LED display for use in high impact environments

Abstract

To provide a structural means for reducing damage due to impact to an LED display board without impairing visual quality of a display.SOLUTION: An LED display unit for use in high impact environments includes a frame disposed within a housing, with a plurality of LED display modules mounted to the frame. Each display module includes a support structure, a foam cushion, a plurality of spring-loaded cushions, a printed circuit board, and a front protective panel. The foam cushion and the spring-loaded cushion are disposed between the frame and the rear surface of the support structure. A printed circuit board is mounted to the front surface of the support structure and includes an array of LEDs covered by a front protective panel. The combination of the foam cushion and the spring-loaded cushion provides adequate cushioning to prevent damage to the printed circuit board when the front protective panel is impacted by an external object.SELECTED DRAWING: Figure 4A

Description

[Technical Field]

[0001] This invention relates to light-emitting diode (LED) display panels used in stadiums and arenas for sporting events for advertising and informational purposes. More particularly, this invention relates to LED display units having structures that protect the array of LEDs and associated electrical circuitry from damage caused by impacts from objects during sporting events. [Background technology]

[0002] Large LED display boards are becoming common in sports venues. They provide advertising and other visual information to stadium attendees during the game. Some boards are placed very close to the boundaries of the field or court where the game is being played. This location is highly visible to both game and television viewers. For example, at Major League Baseball (MLB) games, every stadium has an LED display board just behind home plate. This board is in the frame of the television camera that faces over the pitcher toward home plate for most of the game. Other such boards are typically placed along the outfield wall. A very large screen is usually installed behind the outfield stands.

[0003] One problem with having these display boards so close to the field is the potential for damage from impacts from baseballs. A baseball leaving the bat can travel at speeds of up to 100 mph (161 km / h), impacting the display board with considerable force. Such impacts often damage the LEDs and electrical circuitry located just below the surface of the display board. The cost of repairing the resulting damage is a significant expense for baseball stadium owners. Summary of the Invention [Problem to be solved by the invention]

[0004] What is needed is a structural means to mitigate impact damage to LED display boards in MLB stadiums and other sports venues without compromising the visual quality of the display. [Means for solving the problem]

[0005] These and other needs are met by an LED display unit for use in high-shock environments. The LED display unit includes a frame disposed within a housing, with multiple display modules mounted to the frame. Each display module includes a support structure, a foam cushion, multiple spring-loaded cushions, a printed circuit board, and a front protective panel. The foam cushion and spring-loaded cushion are disposed between the frame and the rear surface of the support structure. The printed circuit board is mounted to the front surface of the support structure and includes an array of LEDs covered by the front protective panel. The combination of the foam cushion and the spring-loaded cushion provides adequate cushioning to prevent damage to the printed circuit board when the front protective panel is impacted by an external object.

[0006] In some embodiments, the foam cushion comprises ethylene vinyl acetate (EVA) foam.

[0007] In some embodiments, the thickness of the foam cushion ranges from about 1 inch to 2 inches.

[0008] In some embodiments, each display module is rectangular, and there are four spring-loaded cushions, each disposed adjacent a corresponding corner of the rectangular display module.

[0009] In some embodiments, each of the spring-loaded dampers includes a spring-loaded piston portion within a sleeve portion.

[0010] In some embodiments, the foam cushion has a plurality of openings, and each of the spring-loaded cushions is disposed within a corresponding one of the plurality of openings.

[0011] In some embodiments, the front protection panel is spaced approximately 2 mm from the array of LEDs.

[0012] In some embodiments, the front protective panel includes a plurality of posts extending from its rear surface, the printed circuit board includes a plurality of openings for receiving the posts, and the front surface of the support structure includes a plurality of receptacles for receiving the posts extending through the openings in the printed circuit board.

[0013] Further advantages of the present invention will become apparent from the detailed description when taken in conjunction with the drawings in which, to more clearly show detail, elements are not drawn to scale and like reference numerals refer to like elements throughout the several views. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a front view of an LED display unit according to an embodiment of the present invention. [Figure 2] This is a rear view of the LED display unit. [Figure 3A] An exploded view of the front of the LED display unit. [Figure 3B] An exploded view of the rear of the LED display unit. [Figure 4A] Rear view of the six individual display modules of the LED display unit with the rear frame attached. [Figure 4B] Rear view of the six individual display modules of the LED display unit with the rear frame removed. [Figure 5A] FIG. 1 is a rear view of the six individual display modules of the LED display unit with the buffers installed. [Figure 5B]Rear view of the six individual display modules of the LED display unit with the buffers removed. [Figure 5C] Rear view of the six individual display modules of the LED display unit. [Figure 6A] FIG. 1 is a rear view of one of the display modules. [Figure 6B] FIG. 1 is an exploded rear view of one of the display modules with spring-loaded cushions. [Figure 7A] FIG. 1 is a front view of one of the display modules. [Figure 7B] FIG. 1 is a front view of one of the display modules with its front protective panel removed. [Figure 7C] FIG. 1 is an exploded front view of one of the display modules. [Figure 7D] An exploded rear view of one of the display modules. [Figure 8] A view showing the rear of one of the front protection panels of the display module. [Figure 9] A diagram showing the front of one printed circuit board of the display module. [Figure 10] FIG. 1 shows the front of one support structure of the display module. [Figure 11] 1 is a cross-sectional view of a front protective panel, printed circuit board, and support structure of a portion of a display module. DETAILED DESCRIPTION OF THE INVENTION

