Patent Application - Vegas Signs

Patent Application

Flexible Lightweight full colour LED Display System

I Michael Marshall of 177 Beckett Road, Doncaster, United Kingdom. Do here by declare a
System for which I hope a Patent will be granted and the method by which it is to be
performed to be described by the following statement:-

Description

Background
The idea for this flexible signage system came about initially as a means of producing
bespoke lighting effects for nightclubs which would offer the ability to display any graphics,
patterns and text in time with the music with the use of real- time editing software or the
patterns saved to an SD card via a controller with SD card reader or PC connectivity. Often
nightclub fixtures are abstract in design and can be difficult to work around for existing
display systems so a flexible, lightweight but strong solution was needed. When testing a
prototype of the system it was realised that the system could also be used for the signage
industry. Standard signage can be un-economical and limited in its adaptability in terms of
post production design and fitting when for example a shop front is bowed or indented or
even follows a contour. The flexibility of this system makes it an ideal solution to this
problem because adjustment to the system can be done at the time of fitting at no extra
cost or delay. The information displayed on the system can also be changed and or adjusted
at any time with the editing software either saved to an SD Card or directly from a PC in real-
time.

Enabling Disclosure
The system comprises of:

1. An RGB LED array made up of LED Modules connected by wiring or ready mounted
on a strip. An LED Module is a control circuit with LED/s that uses the data provided
by the controller to illuminate the LED/s mounted onto the module circuit board
either together or independently to any other module in the array.

2. A power supply.

3. A base panel (to which the LED array is mounted).

4. A diffuser (which protects diodes and diffuses the light emitted from the diodes to
enhance their overall effect.).

5. A controller.

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Before assembly of the system the following must be taken into consideration:

1. Deciding the flexibility needed of the system and the environment in which the
system will be mounted and therefore the choice of components and materials to be
used in the system. For example an outdoor system would need to be waterproof
and therefore the LED array and PSU would be of a waterproof type or ‘IP68
Standard’. An indoor system would not need such restrictions. The flexibility is
determined by the thickness of the base panel and diffuser.

2. Deciding on the quality of the image, the pitch, and the area to be covered by the
system. This will determine the amount of LED’s required in the array, the size of the
PSU (power supply unit) to power the array and the type of controller needed to run
the array.

Once these factors have been taken into consideration the assembly of the system can
begin.

Building a indoor system using LED array made up of modules connected by wring

The first step is to calculate the grid for the area of the display which the LED array will
be mounted into, in the base panel. This is done using a formula using the pitch wanted
and the area of the display wanted (Length divided by pitch times by height divided by
pitch equals the number of LED’s modules to be used.) once you have the total number
of LED modules you can then choose the correct size PSU & controller/s.

Once the formula has been calculated the grid is used to drill holes or recesses ready for
the LED array to be fitted, this is carried out ideally with a CNC machine to get the most
accurate layout possible. This creates the display area.

The array of LED’s is made up of modules connected by data and power wiring. The data
only travels through the array in one direction. The power travelling through the array
diminishes over distance; therefore the LED’s must be inserted into the grid with no
breaks in one continuous strand and may require a spur to receive extra power from the
supply if and when required, this is easily added to the wiring.

Once this is completed the LED array can be connected to the controller and tested,
where power seems to diminish (the LED’s are not as bright, flickering or incorrect
colour) a power spur should be added into the LED array at that point. If numerous
panels containing displays are to be connected together as to make one big display then
the connection should be made to continue the array in the same direction with power
added as and when required.

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Once testing is complete the diffuser can be fitted to complete the system ready for
mounting.

Where systems may need to be amended to avoid obstacles by cutting shapes from the
system (using a knife or hand tool), some LED’s may have to be removed from the array,
in which case the LED’s at either side of the LED’s lost in the array are simply
reconnected and also amended in the software so the display is correct.

The invention will now be described solely by way of example and with reference to the
accompanying drawings in which:

Figure 1 shows a side and bottom view of the (1)RGB LED Module comprising of the
(2)LED Circuit board & LED, wiring connections and control IC, on the board is the
direction for the DATA path and input/output terminals.

Figure 2 shows a side section of the (1)RGB LED module (2)the wiring connecting the two
modules mounted one of them (3) in the (4)panel board and the (5)diffuser.

Figure 3 shows the (4)grid layout of the (3)RGB LED array in a (4)continuous string, these
are connected to the (1)controller to receive the data and the (2)PSU to receive power. It
also shows a (5)spur coming from the PSU for extra power further into the array.

Figure 4 shows a top view of the (1)base panel with the (2)RGB LED’s mounted and a
slice of the (3)diffuser on top of the (1)base panel.

Figure 5 shows a side section of the completed system with the (1)diffuser and (2)base
panel bent to shape with the (3)RGB LED modules mounted into the (2)base panel.

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Claims
1. A unique way of manufacturing an RGB LED display system which makes it Flexible,
lightweight, easy to fit and adjustable when fitting.

2. Said sign system can be bent, twisted and cut provided by extruded flexible plastics.

3. Said sign system is low voltage as the RGB LED only consumes power when actively
emitting light.

4. Said sign system can be expanded easily by means of connecting the wiring with a
simple connector for example a din plug or block connector.

5. Said sign system can be manufactured at a low cost using a CNC machine.

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Patent Application - Vegas Signs

Abstract
A flexible, low energy signage system comprising of multiple RGB LED’s for full colour
animated displays and text. The panels can be bent, twisted, cut and shaped easily and the
LED’s arranged to recreate an animated image or pattern from an SD Card source or
networked PC Via an integrated controller. Flexibility comes from the use of extruded
plastics dependant on customer requirements for example Corex or Foamex. This also makes
the panels lightweight and easy to fit and maintain. Light energy is only generated when
needed and a series of LED’s (quantity dependant on LED type) can be powered by as little
as a 5v supply. Image Quality can be set by the spacing of the LED’s in the array (usually
referred to as the ‘pitch’) the smaller the pitch the clearer the image.