Video display panel mounting and alignment system and method

Abstract

Systems, apparatus and methods are disclosed for mounting and aligning multiple video display panels in a video display wall formed from an array of multiple video display panels. The disclosed embodiments provide a simplified mounting arrangement with reduced tolerances and tolerance stack-up, while also allowing for easy removal of individual video display panels for repair or replacement without requiring removal or movement of multiple video display panels adjacent to the panel being removed.

Description

Technical Field

[0001] Related Application Data This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 231,347, entitled "LED Panel Mounting and Leveling System and Method," filed on Aug. 10, 2021, and U.S. Non-Provisional Patent Application No. 17 / 743,994, entitled "Video Display Panel Mounting and Aligning System and Method," filed on May 13, 2022. These applications are hereby incorporated by reference in their entirety herein. Technical Field

[0002] The present disclosure relates to systems and methods for mounting video display panels to a mosaic video wall, and more particularly, to video display panel mounting and alignment systems and methods.

Background Art

[0003] Modular electronic devices, i.e., electronic systems composed of individual components that are electrically connected to form an entire system, are used in a variety of applications. For example, large electronic graphical displays such as video screens for stadiums and other large performance venues, electronic billboards, and other electronic displays are often composed of modular display panels (sometimes referred to as "tiles," "display tiles," or "LED tiles") that are incorporated into a large array or mosaic that forms an overall composite electronic display. Current means for securing individual display panels to a support structure typically involve some type of mechanical fastening, and current means for electrically connecting individual panels to a display control device often include separate wiring harnesses and / or electrical connectors that require the panel to be in a specific rotational orientation.

[0004] The progress in creating such modular display arrays is described, for example, in U.S. Patent No. 9,477,438, entitled "Devices for Creating Mosaicked Display Systems, and Display Mosaic Systems Comprising Same." Despite the progress in the art, current systems still suffer from disadvantages related to the complexity involved in assembling a display panel array, including challenges in providing a uniform and accurate continuous display surface due to tolerances in some of the components that need to be connected to create a display panel array with current technology.

[0005] Figure 23 shows one problem associated with the accumulation of tolerances in a prior art display panel display system using an LED panel. As shown therein, a conventional system includes a display array body 2 that provides a structural support to which an LED module housing / heat sink 4 is attached. And an LED printed circuit board (PCB) 6 that constitutes the display surface is attached to the LED module housing 4. All of these components are attached to a wall (W) or other mounting substrate. This arrangement presents at least three connection surfaces A, B, and C and a number of tolerances based on the dimensional thicknesses of the components and the design of the connection interface surfaces at each of the connection surfaces A, B, and C. There are many cases of tolerance accumulation due to the large number of components that make up the system. Even with extremely tightly controlled tolerances (e.g., in the range of 1 / 1000 of an inch), it can be difficult to achieve a uniform display surface in a new display system because the resolution is less than 1 mm pixel pitch.

[0006] Accordingly, there continues to be a need in the art for an improved system for connecting and aligning display panels in a modular array display system. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0007] In one implementation, a video display wall according to the present disclosure includes a plurality of video display panels arranged in an array on a support structure. A plurality of adjacent display panels in the array are aligned edge to edge, and a plurality of corners of the plurality of display panels inside the array are adjacent to the inside corners of two or more other display panels, and a plurality of corners of the plurality of display panels along the outer edge of the array are adjacent to the edge corners of at least one other display panel. The video display wall includes a first type of alignment disposed between the plurality of video display panels and the support structure at each of the matching portions of the plurality of corners of the inner display panels. Fitting also includes. A plurality of first type of alignmentFitting Each includes a body member having a support contact surface that engages a support structure and a display contact surface that engages a plurality of corners inside adjacent display panels. The support contact surface and the display contact surface are spaced apart by a constant depth dimension.

[0008] In a further implementation, the video display wall according to the present disclosure also includes a second type of alignment disposed between the plurality of video display panels and the support structure at each corner alignment of two display panels along the outer edge of the array of the plurality of display panels. Fitting may be provided. The second type of alignment Fitting Each includes a body member having a support contact surface that engages a support structure and a display contact surface that engages a corner of an outer edge of an adjacent display panel. The support contact surface and the display contact surface of the second type of alignment Fitting are spaced apart by a constant depth dimension. One edge of the body member of the second type of alignment Fitting substantially coincides with the outer periphery of the video display wall or fits inside the outer periphery of the video display wall.

[0009] In another implementation, the video display wall according to the present disclosure also includes a third type of alignment disposed between the plurality of video display panels and the support structure at each corner of the display wall. Fitting may be provided. The plurality of third type of alignment Fitting Each includes a body member having a support contact surface that engages a support structure and a display contact surface that engages a corner of a plurality of display panels at a plurality of corners of the display wall. The support contact surface and the display contact surface of the third type of alignment are spaced apart by a constant depth dimension. Two edges of the body member of the third type of alignment Fitting substantially coincide with the outer periphery of the video display wall or fit inside the outer periphery of the video display wall.

