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`US 20020122134Al
`
`(19) United States
`(12) Patent Application Publication
`Kalua
`
`(10) Pub. No.: US 2002/0122134 Al
`Sep. 5, 2002
`( 43) Pub. Date:
`
`(54) VIDEO DISPLAY ARRAY OF SEALED,
`MODULAR UNITS
`
`(76)
`
`Inventor: Kevin A. Kalua, Angwin, CA (US)
`
`Correspondence Address:
`Harris Zimmerman
`Law Offices of Harris Zimmerman
`Suite 710
`1330 Broadway
`Oakland, CA 94612-2506 (US)
`
`(21) Appl. No.:
`
`09/798,391
`
`(22) Filed:
`
`Mar. 5, 2001
`
`Publication Classification
`
`(51)
`
`Int. Cl.7 .............................. H04N 5/66; H04N 9/12;
`H04N 5/64
`............................................ 348/383; 348/836
`
`(52) U.S. Cl.
`
`(57)
`
`ABSTRACT
`
`A large format modular video display includes a plurality of
`video image units, each image unit sealed against environ-
`
`mental intrusions. Each image unit includes a housing
`having a front panel and a rear door panel that may be
`opened for access to the interior. Within the housing, a
`strongback member supports an LED circuit board having a
`large plurality of LEDs supported in pixel array, each pixel
`comprised of a plurality of LEDs of various colors. A gasket
`member is dimensioned to cover the pixel array of LEDs,
`and includes an array of LED holes in registration with the
`pixel array of the LED board, so that each LED extends
`through a respective hole in the gasket. The front panel of
`the housing also includes an array of LED holes in regis(cid:173)
`tration with the holes of the gasket member, so that each
`pixel group of LEDs may extend through respective holes in
`the front panel and protrude forwardly therefrom. The LED
`circuit board and front panel are joined in compressive
`fashion with the gasket member sandwiched therebetween to
`seal the LED holes of the front panel and prevent intrusion
`of weather. A sunshade secured to the front panel includes a
`shade panel having an array of pixel holes, so that each pixel
`group of LEDs may protrude through a respective pixel hole
`in the sunshade. The sunshade includes a plurality of shade
`flanges, each shade flange disposed directly above a respec(cid:173)
`tive row of pixel holes in the shade panel.
`
`94
`
`94
`
`92
`
`Samsung Exhibit 1021
`Samsung Elecs. Co., Ltd. v. Ultravision Techns., LLC
`IPR2020-01176
`Page 00001
`
`

`

`Patent Application Publication
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`Sep. 5, 2002 Sheet 1 of 12
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`US 2002/0122134 Al
`
`102
`
`I
`134 I
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`
`43
`
`34
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`FIG. 1
`
`IPR2020-01176 Page 00002
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`Patent Application Publication
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`Sep. 5, 2002 Sheet 2 of 12
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`US 2002/0122134 Al
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`101
`
`42
`
`0
`
`102
`
`43
`
`43
`
`FIG. 2
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`IPR2020-01176 Page 00003
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`Patent Application Publication
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`Sep. 5, 2002 Sheet 3 of 12
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`US 2002/0122134 Al
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`IPR2020-01176 Page 00004
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`

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`Patent Application Publication
`
`Sep. 5, 2002 Sheet 4 of 12
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`US 2002/0122134 Al
`
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`64
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`
`62
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`IPR2020-01176 Page 00005
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`Patent Application Publication
`
`Sep. 5, 2002 Sheet 5 of 12
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`US 2002/0122134 Al
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`64
`
`66
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`63
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`I
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`61 I
`
`67
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`67
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`63
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`IPR2020-01176 Page 00006
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`Patent Application Publication
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`Sep. 5, 2002 Sheet 6 of 12
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`US 2002/0122134 Al
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`69
`
`71
`
`71
`
`68
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`71
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`
`FIG. 7
`
`63
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`67
`
`IPR2020-01176 Page 00007
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`Patent Application Publication
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`Sep. 5, 2002 Sheet 7 of 12
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`US 2002/0122134 Al
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`52
`
`51
`
`92
`
`FIG. 9
`
`91
`
`94
`
`94
`
`92
`
`FIG. 10
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`IPR2020-01176 Page 00008