[0015] The figures illustrate a preferred embodiment of an LED display unit 10 for use in high-shock environments. The unit 10 includes a housing 14, preferably formed from steel, that supports an array of LED display modules 12. Some embodiments of the display unit 10 described herein include six display modules 12 in a 3x2 array. However, it should be understood that the unit 10 can include any number of display modules in various array configurations.

[0016] Each display module 12 includes a printed circuit board (PCB) 16 on which thousands of LEDs are mounted in a rectangular grid. In one embodiment, there are 1,764 LEDs in each module 12. Each display module 12 also includes electrical circuitry for distributing power and control signals to each LED. The general components and function of such electrical circuitry are well understood by those skilled in the art.

[0017] Each display module 12 includes a front protection panel 18 and a support structure 20. The support structure 20 supports the PCB 16 and houses a portion of the electrical circuitry for distributing power and control signals. The front protection panel 18 covers the front of the display module 12 and protects the LEDs on the front side of the PCB 16. The front protection panel 18 is preferably formed from polycarbonate, which has the required impact strength to withstand approximately 2.5 tons (5,500 pounds) of force without cracking and is sufficiently transparent to the light from the LEDs. In one preferred embodiment, the thickness of the front panel 18 is approximately 3 mm, but in other embodiments, the thickness may vary from approximately 2 mm to 5 mm. In a preferred embodiment, the spacing between the front panel 18 and the LEDs on the PCB 16 is only approximately 2 mm (see FIG. 11). This close spacing eliminates image distortion caused by reflections in conventional display panels, where the front panel is spaced 2.54 cm (1 inch) or more from the LED array.

[0018] 7D, 8, and 11, a plurality of posts 38 extend outwardly from the rear surface of the front protective panel 18. These posts 38 are preferably distributed across the rear surface of the front protective panel 18 in an array with vertical and horizontal symmetry. In this preferred embodiment, the posts 38 are an integrally molded portion of the front protective panel 18.

[0019] 7C, 7D, 9, and 11, a plurality of openings 40 are provided through PCB 16 at positions that align with the positions of the posts 38 in front protection panel 18. When front protection panel 18 is attached to display module 12, posts 38 pass through openings 40 and are received in corresponding receptacles 42 on the front surface of support structure 20. In this preferred embodiment, receptacles 42 are integrally formed into support structure 20 during its molding or casting process. As shown in FIG. 11, when posts 38 abut against the front surface of support structure 20 within receptacles 42, the rear surface of front protection panel 18 is spaced approximately 2 mm from the front surface of the LEDs on PCB 16.

[0020] Each display module 12 is attached to the frame 22 by four threaded posts 24 extending from the rear of the support structure 20 and nuts securing the frame 22 to the posts 24. Filling the space between the frame 22 and the support structure 20 for each display module 12 is a foam cushion 28. In a preferred embodiment, the foam cushion has a thickness of between about 1 inch and 2 inches. In a preferred embodiment, the foam cushion 28 has a tensile strength of 930 kg / m 3 It is made from ethylene vinyl acetate (EVA) with a density of 1.025 psi.

[0021] Four spring-loaded bumpers 30 are also attached to the rear surface of the support structure 20, one near each corner of the support structure 20. As shown in FIG. 6B, each bumper 30 includes a piston portion 32 received within a sleeve portion 34. A spring 36 is provided within the sleeve portion 34 to bias the piston portion 32 outward. In a preferred embodiment, the spring 36 has a diameter of approximately 1 mm and provides a spring force of approximately 5.8 kg. When the display module 12 is attached to the frame 22, the outer end of the piston portion 32 contacts the frame 22. In a preferred embodiment, the piston portion 32 has a travel range of approximately 2.54 cm (1 inch), which determines the range of movement of the support structure 20 of the module 12 relative to the frame 22 when a pushing force is applied to the front panel 18 of the module 12.