[0010] In another implementation, each type of alignment FittingAt least one support connector for attaching the main body member to the support structure with the support contact surface in contact with the support structure, and alignment Fitting At least one display connector for attaching the main body member to each of the plurality of corners of the video display panel with the display contact surface in contact with each video display panel may be provided.

[0011] In another implementation form, the alignment of each type of video display wall according to the present disclosure Fitting May also include a support contact surface and a surface display contact surface located in at least substantially parallel X-Y planes that are separated by a constant depth dimension along at least substantially the vertical Z direction. Further, the support connector and the plurality of display connectors may include a plurality of connectors configured to fix the video display panel and the support structure to their respective contact surfaces in the Z direction while allowing changes in their positions within their respective X-Y planes.

[0012] In another implementation form, the constant depth dimension has a single predetermined tolerance range.

[0013] In another implementation form, for the alignment of each type of video display wall according to the present disclosure Fitting The main body member includes a front wall on the display side and a rear wall on the support side. The display contact surface is at least partially disposed on the surface of the front wall, the support contact surface is at least partially disposed on the surface of the rear wall, the plurality of display connectors are disposed on the main body member inside the front wall, and the plurality of support connectors are disposed on the main body member inside the rear wall.

[0014] In another implementation form, in the video display wall according to the present disclosure, the front wall is formed as a series of raised shapes having a plurality of open central portions, the display contact surface surrounds the plurality of open central portions, and the plurality of display connectors are disposed within the plurality of open central portions.

[0015] In another implementation, in the video display wall according to the present disclosure, the front wall is formed as a series of annular walls joined by a plurality of connecting walls disposed on the outer periphery of the main body member on the display side of the main body member, and the plurality of display connectors each include a plurality of magnets disposed inside at least one annular wall in each quadrant.

[0016] In another implementation, in the video display wall according to the present disclosure, the plurality of display connectors further include a plurality of open annular walls configured to receive alignment pins attached to a plurality of corners on the back of the plurality of video display panels. Each quadrant includes one open annular wall and one annular wall having a magnet.

[0017] In another implementation, in the video display wall according to the present disclosure, the first type of alignment Fitting of the display contact surface includes four quadrants, each quadrant being configured to receive a corner of a video display panel, and each quadrant includes at least one of the display connectors.

[0018] In another implementation, in the video display wall according to the present disclosure, the first type of alignment Fitting further includes a plurality of electrical contacts respectively disposed in each quadrant configured to provide at least one of data connection and power connection between adjacent video display panels in alignment with a plurality of electrical contacts of the display panel.

[0019] In another implementation, in the video display wall according to the present disclosure, the second type of alignment Fitting of the display contact surface includes two halves each configured to receive a corner of a video display panel, and each half of the display contact surface includes at least one display connector.

[0020] In another implementation, in the video display wall according to the present disclosure, the second type of alignment Fittingrespectively match a plurality of electrical contacts of the display panel and provide data connection between adjacent display panels And Each half-body further includes a plurality of electrical contacts disposed on each of the half-bodies configured to provide at least one of the power connections.

[0021] In another implementation, in the video display wall according to the present disclosure, the second type of alignment Fitting The main body member has a linear outer edge extending across both halves of the display contact surface. The linear outer edge is configured to match a plurality of outer edges of two adjacent video display panels when attached together to the display contact surface.

[0022] In another implementation, in the video display wall according to the present disclosure, the plurality of support connectors and the plurality of display connectors are configured to engage with a plurality of mating connector portions disposed on the support structure and the video display panel respectively. The plurality of support connectors and the plurality of display connectors include one or more of magnets, threaded connectors, pins, clips, sockets, plug-in Fitting and bearing sleeves.

[0023] In another implementation, in the video display wall according to the present disclosure, the plurality of video display panels are rectangular and arranged in a herringbone pattern.

[0024] In another implementation, in the video display wall according to the present disclosure, the plurality of display panels are trapezoidal and arranged in a chevron pattern.

[0025] In different alternative implementations, video display panel alignment according to the present disclosure FittingIt includes a main body member having opposing support side and display side, a support contact surface on the support side, a display contact surface on the display side, at least one support connector on the support side configured to attach the main body member to the support structure with the support contact surface in contact with the support structure, and at least two display connectors on the display side configured to attach a video display panel to the display contact surface. The support contact surface and the display contact surface are separated by a certain depth dimension.

[0026] In another implementation, for the video display panel alignment according to the present disclosure Fitting the support connector and the plurality of display connectors are configured to engage with a plurality of mating connector portions respectively arranged on the support structure and the video display panel.