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`Patent Application Publication
`
`Sep. 5, 2002 Sheet 8 of 12
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`US 2002/0122134 Al
`
`FIG. 12
`
`FIG. 13
`
`92
`
`91
`
`93
`
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`91
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`FIG. 14
`
`FIG. 11
`
`IPR2020-01176 Page 00009
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`Patent Application Publication
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`Sep. 5, 2002 Sheet 9 of 12
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`US 2002/0122134 Al
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`134
`
`136
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`134
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`132
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`64
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`IPR2020-01176 Page 00010
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`Patent Application Publication
`
`Sep. 5, 2002 Sheet 10 of 12
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`US 2002/0122134 Al
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`161~
`
`141
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`142
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`146
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`144
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`IPR2020-01176 Page 00011
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`Patent Application Publication
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`Sep. 5, 2002 Sheet 11 of 12
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`US 2002/0122134 Al
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`117
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`121
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`FIG. 20
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`113
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`121
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`
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`IPR2020-01176 Page 00012
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`Patent Application Publication
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`Sep. 5, 2002 Sheet 12 of 12
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`US 2002/0122134 Al
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`32
`
`104
`
`L.4-'-...:....C:....,'-"-"-L.L...L--"-'-...................... ~
`
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`
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`
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`
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`
`101
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`IPR2020-01176 Page 00013
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`

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`US 2002/0122134 Al
`
`Sep.5,2002
`
`1
`
`VIDEO DISPLAY ARRAY OF SEALED, MODULAR
`UNITS
`
`BACKGROUND OF THE INVENTION
`
`[0001] The present invention relates to large format video
`displays (video walls), and, more particularly, to large
`format displays employing light emitting semiconductor
`devices in large arrays.
`
`[0002] The development and improvement of light emit(cid:173)
`ting diodes (LEDs), which has resulted in bright light
`sources having colors throughout the visible spectrum. very
`long life, and reasonable prices, has driven the revolution in
`large format video displays from CRT-based systems to
`LED-based systems. LED video systems have brighter out(cid:173)
`put, wider viewing angle, and far greater energy efficiency.
`
`[0003] Although LEDs have an extremely long mean time
`before failure (MTBF), they must be protected from damage
`due to particular operating conditions. For example, when
`LEDs overheat the life expectancy quickly may be shortened
`by factors of 10. Heat buildup may be caused not only by the
`waste heat of the LEDs operating at high power, but also by
`external factors such as hot ambient air due to hot weather,
`high heat loads from direct sunlight, and the like. Generally
`speaking, some form of cooling system must be available to
`rid the LED systems of heat buildup to avoid diminishing the
`life of the LEDs.
`
`[0004] Furthermore, many large format video systems are
`installed outdoors, in stadiums, along highways, and the
`like. In this environment they are subjected to extremes of
`temperature, infiltration by water, damage from freezing
`water, insects, and the like. To overcome this problem,
`systems known in the prior art have resorted to joining the
`assembly of an LED circuit board and other structural
`components with potting compound, thereby creating a solid
`unit that is impervious to water and the damaging effects of
`ice. In addition, the same potting compound is often used to
`retain a sunshade component to the outer surface of the LED
`display.
`
`[0005] Unfortunately, the potting compound forms a per(cid:173)
`manent unit that cannot be disassembled for service. Thus,
`for example, if one pixel of a display is damaged or fails
`spontaneously, it is not possible to disassemble and remove
`and replace the LED circuit board in the video display. Nor
`is it possible to salvage the shade component for further use,
`or other portions of the video display assembly. In this
`example, the entire unit must be junked.
