chamber41via a top opening47. This bead transport system allows at least a portion of the plurality of beads43to be controlled by passing an additional airflow110,114through the at least one conduit42via the screened opening45. The additional airflow110,114is controlled at least partially independently from the variable flow air array106.

In some such embodiments, the bead transport system further comprises a second variable flow air array generation device112that facilitates a variable flow air array110, the second variable flow air array generation device112in fluid communication with the screened opening45in the conduit42. The device112comprises multiple array sections contributing distinct but coordinated air flows114within the conduit42that coalesce with each other into a variable flow air array110.

In certain embodiments, the three or more array sections of the variable flow air array generation device104comprise a damper system221wherein each of the one or more sections is a damper922. An example of this can be seen inFIGS.2-5. Here the embodiments that make use of a central air source such as one more controllable bottom fans12. In this example, a bottom fan12is housed in the fan base10. The fan base10can include a damper11to help control airflow into the base assembly2and into the chamber42as well as to help control the amount of negative pressure in fan base10versus the ambient air outside the base assembly2. Damper11can be implemented in many different ways known to those skilled in the art to create a controllable airflow obstruction between the inside and outside of the box to create a pressure drop from the outside of the box to the inlet of fan12. Fan12is shown as a centrifugal blower; however, any type of blower or fan can be used here such as propeller, axial, mixed flow, inline, computer cooling fan, etc. Although this fan12could be a fixed-speed fan, it would be advantageous that this fan as well as any other fan used in the preferred embodiments also has the capability to vary its speed. Many different mechanical and electronic approaches are well known by those skilled in the art to vary the speed of any fan used in an embodiment of this invention. For example, an inline centrifugal blower could be used with an electronically commutated DC motor that is controlled with its variable speed controller thorough, e.g., a 0 to 10 Volt analog or digital control signal.

Fan12discharges into and feeds the chamber base20(in this case through column base30). The three or more array sections of the variable flow air array generation device104, in this example damper system221, are disposed between the bottom fan12and the screened opening44of the bottom of the chamber41. In this example, each of the individual dampers922are mounted in an array on a mounting plate921below the screened opening44to form the damper system221such the discharge from the fan12passes through the individual dampers922of system221creating distinct but coordinated air flows108within the chamber41that coalesce with each other into forming the variable flow air array106.

In certain embodiments, the controllable damper system221comprises a second damper system222. An example of this can be seen inFIG.5. Here the second damper system222comprises multiple individual controllable dampers922mounted to the opposite side of the mounting plate921such that each damper922of the second damper system222is in fluid communication with a damper922of the first damper system221. In such cases, one of the dampers922in series operates as a fast on/off mechanism while the other damper922at least partially controls the quantity, rate and/or direction of airflow. Each damper922can be controlled individually by the controller801.

In certain embodiments, the system100further comprises a honeycomb airflow straightener22or fine mesh screen disposed between and in fluid communication with the screened opening44of the bottom34of the chamber41and one or more of the three or more array sections (damper system221inFIGS.2-5) of the variable flow air array generation device104.

In certain embodiments, the visual display system100further comprises one or more light sources421,451. Here, light sources421are disposed between the screened opening44of the bottom34of the chamber41and the one or more of the three or more array sections of the variable flow air array generation device104to shine up into the chamber41to illuminate the underside of the chamber41. In some such embodiments, at least one of the one or more light sources421is disposed in at least one of the three or more array sections. Light sources451are disposed in the top cap50so as to shine down into the chamber41and illuminate the chamber41from the top. These lights can be of any type, but LED lights whose color and intensity can be controlled by the controller801either manually or digitally through DMX 512 type or other types of electronic control systems and programmed to run with a preset routine or interactively are preferred.

In embodiments where the visual display system100further includes a bead transport control subsystem, this system can also include one or more dampers211,231,232configured to vary at least a volume of the additional airflow to fluidize or cause the plurality of beads43to move through the at least one conduit42. In the embodiments ofFIGS.2-5the bead transport control subsystem further comprises an airflow control device configured to control the additional airflow into or out of the at least one conduit42through the screened opening45. The airflow control device comprises a first damper system231mounted to mounting plate931and a second damper system211. The first damper system231has a first end connected to an at least partially enclosed space of the conduit base30and also connected to one or more bottom fans12wherein a second end of the first damper system231is configured to blow at least a portion of outlet airflow of the one or more bottom fans12into the at least one conduit42through the screened opening45as the additional airflow110. The second damper211has a first end connected to a second at least partially enclosed space of the fan base10and also connected to an inlet of the one or more bottom fan12wherein a second end of the second damper211is configured to pull the additional airflow110out of the at least one conduit42through the screened opening45into the inlet of the one or more bottom fan12.