[0027] In another implementation, for the video display panel alignment according to the present disclosure Fitting the support contact surface and the display contact surface are located in parallel X - Y planes separated by a certain depth dimension along at least substantially the vertical Z direction, and the support connector and the plurality of display connectors include a plurality of connectors configured to fix the video display panel and the support structure to their respective contact surfaces in the Z direction while allowing variations in their positions within their respective X - Y planes.

[0028] In another implementation, for the video display panel alignment according to the present disclosure Fitting the plurality of support connectors and the plurality of display connectors include one or more of threaded connectors, pins, clips, sockets, plug - in Fitting and bearing sleeves.

[0029] In another implementation, for the video display panel alignment according to the present disclosure FittingIn this case, the main body member includes a front wall on the display side and a rear wall on the support side. The display contact surface is at least partially disposed on the surface of the front wall, the support contact surface is at least partially disposed on the surface of the rear wall, a plurality of display connectors are disposed on the main body member inside the front wall, and a plurality of support connectors are disposed on the main body member inside the rear wall.

[0030] In another implementation form, video display panel alignment according to the present disclosure Fitting In this case, the front wall is formed as a series of raised shapes having a plurality of open central portions, the display contact surface surrounds the plurality of open central portions, and a plurality of display connectors are disposed within the plurality of open central portions.

[0031] In another implementation form, video display panel alignment according to the present disclosure Fitting In this case, the front wall is formed as a series of annular walls joined by a plurality of connecting walls disposed on the outer periphery of the main body member on the display side of the main body member, and a plurality of display connectors include a plurality of magnets disposed inside at least one annular wall in each quadrant.

[0032] In another implementation form, video display panel alignment according to the present disclosure Fitting In this case, the plurality of display connectors further include a plurality of open annular walls configured to receive alignment pins attached to a plurality of corners on the back of the plurality of video display panels. Each quadrant includes one open annular wall and one annular wall having a magnet.

[0033] In another implementation form, video display panel alignment according to the present disclosure Fitting In this case, the display contact surface includes four quadrants, each quadrant is configured to receive a corner of the video display panel, and each quadrant includes at least one of the display connectors.

[0034] In another implementation form, video display panel alignment according to the present disclosureFitting It also includes at least two display connectors in each quadrant of the display contact surface.

[0035] In another implementation, the video display panel alignment according to the present disclosure Fitting also includes a plurality of electrical contacts arranged in each quadrant configured to provide at least one of data connection and power connection between adjacent display panels that match the electrical contacts of the display panel. And

[0036] In another implementation, the video display panel alignment according to the present disclosure Fitting wherein the display contact surface includes two halves each configured to receive a corner of the video display panel, and each half of the display contact surface includes at least one display connector.

[0037] In another implementation, the video display panel alignment according to the present disclosure Fitting also includes a plurality of electrical contacts arranged in each half configured to provide at least one of data connection and power connection between adjacent display panels that match the plurality of electrical contacts of the display panel. And

[0038] In another implementation, the video display panel alignment according to the present disclosure Fitting wherein the body member has a linear outer edge extending across both halves of the display contact surface. The linear outer edge is configured to match a plurality of outer edges of two adjacent video display panels when attached together to the display contact surface.

[0039] In another implementation, the video display panel alignment according to the present disclosure FittingIn this case, the display contact surface comprises two halves each configured to receive a side portion of the video display panel. Each half of the display contact surface includes at least one display connector.

[0040] In another implementation, the video display panel alignment according to the present disclosure Fitting also includes a plurality of electrical contacts disposed on each of the halves configured to provide at least one of a data connection and a power connection between adjacent video display panels that align with a plurality of electrical contacts of the display panel. And

[0041] In another implementation, the video display panel alignment according to the present disclosure Fitting also includes a power connector that electrically communicates with a selected plurality of the plurality of electrical contacts.

[0042] In another implementation, the video display panel alignment according to the present disclosure Fitting wherein the body member has a rectangular shape having a plurality of opposing short sides and a plurality of opposing long sides, the display contact surfaces in each of the halves include two annular walls spaced along each of the long sides, and the plurality of display connectors are disposed inside the plurality of annular walls.

[0043] In another implementation, the video display panel alignment according to the present disclosure Fitting wherein a plurality of alignments Fitting are integrated with a support frame on the support side.

[0044] In a further implementation of the present disclosure, the video display panel alignment described herein Fitting is incorporated into a video display wall comprising a plurality of video display panels, a plurality of panel alignments Fitting and a support structure.

[0045] ​In a further implementation of the present disclosure, a method of attaching and aligning a plurality of video display panels to a video display wall includes attaching a plurality of alignment Fitting arrays directly to a support structure. Each alignment Fitting has the same thickness dimension with a uniform tolerance in the thickness dimension. Further, the method includes attaching a plurality of video display panels directly to the plurality of alignments Fitting at respective corners. The plurality of alignments Fitting form a single layer having a thickness dimension between the plurality of video display panels and the support structure.