`
`[0006] There is a need in the prior art for a video display
`system that is sealed and weatherproof to avoid damage
`from environmental factors, yet may be dismantled for
`repair and replacement of component parts.
`
`SUMMARY OF THE INVENTION
`[0007] The present invention generally comprises a large
`format video display that is highly modular in construction
`and adaptable to a variety of uses and installations. The
`modular arrangement includes a plurality of video image
`units, and each image unit is sealed against weather and
`other environmental intrusions, yet may be disassembled for
`repair and replacement of damaged components.
`
`[0008]
`In one aspect of the invention, each image unit is
`comprised of a rectangular housing having a front panel and
`
`a rear door panel that may be opened for access to the
`interior of the housing. Within the housing, a strongback
`member extends generally parallel to the front panel, and
`includes mounting holes for a driver circuit board at the rear
`surface thereof. Joined to the front surface of the strongback
`member is an LED circuit board, on which a large plurality
`of LEDs are supported and connected to traces that are in
`turn connected to the driver board. The LEDs are grouped in
`pixel array, each pixel comprised of LEDs of various colors
`and combined to emit light across the visible spectrum.
`
`[0009] The image unit assembly further includes a gasket
`member comprised of a sheet of flexible, impervious mate(cid:173)
`rial. The gasket member is sufficiently wide and long to
`cover the pixel array of LEDs. An array of pixel holes in the
`gasket member is formed to be in registration with the pixel
`array of the LED board, so that each pixel group of LEDs
`extends through a respective pixel hole in the gasket. The
`front panel of the housing also includes an array of pixel
`holes in registration with the pixel holes of the gasket
`member, so that each pixel group of LEDs may extend
`through a respective pixel hole in the front panel and
`protrude forwardly therefrom. The LED circuit board and
`front panel are joined by a threaded fastener system in
`compressive fashion with the gasket member therebetween
`to seal the pixel holes of the front panel and prevent
`intrusion of weather. Thus the system is sealed, yet is
`disassemblable for service and repair.
`
`[0010]
`In a further aspect of the invention, each image unit
`assembly is provided with a sunshade removably secured to
`the front panel of the unit. The sunshade includes a shade
`panel having another array of pixel holes in registration with
`the pixel holes of the front panel and the gasket member, so
`that each pixel group of LEDs may protrude through the
`sunshade. The sunshade further includes a plurality of shade
`flanges, each shade flange extending laterally and disposed
`directly above a respective row of pixel holes in the shade
`panel. Each shade flange extends outwardly and forwardly
`from the surface of the shade panel to block at least partially
`the bright light emanating from the sun and sky from
`impinging on the protruding output ends of the LEDs. The
`shade panel and shade flanges may be provided with a dark
`absorptive coating, such a black anodized aluminum, to
`minimize reflection of light from bright sources, and to
`maximize the effect of the LEDs outputs.
`
`[0011]
`In another aspect, the invention includes a particu(cid:173)
`lar pixel grouping that is designed to minimize the effects of
`bright light impinging on the each pixel group. Each pixel
`group is formed of five LEDs disposed in parallel rows of
`three and two LEDs. The top row is formed of red, blue, and
`green LEDs, and is directly under the respective shade
`flange of the pixel. The bottom row is formed of red and
`green LEDs centered at the interstitial spacing of the top
`row. The top row is in the deepest shade of the respective
`shade flange, and sunlight from high angles may shine on the
`bottom row but will not impinge on the top row of LEDs.
`Since the top row includes the blue LED as well as the red
`and green, sunlight shining on the lower part of each pixel
`will not adversely affect the color rendition of the image
`unit.