In some such embodiments, further including a bead transport control subsystem, such as seen inFIG.2-5the bead transport system may also include a honeycomb airflow straightener32or fine mesh screen disposed between and in fluid communication with the screened opening45of the conduit42and the multiple array sections of the second variable flow air array generation device112(damper system231inFIGS.2-5) of the variable flow air array generation device104.

FIG.6andFIG.7depict an embodiment utilizing one or more controllable top fans62. Here the top36of the chamber41comprises a screened opening48and a controllable top fan62disposed in a top fan cap60in fluid communication with the screened opening48configured to draw airflow through the interior volume of the chamber41and out through a screened opening48of the top36. Fan62is shown as a centrifugal blower; however, any type of blower or fan can be used here such as propeller, axial, mixed flow, inline, computer cooling fan, etc. Although this fan62could be a fixed-speed fan, it would be advantageous that this fan as well as any other fan used in the preferred embodiments also has the capability to vary its speed. Many different mechanical and electronic approaches are well known by those skilled in the art to vary the speed of any fan used in an embodiment of this invention. For example, an inline centrifugal blower could be used with an electronically commutated DC motor that is controlled with its variable speed controller thorough, e.g., a 0 to 10 Volt analog or digital control signal. It should be apparent to one skilled in the art that a top fan62could also be used in conjunction with a bottom fan12or another airflow mechanism.

In certain embodiments, the top fan cap60further includes light sources462disposed in the top fan cap60so as to shine down into the chamber41and illuminate the chamber41from the top. The lights are arranged so as to not impede airflow. These lights can be of any type, but LED lights whose color and intensity can be controlled by the controller801either manually or digitally through DMX 512 type or other types of electronic control systems and programmed to run with a preset routine or interactively are preferred.

In some versions of this embodiment including a bead transport control subsystem that uses a damper system231, the controllable damper system231comprises a second damper system232. An example of this can be seen inFIG.7. Here the second damper system232comprises multiple individual controllable dampers mounted to the opposite side of the mounting plate931such that each damper of the second damper system232is in fluid communication with a damper of the first damper system231. In such cases, one of the dampers in series operates as a fast on/off mechanism while the other damper controls at least partially the quantity, rate, and/or direction of airflow. Each damper of damper can be controlled individually by the controller801.

FIG.8andFIG.9depict an embodiment where the three or more array sections of variable flow air array generation device104comprise a fan system321. Here the embodiment does not make use of one or more bottom fans12or top fans62. Instead, the fan system321consists of three or more individual fans926mounted in an array to a mounting plate925below the screened opening44to form the fan system321which is the source of variable flow air array106and distinct but coordinated airflows108into the chamber41. Each fan926of the fan system321pulls in air through the air inlet23and discharges distinct but coordinated air flows108within the chamber41that coalesce with each other into forming the variable flow air array106. An example of a suitable fan for each fan926is a computer cooling fan that can be controlled with a PWM (Pulse Width Modulated) control signal whose pulse width can be varied to change the speed of the motor or analog voltage or digital addressed control via the controller801. In certain embodiments, one or more of the controllable array fans926comprises a variable pitch fan blade. In some embodiments, the controllable array fan system321comprises a controllable bidirectional array fan or a bidirectional array fan system comprising two controllable array fans in fluid communication that are directed toward each other or away from each other. Other possible configurations will be apparent for one skilled in the art given the benefit of this disclosure.

In embodiments where the visual display system100further includes a bead transport control subsystem, this system can also include additional airflow control device331comprising one or more bead transport fans936,937configured to vary at least a volume of the additional airflow. An example of this can be seen inFIG.9. Fan936is configured to direct airflow110into the conduit42while fan937is configured to draw airflow110out of the conduit42. When the additional airflow110flows out of the at least one conduit42through the screened opening45a first subset of the plurality of beads43are pulled against the screened opening45or are frozen in place near the screened opening45such that the first subset of the plurality of beads43stops or restricts a flow of a second subset of the plurality of beads43through the at least one conduit42.