[0046] In another implementation of the method according to the present disclosure, each of the plurality of video display panels includes an array of light emitting elements supported on a printed circuit board (PCB), and the plurality of said alignments Fitting are attached directly to the plurality of said PCBs.

[0047] In another implementation of the method according to the present disclosure, the plurality of PCBs are magnetically connected to the plurality of alignments Fitting ..

[0048] In another implementation, the method according to the present disclosure further includes removing one or more individual video display panels from the video wall in a direction perpendicular to the video wall display surface without moving the plurality of video display panels adjacent to the removable video display panel.

[0049] In another implementation, the method according to the present disclosure further includes managing such that the uniform tolerance is within a range of about + / - 0.01 mm or less.

Brief Description of the Drawings

[0050] To illustrate the present disclosure, the drawings show aspects of one or more embodiments of the present disclosure. However, it should be understood that the present disclosure is not limited to the exact arrangements and means shown in the drawings.

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[0051] The embodiments disclosed herein solve problems in the attachment and alignment of modular display panels that can arise from the complexity of existing attachment systems, particularly the accumulation of tolerances in panel assembly. The disclosed embodiments also provide the further advantage of allowing a panel to be removed perpendicular to the face of the display without affecting the surrounding display panels. The embodiments disclosed herein, as well as the principles, teachings, and advantages taught through the disclosed embodiments, generally apply to modular or mosaic video displays consisting of an array of display panels. Examples of such display panels suitable for use in such an array include, but are not limited to, OLED panels, LED panels, LCD panels, and bistable display panels. Accordingly, the use of LED panels in the following description of exemplary embodiments is for illustrative purposes and is not intended to specifically limit or otherwise limit the present disclosure to LED panels.

[0052] In one example, as shown in FIGS. 1 to 4, the display wall 100 is composed of an array of display panels 101. The display panels can be provided in a number of different configurations. For example, as is known in the art, three-color integrated LEDs are soldered onto a printed circuit board (PCB) 102 using conventional surface mount technology (SMT) to form the pixels of the panel. In another example, chip-on-board (COB) technology can be used, where individual LED dies (single-color, three dies R+G+B forming one pixel) are taken directly from a silicon wafer and bonded to the PCB 102. In COB technology, usually, there is an additional protective layer (not shown), such as epoxy, on the bonded wafer and the PCB 102, and a multi-layer panel 101 is formed. Regardless of the display type or panel manufacturing technology, the light-emitting elements of the individual panels are mounted directly or indirectly on the PCB 102 or other similar substrates. Thus, as used herein, PCB refers to any such substrate to which the light-emitting elements of the display are directly or indirectly mounted or bonded.

[0053] Referring to FIGS. 2 to 4, in this particular example, the LED panel 101 has any panel electronic device module 103 attached to the back of the PCB 102, and in this case, this module includes a panel control device 107. In some cases, the panel electronic device module 103 can be omitted by directly integrating its functions into the PCB, in which case there can be an exposed PCB back, or alternatively, a cosmetic cover similar in appearance to the electronic device module 103 can be used in its place. The presence or variation of the panel electronic device module 103 does not affect the attachment and alignment of the display panel according to the embodiments disclosed herein. This is because, as will be described in more detail below, the structural connections for attachment and alignment are made directly to the back of the panel PCB 102.

[0054] As further shown in FIGS. 1 to 4, the attachment and alignment of the display panel 101 are at the corners provided at the corners of the panelFitting 104, and side portions provided on the sides of adjacent panels Fitting is achieved by 106. In various embodiments, the corner Fitting 104 and the side portions Fitting one or both of 106 may provide a structural connection and / or an electrical connection. As shown in FIG. 6, the corner Fitting 104 is attached to the panel at the structural contact area 110 on the back of the PCB 102. The side portion Fitting 106 is attached to the electrical contact area 108 on the back of the PCB 102.

[0055] As shown in FIGS. 3 and 4, the distance (D) is the only tolerance between the wall (W) to which the panel is attached and the back of the PCB 102. Since the tolerance of the distance (D) is known and tightly controlled, this structure and mounting method eliminates all but one tolerance compared to prior art mounting systems having three or more tolerance positions, providing higher accuracy and reproducibility for mounting and aligning the display panel. At one tolerance position, there is no accumulation of tolerances, providing ease of accuracy management, ease of assembly and attendant cost reduction, thus solving problems long associated with conventional mounting systems.

[0056] As shown in more detail in FIGS. 5-7, each of the structural contact areas 110 includes a connector disk 112 which is a magnet or an iron disk attached to the back of the PCB 102. The connector disk 112 is arranged to mate with the connector magnet 120 in the corner Fitting 104 as described below. The electrical contact area 108 also includes a magnet or an iron connector disk 114 and one or more electrical contacts 116. The connector disk 114 is positioned to mate with the connector magnet 118 on the side portion Fitting 106. The electrical contacts 116 are arranged to mate with the electrical contacts 119 in the side portion Fitting 106.