`
`[0012]
`In an additional aspect of the invention, each
`rectangular housing includes opposed top and bottom panels
`that are adapted for vertical stacking. A system of male and
`
`IPR2020-01176 Page 00014
`
`

`

`US 2002/0122134 Al
`
`Sep.5,2002
`
`2
`
`female guide features are provided in the top and bottom
`panels whereby each top panel of one unit is provided with
`at least one male or female guide feature that interfits with
`a respective female or male guide feature on the bottom
`panel. The image units are stacked top to bottom, and the
`guide features assure that the stack is substantially orthogo(cid:173)
`nal ( or whatever other arrangement is desired). Likewise, the
`side panels of the housing may be provided with similar
`guide features, although it is not deemed essential.
`[0013] The image units are arrayed in columns and rows,
`and the bottom row is supported on a manifold that supplies
`cold air or other coolant through spaced holes in the mani(cid:173)
`fold. the top and bottom panels of each image unit includes
`at least one vent hole to promote the flow of coolant
`upwardly through the columns of image units. An exhaust
`manifold is secured to the top of the uppermost row of the
`array to carry away the coolant, whereby substantial heat is
`removed from the video array. Each image unit further
`includes at least one access hole in each side panel, whereby
`power cables and signal cables may be connected and run
`throughout the image units of each row in the array.
`[0014] Another aspect of the invention is the threaded
`fastener system mentioned above. A plurality of threaded
`assemblies join the strongback to the LED circuit board,
`each having a standoff component that defines a spacing
`between the strongback and the LED board. The first stand(cid:173)
`off component includes a forward portion that extends
`through aligned mounting holes in the LED board, the
`gasket member, and the front panel of the housing. A second
`standoff component includes internal threads to engage the
`forward portion of the first standoff component. The second
`standoff component is disposed forwardly of the front panel,
`and joins the LED board to the rear surface of the front panel
`in compressive fashion with the gasket member entrained
`therebetween in sealing fashion.
`[0015] The threaded assemblies further include a captive
`screw component that engages a threaded portion of the
`second standoff component. The captive screw components
`extend through similarly aligned mounting holes in the
`shade assembly, and may be tightened to secure the shade
`assembly to the forward extends of the second standoff
`member. This arrangement securely and rigidly supports the
`shade assembly on the housing, while also defining a mini(cid:173)
`mum spacing between the shade assembly and the front
`panel of the housing. As a result, any heat buildup in the
`shade assembly due to solar heating thereof, or heat absorp(cid:173)
`tion from the LEDs themselves, cannot be conducted
`directly to the front panel of the housing, nor to the gasket
`member and LED board. Thus a major heat load factor in
`prior art systems is obviated.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0016] FIG. 1 is a partially cutaway front perspective
`view of the sealed video module of the present invention.
`[0017] FIG. 2 is a rear perspective view of the sealed
`video module shown in FIG. 1.
`[0018] Figure 3 is a partial perspective view of the LED
`circuit board of the sealed video module of FIGS. 1 and 2.
`[0019] FIG. 4 is a front plan view of the strongback
`component of the sealed video module of the present inven(cid:173)
`tion.
`
`[0020] FIG. 5 is a rear plan view of the strongback
`component shown in FIG. 4.
`[0021] FIG. 6 is a cross-sectional elevation of the strong(cid:173)
`back component, taken along line 6-6 of FIG. 4.
`[0022] FIG. 7 is a cross-sectional elevation of the strong(cid:173)
`back component, taken along line7-7 of FIG. 4
`[0023] FIG. 8 is a cross-sectional elevation of the strong(cid:173)
`back component, taken along line 8-8 of FIG. 4
`[0024] FIG. 9 is a detail view of a pixel hole and the LED
`holes associated with it according to the present invention.
`[0025] FIG. 10 is a plan view of the gasket component of
`the present invention.
`[0026] FIG. 11 is an enlarged plan view of a portion of the
`gasket component shown in FIG. 10.
`[0027] FIG. 12 is a cross-sectional view of the gasket
`component, taken along line 12-12 of FIG. 11.
`[0028] FIG. 13 is a cross-sectional view of the gasket
`component, taken along line 13-13 of FIG. 11.