[0022] Testing has shown that the combination of spring-loaded cushion 30 and foam cushion 28 reduces the impact force on PCB 16 caused by a baseball hitting module 12 at a speed of over 100 mph (161 km / h) and approximately 1800 Newtons.

[0023] Advantages of the LED display panel 10 described herein compared to conventional display panels include: -Higher impact resistance, -Reducing or eliminating interruptions such as advertisements, play clocks, etc. -Waterproofing the LED module for longer lifespan; - The front panel 18 can be positioned very close to the LEDs on the PCB 16, thereby eliminating image distortion / reflection that occurs with conventional display panels that require the LEDs to be spaced at least 1 inch from the front panel. Includes:

[0024] Although the structure of display unit 10 is specifically designed to handle impacts from baseballs, it will be understood that unit 10 may also be used in hockey, football, soccer, car racing, and other sports where impact damage to the video display screen is possible.

[0025] The foregoing descriptions of preferred embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications and variations are possible in light of the above teachings. The embodiments have been chosen and described in order to best illustrate the principles of the invention and its practical application, thereby enabling those skilled in the art to utilize the invention in various embodiments, with various modifications suited to the particular uses contemplated. All such modifications and variations are within the scope of the invention, as defined by the appended claims when such claims are fairly, legally, and equitably interpreted.

Claims

1. 1. A light emitting diode (LED) display unit for use in a high shock environment, comprising: a frame disposed within the housing; and a plurality of display modules mounted on the frame, each display module comprising: a support structure having a rear surface and a front surface; a foam cushion disposed between the frame and the rear surface of the support structure; a plurality of spring-loaded shock absorbers disposed between the frame and the rear face of the support structure; a printed circuit board mounted on the front surface of the support structure and having an array of LEDs; a front protective panel covering the LED array; Multiple display modules including wherein the foam cushion and the plurality of spring-loaded cushions combined provide cushioning to prevent damage to the printed circuit board when the front protection panel is impacted by an external object.

2. 10. The LED display unit of claim 1, wherein the foam cushion comprises ethylene vinyl acetate (EVA) foam.

3. 10. The LED display unit of claim 1, wherein the foam cushion has a thickness ranging from approximately 1 inch to 2 inches.

4. 2. The LED display unit of claim 1, wherein each display module is rectangular, and the plurality of spring-loaded cushions includes four spring-loaded cushions, each spring-loaded cushion disposed adjacent a corresponding corner of the rectangular display module.

5. 10. The LED display unit of claim 1, wherein each of the spring-loaded buffers comprises a spring-loaded piston portion within a sleeve portion.

6. 2. The LED display unit of claim 1, wherein each of the spring-loaded cushions is disposed within a corresponding one of a plurality of openings in the foam cushion.

7. 10. The LED display unit of claim 1, wherein the front protection panel is spaced approximately 2 mm from the array of LEDs.

8. the front protective panel includes a plurality of posts extending from a rear face of the front protective panel; - the printed circuit board includes a plurality of openings through which the plurality of posts extending from the front protective panel are received; the front surface of the support structure includes a plurality of receptacles for receiving the posts extending through the openings in the printed circuit board; 10. The LED display unit of claim 1.

9. 1. A light emitting diode (LED) display unit for use in a high shock environment, comprising: a frame disposed within the housing; and a plurality of display modules mounted on the frame, each display module being substantially rectangular in shape; and a support structure having a rear surface and a front surface; a foam cushion disposed between the frame and the rear surface of the support structure, the foam cushion having a plurality of openings; a plurality of spring-loaded cushions, each of which is disposed within a corresponding one of the plurality of openings in the foam cushion, each of which includes a spring-loaded piston portion within a sleeve portion, at least four of the spring-loaded cushions being disposed adjacent corresponding corners of the display module; a printed circuit board attached to the front surface of the support structure and having an array of LEDs and a plurality of openings disposed within the array of LEDs; a front protective panel covering the array of LEDs, the front protective panel including a plurality of posts extending from a rear surface of the front protective panel, the plurality of posts being received within the plurality of openings disposed within the array of LEDs; wherein the front surface of the support structure includes a plurality of receptacles for receiving the plurality of posts extending through the openings in the printed circuit board. wherein the foam cushion and the plurality of spring-loaded cushions combined provide cushioning to prevent damage to the printed circuit board when the front protection panel is impacted by an external object.

10. 10. The LED display unit of claim 9, wherein the foam cushion comprises ethylene vinyl acetate (EVA) foam.

11. 10. The LED display unit of claim 9, wherein the foam cushion has a thickness ranging from approximately 1 inch to 2 inches.

12. 10. The LED display unit of claim 9, wherein the front protection panel is spaced approximately 2 mm from the array of LEDs.

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