[0057] Generally, as shown in FIGS. 8 and 9, a corner configured to support adjacent corners of four display panels in a video wall array Fitting has connectors arranged in four quadrants (Q1-Q4) in the X-Y plane, with at least one connector in each quadrant. A critical depth dimension (D) exists along the Z direction that is at least substantially perpendicular to the X-Y plane. The corner Fitting 104 is an example of an embodiment of a corner according to the present disclosure, as shown in detail in FIGS. 8 and 9 Fitting . In this example, the corner Fitting 104 includes a body member 121 in which a connector magnet 120 is disposed inside a front wall structure 123. Here, the front wall structure 123 is configured as a series of annular walls 122 formed around the display side of the corner Fitting 104. The annular wall is a convenient wall shape that complements circular connectors such as disk magnets or screws, but the specific shape of the wall is not a critical feature with respect to the Fitting function. The annular wall 122 can be joined by any connecting wall 124 to enhance rigidity. In this embodiment, the upper surface of the front wall structure formed by the annular wall or the connecting wall 122 / 124 defines a display contact surface 126. On the opposite side of the body member 121, a rear wall 130 surrounds the outer periphery of the corner Fitting . The rear wall 130 has an outer surface that defines a rearward support contact surface 132. The support contact surface 132 is disposed at a depth (D) that is precisely controlled from the display contact surface 126. Ideally, the tolerance at the distance D is grasped as precisely as possible for the manufacturing technology used. In some embodiments, the tolerance range of the distance D can be about + / -0.01 mm, and in other embodiments, more preferably about + / -0.005 mm

[0058] At the center of the corner Fitting 104, a mounting screw 128 is provided, and an inner rear mounting surface 140 that can be in the same plane as the contact surface 132 is formed around it. The threaded end of the mounting screw 128 extends from the rear side of the corner Fitting 104. Also, the corner FittingOn the back side of 104, another connector magnet 138 is optionally provided. This can be used instead of the screw 128 or together with the screw 210, and the corner Fitting is attached to the iron wall (W) or other suitable display support structure.

[0059] Figures 10 and 11 show an alternative display wall 200 to which the LED display panel 202 is attached to the support grid 220. The display wall 200 is shown in a front view in Figure 10, in which some individual panels 202 are removed to show the support grid 220 behind the panels. Many types of support structures can be used, and the video wall is fixed to the underlying structural wall or other structural support. In this example, the support grid 220 comprises a plurality of vertical members 222 joined by horizontal supports 224. The support grid 220 is modularly configured to be assembled into structures of any size at the connections between the vertical members and the horizontal supports. The vertical members 222 can be continuous or formed in parts connected to each other. In other embodiments, the horizontal support 224 can be formed instead as a continuous member to which short vertical members are connected therebetween. Other support configurations can be provided by those skilled in the art based on the teachings of the present disclosure.

[0060] Corner Fitting 104 is attached to the support grid 220 at each intersection of the vertical member 222 and the horizontal support 224, for example, by using the mounting screws 128 and / or the connector magnet 138 as described above. Corner Fitting 104 (and alternatives 230, 260 and 284) are configured to support the corners of the display panel inside an array of display panels. The half corner Fitting 204 (see also Figure 12) is provided along the outer edge of the display wall 200 having a straight outer edge so as not to protrude beyond the outer edge of the array of display panels 202. The half corner Fitting 204 has a display contact surface divided into two halves H1, H2 along the X / Y axis. Thus, the half corner Fitting204 is configured to support the corners of the display panel along the outer edges of the array of the display panel. Quarter corner Fitting 205 is used at the four corners of the display wall 200 for the same reason and supports the display panel at the outer corners in the array of the display panel, as shown in FIG. 13 (not visible in FIGS. 10 and 11). Quarter corner Fitting 205 has two straight outer edges so as not to protrude beyond the outer edge of the array of display panels 202 at each corner of the array. In this embodiment, alternative sides Fitting 206 (see also FIG. 14) is utilized for both electrical connection and mechanical support along the panel edge. In the display wall configuration shown in FIGS. 10 and 11, a power supply 208 is provided on a support grid 220, and power is supplied to the panel 202 via the side Fitting 206 as further described below.

[0061] As shown in FIG. 14, the alternative side Fitting 206 is configured to provide power connections and data connections, along with auxiliary mechanical means, via a connector magnet 120 disposed inside the annular wall 122, as described above with respect to corner Fitting 104 and other disclosed embodiments. Fitting 206 includes a housing 210, and the housing 210 defines an annular wall 122 and carries a pin plate 212 that provides a plurality of electrical contacts 214. The electrical contacts 214 can provide both power connections and data connections. In one example, power is supplied from a power supply 208 (e.g., FIG. 11) via a power connector 216. The annular wall 122 and the connector magnet 120 can assist in the alignment of the data pins and can also provide alignment advantages in the Z-axis (with respect to the display surface). Alternatively, the side Fitting 206 can include an internal PCB to facilitate routing of data and power. The side Fitting 206 is also divided into two halves H1, H2 along the X / Y axis. The side FittingAlthough 206 does not need to be attached to the support structure, an optional attachment flange 218 may be provided and the sides may be temporarily fixed in place prior to installation of the display panel. Fitting Note that it is temporarily fixed in place.