`[0029] FIG. 14 is a cross-sectional view of the gasket
`component, taken along line 14-14 of FIG. 11.
`[0030] FIG. 15 is a partial plan view of the shade com(cid:173)
`ponent of the present invention.
`[0031] FIG. 16 is an end view of the portion of the shade
`component shown in FIG. 15.
`[0032] FIG. 17 is an exploded view of the threaded
`standoff assembly of the present invention.
`[0033] FIG. 18 is an exploded schematic assembly of the
`threaded standoff assembly and the shade component, front
`panel, gasket, LED circuit board, strongback, and driver
`circuit board.
`[0034] FIG. 19 is a plan view of the female guide member
`for interconnecting the sealed video modules of the inven(cid:173)
`tion.
`[0035] FIG. 20 is a cross-sectional side elevation of the
`female guide component, taken along line 20-20 of FIG. 19.
`[0036] FIG. 21 is a cross-sectional side elevation of the
`female guide component, taken along line 21-21 of FIG. 19.
`[0037] FIG. 22 is a perspective view of the female guide
`component shown in FIGS. 19-21.
`[0038] FIG. 23 is a plan view of the male guide compo(cid:173)
`nent for interconnecting the sealed modules of the invention.
`
`[0039] FIG. 24 is a cross-sectional side elevation of the
`male guide component, taken along line 24-24 of FIG. 23.
`[0040] FIG. 25 is a cross-sectional side elevation of the
`male guide component, taken along line 25-25 of FIG. 23.
`[0041] FIG. 26 is a perspective view of the male guide
`component shown in FIGS. 23-25.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`
`[0042] The present invention generally comprises a large
`format video display that is highly modular in construction
`and adaptable to a variety of uses and installations. The
`
`IPR2020-01176 Page 00015
`
`

`

`US 2002/0122134 Al
`
`Sep.5,2002
`
`3
`
`modular arrangement includes a plurality of video image
`units, and each image unit is sealed against weather and
`other environmental intrusions, yet may be disassembled for
`repair and replacement of damaged or worn components.
`[0043] With regard to FIGS. 1 and 2, the invention
`provides a basic modular video output unit 31. The unit 31
`includes top and bottom panels 32 and 33 and laterally
`opposed side panels 34 and 36 joined in a rectangular
`assembly, with rectangular front panel 37 spanning the
`panels 32-36 contiguously to form a rigid enclosure. A rear
`panel 38 also spans the panels 32-36, and includes a hinged
`door 39 that provides access to the interior of the modular
`unit 31. The door 39 is latched by handle assemblies 41. At
`least one vent hole 42 extends through the top panel 32 and
`bottom panel 33 (not shown) to permit air flow or coolant
`flow through the unit 31. In addition, at least one access hole
`43 extends through the side panels 34 and 36 to accommo(cid:173)
`date power cables, signal wires, and the like to extend
`laterally through adjacent units 31 in a respective row of an
`array of the units 31. The bottom row of the array of units
`31 is supported on a coolant supply manifold 44 that extends
`the width of the bottom row and is joined thereto to deliver
`cool air or other coolant to the vent holes 42 of the bottom
`panels of the bottom row, from which the coolant may rise
`through the array to remove heat therefrom. An exhaust
`manifold (not shown) similar to the supply manifold may be
`secured to the top panels of the top row of the array of units
`31 to remove the heated air or coolant, or return it through
`a refrigeration cycle.
`
`[0044] With regard to FIGS. 1 and 9, the front panel 37
`of each unit 31 is provided with a plurality of LED holes 51
`grouped in a pixel arrangement. Each pixel 52 includes a top
`row of three holes 51 and a bottom row of two holes 51, and
`the pixel shape is generally a regular trapezoidal having
`rounded vertices. The holes 51 are dimensioned to permit
`the output ends of LEDs to extend therethrough. In particu(cid:173)
`lar, the top row is provided with red, blue, and green LEDs,
`and the bottom row comprises red and green LEDs, for
`purposes to be explained in the following description. As
`shown in FIG. 1, the LED holes in their pixel groupings are
`formed a regular matrix, such as a 16x16 array (shown) or
`any other layout that is consonant with a video display
`format. The front panel also includes a plurality of mounting
`holes 53 in a predetermined pattern, for purposes to be
`explained below.