FIG.10depicts an embodiment where the fan system321further comprises a damper system222used in conjunction with the fan system321so that each fan926has a corresponding damper922mounted opposite on the mounting plate925and in fluid communication with each fan926. The damper922can operate as a backdraft or a fast on/off controllable damper and is controlled by the controller801in a manner similar to the embodiment ofFIG.5.

For a wider range of effects, some of the fans926may be either turned off or run at very low speed. Under these conditions where some of the fans926are operating at higher speeds, the positive pressure generated by the higher speed operating fans can force air back down or in reverse through the fans that are turned off or are operating at much lower speeds. To prevent this leakage or wasteful short-circuiting of airflow back around the higher speed fans, either a gravity-fed or spring-loaded damper922in series with the low or zero-speed fans may automatically close or a controllable damper922can be commanded closed to prevent this backflow of air or uncontrolled reversal of airflow through the lower speed or turned off fans. In lieu of using these extra backdraft or controllable on/off fans, reverse flow can be prevented in embodiments such as shown inFIG.9which have no dampers922in series with the fans926by ensuring that all the fans926are always operating and have at least some minimum speed that is enough at low or zero flow conditions to generate a positive pressure that is approximately equal to the positive pressure of the higher speed fans running at higher flows in order to prevent this backward flow of air through these slower fans.

The other purpose for at least a fast operating on/off damper922is to provide a rapid change in the volume of airflow through the chamber41or conduit42. Fans926typically have enough inertia in their fan wheels or blades so it can take 5 to 20 seconds or more to accelerate to full or a higher speed or decelerate to zero or a lower speed. A damper922with a fast, 0.5 to 5 second damper operator, a fast linear actuator, or a fast linear or rotary solenoid can open or close a damper922much faster to increase or decrease the air into the column more quickly than by just using a fan926alone. This can be used to enhance various effects.

In embodiments where the visual display system100further includes a bead transport control subsystem, this system can also include a damper system232used in conjunction with the additional airflow control device331comprising one or more bead transport fans936,937.

FIG.11is the system ofFIG.10used in further conjunction with a bottom fan12as described in regard toFIGS.2-5. This bottom fan12can for example help boost the flow of the fans926and also to help prevent backwards flow through those fans operating slowly or have been turned off.

FIG.12. depicts an embodiment of the system100wherein the honeycomb filter22is disposed between a fan system321and an airflow angle controller522. The airflow angle controller522varies at least a portion of the airflow passing through the screened opening44of the bottom34of the chamber41to an angle other than perpendicular to the screened opening44of the bottom34of the chamber41. Here the airflow angle controller comprises one or more damper device928with controllable blades to vary the angle of the airflow passing through the airflow angle controller522. Each damper or airflow angle control device928can be controlled individually by the controller801to either statically set the individual airflow angles or the angle of the airflows can be controlled dynamically to create various effects similar to fountain displays that can vary and sway the angle of the water jet that shoots up into the air in synchronism with music.