[0062] FIG. 15 shows a further alternative corner 230 having electrical contact pins 232. Fitting Corner Fitting The structure of 230 may be substantially similar to that of corner 104 described above in other respects. The electrical contact pins 232 may provide power and / or data connections in the same manner as the contact pins on sides 106 and 206, and their connectors are complemented or replaced. For example, in a further alternative embodiment, data communication with individual display panels and data communication between individual display panels may be provided via one of several wireless communication protocols, reducing the requirement for physical pin contacts. In one such configuration, WiFi (or other wireless payload) may be incorporated into the LED PCB or panel controller or proximity non-contact short-range data connection. Similarly, the power may be inductive and / or may be transferred to corner 230 via electrical contacts 232, reducing the total number required. Fitting 104 and 206, and their connectors are complemented or replaced. For example, in a further alternative embodiment, data communication with individual display panels and data communication between individual display panels may be provided via one of several wireless communication protocols, reducing the requirement for physical pin contacts. In one such configuration, WiFi (or other wireless payload) may be incorporated into the LED PCB or panel controller or proximity non-contact short-range data connection. Similarly, the power may be inductive and / or may be transferred to corner 230 via electrical contacts 232, reducing the total number required. Fitting 106 and 206, and their connectors are complemented or replaced. For example, in a further alternative embodiment, data communication with individual display panels and data communication between individual display panels may be provided via one of several wireless communication protocols, reducing the requirement for physical pin contacts. In one such configuration, WiFi (or other wireless payload) may be incorporated into the LED PCB or panel controller or proximity non-contact short-range data connection. Similarly, the power may be inductive and / or may be transferred to corner 230 via electrical contacts 232, reducing the total number required. Fitting 230, reducing the total number required. Fitting of the total number required.

[0063] FIG. 16 shows an alternative display panel 240 utilizing an alternative PCB 242 having a corner contact area 244 for receiving an alternative corner 230 and a side contact area 248 for receiving an alternative side 206. In this embodiment, the corner contact area 244 comprises electrical contacts 246 configured to mate with the electrical contacts 232 of corner 230. The corner contact area 244 may be configured differently as described for the structural contact area 110 shown in FIG. 6, for example. The side contact area 248 includes electrical contacts 250 configured to mate with the electrical contacts 214 and two connector disks 114 configured to mate with the magnets 120 of the alternative side 206. Fitting 230 and a side contact area 248 for receiving an alternative side 206. In this embodiment, the corner contact area 244 comprises electrical contacts 246 configured to mate with the electrical contacts 232 of corner 230. The corner contact area 244 may be configured differently as described for the structural contact area 110 shown in FIG. 6, for example. The side contact area 248 includes electrical contacts 250 configured to mate with the electrical contacts 214 and two connector disks 114 configured to mate with the magnets 120 of the alternative side 206. Fitting 206. In this embodiment, the corner contact area 244 comprises electrical contacts 246 configured to mate with the electrical contacts 232 of corner 230. The corner contact area 244 may be configured differently as described for the structural contact area 110 shown in FIG. 6, for example. The side contact area 248 includes electrical contacts 250 configured to mate with the electrical contacts 214 and two connector disks 114 configured to mate with the magnets 120 of the alternative side 206. Fitting 230. The corner contact area 244 may be configured differently as described for the structural contact area 110 shown in FIG. 6, for example. The side contact area 248 includes electrical contacts 250 configured to mate with the electrical contacts 214 and two connector disks 114 configured to mate with the magnets 120 of the alternative side 206. Fitting 206.

[0064] Further alternative corners Fitting Embodiments are shown in FIGS. 17 and 18. In this embodiment, every other annular wall 122 defines an alignment pin opening 262 configured to receive an alignment pin 264 attached to a contact area 266 on the back of an alternative PCB 268, except that the corner Fitting 260 is substantially configured as described above for corner Fitting 104. The pins 264 are shown as cylindrical, but those skilled in the art will understand that other shapes may be utilized. Also, the pin openings 262 and the pins 264 may be designed with a particular type of fit, such as a loose fit to an over-tight fit, providing predictable and reproducible tolerances and accommodating appropriate ease of assembly and accuracy for a particular application.