`
`[0045] Within each unit 31, the major structural compo(cid:173)
`nent is the strongback 61, shown in FIGS. 4-8. The strong(cid:173)
`back 61 is generally described as a fortified panel that
`includes a plurality of reinforcing ribs 62 disposed about the
`periphery and formed in a grid pattern that extends from the
`front face thereof, as shown in FIG. 4. Furthermore, rein(cid:173)
`forcing ribs 63 are disposed about the periphery and formed
`in an obtuse grid pattern extending from the rear face of the
`strongback 61, as shown in FIG. 5. A plurality of mounting
`holes 64 extend through the strongback from front to back,
`each mounting hole surrounded by a boss 66 that protrudes
`from the front and rear surfaces. The mounting holes 64 are
`disposed in a pattern that is identical to the pattern of the
`mounting holes 53 in the front panel 37 of each unit 31. Note
`that each boss 66 is disposed to be intersected by at least one
`of the reinforcing ribs 62 at the front surface, and is disposed
`at a converging point of two reinforcing ribs 63 at the rear
`surface of the strongback, so that each point of support is
`
`doubly reinforced. Furthermore, a small cylindrical protu(cid:173)
`berance 65 extends coaxially from the front end surface of
`each boss 66, the respective hole 64 extending through the
`protuberance 65, as shown in FIG. 7.
`[0046] The strongback 61 also includes large rectangular
`cutout openings 67 extending therethrough and disposed in
`a rectangular grouping in the medial portion thereof. A
`quartet of tubular cylindrical projections 68 extend from the
`back surface of the strongback, arranged in two pairs of two
`that are disposed at laterally opposed sides of the cutout
`openings 67. Each projection 68 includes a coaxial hole 69
`extending coaxially in the end wall thereof. A web 71
`extends from the adjacent rib surface to each respective
`projection 68 for added rigidity and strength. The projec(cid:173)
`tions serve as handles for manipulating the strongback and
`the components assembled thereto, as explained below.
`[0047] Another major component of each unit 31 is an
`LED circuit board 81, as shown in FIG. 3. The front surface
`82 of the board 81 supports a plurality of LEDs 83, the LEDs
`being grouped in a pixel array in which each pixel is
`comprised of five LEDs, as described with reference to FIG.
`9. The LEDs 83 are disposed in registration with the holes
`51 in the front panel 37, and are arranged to extend through
`all the holes 51 when the unit is fully assembled. Each board
`81 may support an array of pixel groupings, such as a 16x16
`matrix, or any other usable format. The board also includes
`a plurality of mounting holes 84 which are arranged in a
`pattern identical to the mounting holes 53 of the front panel
`and the mounting holes 64 of the strongback. The rear
`surface of the board is provided with printed traces that
`connect and address each of the LEDs 83 individually.
`[0048] With regard to FIGS. 10-14, each unit 31 further
`includes a gasket component 91, comprised of a sheet of
`impervious, resilient material. The gasket 91 is provided
`with a plurality of LED holes 92, which are arranged in pixel
`groupings identical to those shown in FIG. 9. Between the
`pixel groupings, the gasket is provided with reduced thick(cid:173)
`ness portions 93 which diminish the amount of material in
`the gasket and define seal-forming surfaces around and
`about all of the LED holes 92. The gasket 91 is also provided
`with a plurality of mounting holes 94 which are disposed in
`the same pattern as the mounting holes 84 of the LED board,
`the mounting holes 53 of the front panel, and the mounting
`holes 64 of the strongback.