In certain embodiments, one or more of the three or more array sections of the variable flow air array generation device104further comprises a channel621,622in fluid communication with the array section providing a better definition to the airflow exiting the array section. Examples of these channels621,622can be seen inFIGS.13-19. InFIG.13channels621are disposed between a fan system321, such as seen inFIGS.8-9, and the honeycomb filter22while channels622are disposed between the honeycomb filter22and the screened portion44of the bottom34. of the chamber41. InFIG.14channels621are disposed between a fan system321comprising a controllable bidirectional array fan or a bidirectional array fan system comprising two controllable array fans926,927in fluid communication that are directed toward each other or away from each other and the honeycomb filter22while channels622are disposed between the honeycomb filter22and the screened portion44of the bottom34. of the chamber41. Having channels621and622used in combination with bidirectional fans helps prevent short-circuiting of airflows within the base assembly2containing the fans, particularly when some fans in the variable flow air array generation device104are moving air in one direction and other fans in the variable flow air array generation device104are simultaneously running airflow in the reverse direction. InFIG.15channels621are disposed between a fan system321, such as seen inFIGS.8-9, and the honeycomb filter22while channels623are disposed between the honeycomb filter22and the screened portion44of the bottom34of the chamber41in a single array along the middle of the screened portion, allowing light sources421to be disposed along the front and back edges. InFIG.16channels621are disposed between a fan system321, such as seen inFIG.9, and the honeycomb filter22while channels622are disposed between the honeycomb filter22and the screened portion44of the bottom34of the chamber41in an alternating pattern, which still provides containment of each fan's airflow but without each fan having its own channel622. InFIG.17channels621are disposed between a fan system321that includes both fans926and dampers922, such as seen inFIG.10, and the honeycomb filter22, while channels622are disposed between the honeycomb filter22and the screened portion44of the bottom34of the chamber41in an intermittent pattern. InFIG.18channels621are disposed between a fan system321, having fans926,929of different sizes and/or configurations to match what is needed for different degrees of control and resolution of the airflow potentially using less fan or damper elements or ones that better fit the geometry of the desired variable flow air array106, and the honeycomb filter22while channels622are disposed between the honeycomb filter22and the screened portion44of the bottom34of the chamber41. InFIG.19channels621are disposed between a fan system321, having fans926,929of different sizes and/or configurations, and the honeycomb filter22while channels624,625, and626are disposed between the honeycomb filter22and the screened portion44of the bottom34of the chamber41. Channels624are configured to decrease the velocity of airflow passing through the channels624. Channels625and626are configured to increase the velocity of airflow passing through the channels625and626. Channels626are further configured to redirect the airflow passing through the channels626.

In visual display systems100further including a bead transport control subsystem, the system100can also include channels631configured in a similar fashion as channels621and622.

In certain embodiments, at least a portion of one of the channels621, and622is lined with sound dampening material as would be readily understood by those of ordinary skill in the art to help reduce the level of noise from the fans that is heard outside the visual display device.

FIG.20andFIG.21depict alternate configurations of the three or more array sections of the variable flow air array generation device104. InFIG.20the variable flow air array generation device104has a series of six fans926in a two-by-three (2×3) array configuration that comprises 40% of a total area of the bottom34having the screened opening44therethrough. InFIG.21variable flow air array generation device104has a series of eight fans929in a ring configuration that comprises 53% of a total area of the bottom34having the screened opening44therethrough.

It should be understood that the examples and embodiments depicted herein can be modified and combined in any number of combinations. For example, one or more of the three or more array sections of the variable flow air array generation device104can have a different size or configuration from the other array sections of the variable flow air array generation device. Other possible configurations and implementations will be apparent to one skilled in the art given the benefit of this disclosure.

As utilized herein, the terms “comprises” and “comprising” are intended to be construed as being inclusive, not exclusive. As utilized herein, the terms “exemplary”, “example”, and “illustrative”, are intended to mean “serving as an example, instance, or illustration” and should not be construed as indicating, or not indicating, a preferred or advantageous configuration relative to other configurations. As utilized herein, the terms “about”, “generally”, and “approximately” are intended to cover variations that may existing in the upper and lower limits of the ranges of subjective or objective values, such as variations in properties, parameters, sizes, and dimensions. In one non-limiting example, the terms “about”, “generally”, and “approximately” mean at, or plus 10 percent or less, or minus 10 percent or less. In one non-limiting example, the terms “about”, “generally”, and “approximately” mean sufficiently close to be deemed by one of skill in the art in the relevant field to be included. As utilized herein, the term “substantially” refers to the complete or nearly complete extend or degree of an action, characteristic, property, state, structure, item, or result, as would be appreciated by one of skill in the art. For example, an object that is “substantially” circular would mean that the object is either completely a circle to mathematically determinable limits, or nearly a circle as would be recognized or understood by one of skill in the art. The exact allowable degree of deviation from absolute completeness may in some instances depend on the specific context. However, in general, the nearness of completion will be so as to have the same overall result as if absolute and total completion were achieved or obtained. The use of “substantially” is equally applicable when utilized in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result, as would be appreciated by one of skill in the art.

Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. Within this specification embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the invention. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.

It is also to be understood that the following claims are to cover all generic and specific features of the invention described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.