[0065] FIG. 19 shows a further alternative modular support structure having an integral structure Fitting . In one embodiment, the support frame module 280 includes a frame member 282 having integral structures Fitting 284, 286, and 288. For example, the integral full corner Fitting 284 is substantially configured the same as corner Fitting 104, except that it is integrally formed with the frame member 282. Similarly, the integral half Fitting 286 is substantially configured the same as half corner Fitting 204, and the integral quarter Fitting 288 is substantially configured the same as quarter corner Fitting 205. And a display panel, such as panel 101 / 202, can be attached to the structure Fitting as described above. An open space 290 may be provided within the frame member 282 to reduce weight. Any suitable configuration of similar support frame modules may be provided to support a complete display wall. For example, the modules 280 shown may be butted against each other along a narrow edge 292 or a long edge 294, with integral half or quarter bodies of a preferred shape Fittingmatches, and the structural support of each display panel is completed. However, for the integrated structure Fitting Along the edge 296 where there are available portions of the Fitting , the next module 280 can be spaced apart by the width of the display panel. Based on the teachings of the present disclosure, one of ordinary skill in the art can derive a variety of configurations for the modular support frame. As will be understood by one of ordinary skill in the art based on the teachings contained herein, the contact surface features each serve a specific independent purpose for X, Y, and Z alignment. The nature of how these surface features interact, and the structure Fitting 104 matches with the four panels, the X and Y panel alignment is determined by the panels themselves (via the connector disk 112), and the Z panel alignment is determined by a single plane of the structural contact surface and the back surface of the PCB (which means that the only Z-axis tolerance to be managed is the PCB thickness itself). The annular wall 122 has a height sufficient for the display contact surface 126 to be disposed above the surface of the magnet 120, and the magnet and the connector disk are not involved in the tolerance of the dimension (D).

[0066] Figures 20 and 21 show further alternative embodiments of a video display wall 300 having a rectangular video display panel 302 arranged in a cedar twill pattern. The panel 302 can be configured as described elsewhere herein and can mate with a connector 306 (which can include connectors or pins such as 112, 113, 120, 138, 264, etc.). Fitting 304( Fitting which can include any of 104, 106, 204, 205, 206, 260, 284, 286, 288, etc.) can be joined by an appropriate selection and combination. Electrical contacts (not shown) can also be provided as described herein.

[0067] Figure 22 shows another alternative embodiment of a video display 308 having a trapezoidal video display panel 310 arranged in a chevron pattern. The panel 310 can also be configured as shown elsewhere herein using 304 and the connector 306 as described herein. Fitting 304 and the connector 306 and can be configured as shown elsewhere herein.

[0068] As will be appreciated, the embodiments disclosed herein provide for a reduction in the accumulation of tolerances associated with LED displays and their fixtures / machinery. The disclosed embodiments also provide a connection / attachment / leveling system as compared to conventional display wall connection systems and are compatible with a wide variety of display wall and display panel shapes and configurations as shown in the examples of FIGS. 1, 10, 19, 20, and 22. Utilizing the teachings of the present disclosure, one of ordinary skill in the art may derive other shapes, configurations, and combinations of display panels and Fitting many different video display wall structures, shapes, and configurations are created.

[0069] The foregoing is a detailed description of exemplary embodiments of the present disclosure. In this specification and the appended claims, connection terms such as "at least one of X, Y, and Z" and "one or more of X, Y, and Z" are to be construed, unless otherwise specified or indicated, to mean that each item in the connection list may be present in any number, excluding all other items in the list, or in any number in combination with any or all other items in the connection list, and each of those may also be present in any number. Note that applying this general rule, the connection phrase in the foregoing example where the connection list consists of X, Y, and Z is to be taken to include each of "one or more X", "one or more Y", "one or more Z", "one or more X and one or more Y", "one or more Y and one or more Z", "one or more X and one or more Z", and "one or more X, one or more Y, and one or more Z".

[0070] Without departing from the spirit and scope of the present disclosure, various modifications and additions can be made. Each feature of the various embodiments described above can be combined with the features of other described embodiments as necessary, providing combinations of numerous features in related new embodiments. Further, although several separate embodiments have been described above, what has been described herein is merely an exemplification of the application of the principles of the present disclosure. Further, the particular methods herein may be illustrated and / or described as being performed in a particular order, but the ordering is highly variable within the ordinary skill to achieve aspects of the present disclosure. Accordingly, this description is intended to be construed only as an example and is not intended to limit the scope of the present disclosure or the scope of the invention described in the following claims.

Claims

1. A main body member having opposing support and display sides, a support contact surface on the support side in the first X-Y plane, and a display contact surface on the display side in a second X-Y plane that is at least substantially perpendicular to the first X-Y plane, wherein the support contact surface and the display contact surface are separated by a constant depth dimension along a Z direction that is at least substantially parallel to the first X-Y plane and the second X-Y plane, at least one support connector on the support side configured to attach the main body member to the support structure with the support contact surface in contact with the support structure, and at least two display connectors on the display side configured to attach a video display panel to the display contact surface. A video display panel alignment fixture.