`
`It may be noted that the strongback 61 is secured
`[0049]
`within the unit 31, with the front surface of the strongback
`facing the front panel 37. The LED board 81 is assembled to
`the strongback in a spaced apart relationship, and the gasket
`91 is assembled to the front surface of the LED board 81,
`with each LED 83 extending through a respective hole 92.
`The LEDs 83 further extend through the front panel 37, with
`the output end of each LED 83 extending through a respec(cid:173)
`tive LED hole 51 in the front panel. The gasket 91 is
`sandwiched between the front panel 37 and the LED board
`81, and is compressed therebetween to form a weatherproof
`seal therewith. Thus the LED output ends protrude from the
`front panel to provide excellent visibility and viewing angle,
`while the front assembly is sealed to exclude water, mois(cid:173)
`ture, insects, and other detrimental environmental factors.
`
`[0050] Another major component of each unit 31 is a
`shade assembly 131, shown in FIGS. 1, 15, and 16. The
`shade assembly 131 includes a flat panel 132 extending the
`
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`height and width of the front panel 37, and having a plurality
`of pixel holes 133 formed therein in a matrix that matches
`the pixel layout shown in FIG. 9. The pixel holes 133
`corresponds and register with the pixel grouping of the LED
`board, the gasket, and the front panel. That is, each pixel
`hole 133 in the shade panel 132 corresponds to and is
`aligned with a respective one of the pixel groupings 52
`described previously, so that each pixel grouping of LEDs
`may protrude through a respective hole 133 in the shade
`panel. A plurality of mounting holes 136 are disposed in a
`pattern that is in registration with the mounting holes 53 of
`the front panel 37, and thus with the mounting holes of the
`gasket, LED circuit board, and strongback.
`[0051] A salient feature of the shade assembly is a plu(cid:173)
`rality of shade flanges 134 extending laterally in parallel
`array and projecting forwardly from the front surface of the
`shade panel 132. Each shade flange 134 extends approxi(cid:173)
`mately orthogonally from the panel 132, and is positioned
`directly above a row of pixel holes 133 to block at least
`partially the bright light emanating from the sun and sky
`from impinging on the protruding output ends of the LEDs.
`The shade panel and shade flanges may be provided with a
`dark absorptive coating, such a black anodized aluminum, to
`minimize reflection of light from bright sources, and to
`maximize the effect of the LEDs outputs.
`[0052] With regard to FIG. 1, the shade configuration
`described above interacts with the pixel layout shown in
`FIG. 9 to preserve (to the greatest extent possible) the color
`rendition of the image portion projected by each unit 31. It
`is generally true that the strongest sunlight occurs when the
`sun is highest in the sky, approximated by the perspective
`view angle of FIG. 1. The shade flanges 134 block direct
`sunlight from impinging on the upper row of LEDs 51 in
`each pixel hole 133, so that the output of the upper row of
`LEDs of each pixel is not diminished by reflected sunlight
`( and other high angle bright light sources). Due to the fact
`that the blue LED is located in the upper row of each pixel,
`the output of each pixel grouping maintains proper color
`balance even during those periods when sunlight tends to
`attenuate the output of the lower row of LEDs of each pixel.
`[0053]
`It is noted that the front panel, LED circuit board,
`gasket, and shade assembly all are provided with substan(cid:173)
`tially the same rectangular configuration and dimensions, so
`that each unit 31 provides a complete incremental portion of
`a larger video image portrayed by the entire video array.
`
`[0054] Each unit 31 further includes external features that
`facilitate properly aligned stacking of multiple units in true
`vertical relationship. With regard to FIGS. 1 and 2, the top
`panel 32 of each unit 31 is provided with at least one male
`guide 101 and/or female guide 102, and the bottom panel 33
`is provided with at least one female guide 102 and/or male
`guide 101 positioned for complementary fit when two units
`31 are aligned and stacked vertically. The complementary fit
`enables an installer to stack two or more units in rough
`vertical alignment, and the complementary interfit of the
`guides 101 and 102 causes the units to assume true align(cid:173)
`ment.