2. The support connector and the display connector each comprise a plurality of connectors configured to fix the video display panel and the support structure to respective ones of the support contact surface and the display contact surface in the Z direction while allowing variation in position in each of the first X-Y plane and the second X-Y plane. The video display panel alignment fixture according to Claim 1.

3. The support connector and the display connector each comprise one or more of a magnet, a threaded connector, a pin, a clip, a receptacle, a plug-in fixture, and a bearing sleeve. The video display panel alignment fixture according to Claim 1.

4. The main body member has a front wall on the display side and a rear wall on the support side, the display contact surface is at least partially disposed on the surface of the front wall, the support contact surface is at least partially disposed on the surface of the rear wall, the plurality of display connectors are disposed in the main body member inside the front wall, and the plurality of support connectors are disposed in the main body member inside the rear wall. The video display panel alignment fixture according to Claim 1.

5. The front wall is formed as a series of raised shapes having a plurality of open central portions, the display contact surface surrounds the plurality of open central portions, and the display connectors are disposed within the plurality of open central portions. The video display panel alignment fixture according to claim 4.

6. The front wall is formed as a series of annular walls joined by a plurality of connecting walls disposed on the outer periphery of the body member on the display side of the body member, A plurality of the display connectors include a plurality of magnets disposed inside at least one annular wall in each quadrant The video display panel alignment fixture according to claim 5.

7. The display connector further includes a plurality of open annular walls configured to receive alignment pins attached to a plurality of corners on the back of the video display panel, Each quadrant includes one of the open annular walls and one annular wall having the magnet The video display panel alignment fixture according to claim 6.

8. The display contact surface comprises four quadrants, each quadrant being configured to receive a corner of the video display panel, and each quadrant includes at least one of the display connectors The video display panel alignment fixture according to claim 1.

9. Each of the quadrants of the display contact surface further includes at least two display connectors The video display panel alignment fixture according to claim 8.

10. Each of the quadrants further includes a plurality of electrical contacts configured to provide at least one of data connection and power connection between adjacent video display panels in alignment with a plurality of electrical contacts of the display panel The video display panel alignment fixture according to claim 8.

11. The display contact surface comprises two halves each configured to receive a corner of the video display panel, Each half of the display contact surface includes at least one display connector The video display panel alignment fixture according to claim 1.

12. The body member has a linear outer edge extending across both halves of the display contact surface, The linear outer edge is configured to coincide with a plurality of outer edges of two adjacent video display panels when attached together to the display contact surface The video display panel alignment fixture according to claim 11.

13. The display contact surfaces each comprise two halves configured to receive the sides of the video display panel. Each half of the display contact surfaces includes at least one display connector. A plurality of electrical contacts disposed on each of the halves are configured to mate with the electrical contacts of the display panel to provide at least one of data connection and power connection between a plurality of adjacent display panels. The video display panel alignment fixture according to claim 1.

14. Further comprising a power connector in electrical communication with a selected plurality of the plurality of electrical contacts. The video display panel alignment fixture according to claim 13.

15. The body member has a rectangular shape having a plurality of opposing short sides and a plurality of opposing long sides. The display contact surface in each half includes two annular walls spaced along each long side. The plurality of display connectors are disposed inside the plurality of annular walls. The video display panel alignment fixture according to claim 13.

16. A plurality of the alignment fixtures are integrated with a support frame on the support side. The video display panel alignment fixture according to claim 1.

17. A video display wall comprising a plurality of the video display panels attached to the support structure by a plurality of the panel alignment fixtures, the plurality of panel alignment fixtures each having the same constant depth dimension with a uniform tolerance with respect to a constant depth dimension. The video display panel alignment fixture according to claim 1.

18. Providing a video display panel support structure to be horizontal, Directly attaching an array of a plurality of alignment fixtures to the video display panel support structure, Directly attaching a plurality of video display panels to the plurality of alignment fixtures at each corner, Each alignment fixture has the same thickness dimension with a uniform tolerance in the thickness dimension, The plurality of alignment fixtures form a single layer having the thickness dimension between the plurality of video display panels and the video display panel support structure. A method of attaching and aligning a plurality of video display panels to a video display wall.

19. Each of the plurality of the video display panels includes an array of a plurality of light-emitting elements supported on a printed circuit board, and directly attaching the plurality of the video display panels includes directly attaching the plurality of the alignment fixtures to the plurality of the printed circuit boards. The method according to claim 18.

20. The plurality of the printed circuit boards are magnetically connected to the plurality of the alignment fixtures. The method according to claim 18.

21. Further comprising removing one or more individual ones of the video display panels from the video display wall in a direction perpendicular to the display surface of the video display wall without moving the plurality of the video display panels adjacent to the video display panel to be removed. The method according to claim 18.

22. Further comprising controlling such that the uniform tolerance in the thickness direction is within a range of about ±0.01 mm or less. The method according to claim 18.

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