`
`lug 107 extends outwardly from the face 105, and includes
`a central hole 108 therein that is threaded internally. Another
`tapped hole 109 extends into the face 105, and does not
`extend through to the bottom surface of the disk 103. The lug
`107 and hole 109 are diametrically opposed with respect to
`the central axis of the disk 103. In addition, a pair of
`mounting holes 111 are provided in diametrically opposed
`relationship in the peripheral portion of the disk 103. The
`holes 111 enable the guide 101 to be mounted in the top or
`bottom panel 32 with the face 105 thereof substantially flush
`with the outer surface of the panel.
`
`[0056] With regard to FIGS. 19-22, the female guide 102
`includes a disk 113 and a central annulus 114 extending
`coaxially therefrom. The annulus 114 is provided in its outer
`face 115 with an annular groove 116 adapted to secure an
`O-ring gasket or the like (not shown). A tapered channel 117
`extends inwardly and diametrically in the face 115, and
`includes a hole 118 at one end of the channel that extends
`through to the bottom face of the disk. In addition, a pair of
`mounting holes 121 are provided in diametrically opposed
`relationship in the peripheral portion of the disk 113. The
`holes 121 enable the guide 101 to be mounted in the top or
`bottom panel of the unit 31 with the face 115 thereof
`substantially flush with the outer surface of the panel.
`
`[0057] With particular reference to FIG. 21, the tapered
`cylindrical lug 107 of the male guide 101 is dimensioned to
`be received in the channel 117 with minimal clearance, so
`that the two guides are drawn into alignment by engagement.
`The tapped holes 108 and 109 are positioned so that one of
`them is in alignment with the hole 118 through the female
`guide 102. That is, no matter which end of the channel 117
`receives the lug 107, there is hole alignment so that a screw
`or bolt may be extended through the hole 118 to secure the
`male guide 101 thereto. Thus the male/female guide engage(cid:173)
`ment assures alignment of the units 31 to which they are
`joined, and they also provide a means to fasten the units
`together to form a large video array. Also note that the
`O-ring seal retained in grooves 106 and 116 eliminate any
`intrusion of environmental factors into the array through the
`guide assemblies.
`
`[0058] With regard to FIG. 17, the invention includes a
`plurality of threaded assemblies 141 that join the strong(cid:173)
`back, LED circuit board, and gasket to the front panel within
`each unit 31, and that secures the shade assembly to the
`exterior of the front panel of the unit 31. The assembly 141
`includes a captive screw 142, comprised of a knurled head
`143, a shank 144, and a threaded distal end 146 that is
`greater in diameter than the shank. The shank and tapped
`portion 146 extend through a captive screw standoff com(cid:173)
`ponent 147. The standoff 147 includes a head 148 having a
`tapped hole 150 extending axially therethrough to join a
`bore 152 that extends axially through the tubular body
`portion 149. The distal end portion 151 of the body 149 is
`knurled. Note that the tapped portion 146 of the screw 147
`may be threaded through the tapped hole 150, whereafter the
`shank 144 may translate freely through the hole 150. Thus
`the screw 142 is held captive in the standoff 147.
`
`[0055] With regard to FIGS. 23-26, each male guide 101
`includes a disk 103 and a central annulus 104 extending
`coaxially therefrom. The annulus 104 is provided in its outer
`face 105 with an annular groove 106 adapted to secure an
`O-ring gasket or the like (not shown). A tapered cylindrical
`
`[0059] The assembly 141 also includes a swage standoff
`(spacer) component 153, which includes a tubular body
`portion 154. A tubular neck 156 extends from the proximal
`end of body 154, and is dimensioned to be received in the
`bore 152 with minimal clearance. A knurled portion 157
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`extends from the distal end of body 154, and a threaded
`distal end 158 extends from portion 157. A bore 159 extends
`axially through the standoff 153, and is threaded through