Patent Grant
10078975
Variable message signs are used to display messages to motorists and provide them information about hazards, accidents ahead, weather information, etc. There has been a push to provide variable message signs that provide more detail and/or are in color. There has also been a problem with signs being visible to motorists that are not the intended viewers of the variable message sign. Adding multiple lighting elements per aperture only increases this problem.
For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the present disclosure. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure. The same reference numerals in different figures denote the same elements.
The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.
The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and/or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.
The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood and refer to connecting two or more elements mechanically and/or otherwise. Two or more electrical elements may be electrically coupled together, but not be mechanically or otherwise coupled together. Coupling may be for any length of time, e.g., permanent or semi-permanent or only for an instant. “Electrical coupling” and the like should be broadly understood and include electrical coupling of all types. The absence of the word “removably,” “removable,” and the like near the word “coupled,” and the like does not mean that the coupling, etc. in question is or is not removable.
As defined herein, two or more elements are “integral” if they are comprised of the same piece of material. As defined herein, two or more elements are “non-integral” if each is comprised of a different piece of material.
As defined herein, “approximately” can, in some embodiments, mean within plus or minus ten percent of the stated value. In other embodiments, “approximately” can mean within plus or minus five percent of the stated value. In further embodiments, “approximately” can mean within plus or minus three percent of the stated value. In yet other embodiments, “approximately” can mean within plus or minus one percent of the stated value.
Various embodiments of a highway message sign comprise a housing and one or more circuit boards. In many embodiments, each of the one or more circuit boards have a plurality of pixels, and each pixel of the plurality of pixels can include one or more lighting elements. The highway message sign can further comprise a glazing adjacent to the lighting elements and a mask attached to the housing and adjacent to the glazing. The mask can have a plurality of apertures aligned with the plurality of pixels at an offset, wherein each pixel of the plurality of pixels is aligned at a different one of the plurality of apertures such that the one or more lighting elements of any pixel of the plurality of pixels are aligned to the same aperture. The highway message sign can further comprise one or more pins having a first end attached to the mask and a structural return separate from the one or more pins and having a first end attached to the mask. In many embodiments, each of the one or more pins extend from the mask and through the glazing and the one or more pins have a second pin end attached to at least one of the one or more circuit boards.
In some embodiments, the highway variable message sign comprises a mask with a plurality of apertures and a housing having the mask at a front face of the housing, the mask comprising a plurality of apertures. The highway variable message sign can further comprise one or more printed circuit boards comprising a plurality of pixels, wherein each pixel of the plurality of pixels comprises a plurality of lighting elements, wherein each pixel is aligned with at least one of the plurality of apertures at an offset. In many embodiments, the highway variable message sign can comprise a glazing between the mask and the one or more printed circuit boards, one or more pins having a first end attached to the mask, and a center of each pixel is equidistant to an adjacent center of each adjacent pixel. In some embodiments, each of the one or more pins extend from the mask and through the glazing and the one or more pins have a second pin end attached to at least one of the one or more printed circuit boards.
In many embodiments, the highway variable message sign comprises a housing, and a plurality of printed circuit boards. In some embodiments, each of the plurality of printed circuit boards can have a plurality of pixels, and each pixel includes a plurality of lighting elements, wherein the plurality of lighting elements are contained in a single LED. In some embodiments, the highway variable message sign can further comprise a glazing adjacent to the plurality of lighting elements and a mask attached to the housing, adjacent to the glazing, and coupled to the plurality of printed circuit boards. In many embodiments, the mask has a plurality of apertures aligned with the plurality of pixels at an offset, wherein each pixel is aligned at a different one of the plurality of apertures. In some embodiments, the highway message sign further comprises a structural return having a first end attached to the mask.
In many embodiments, the highway variable message sign comprises a housing and a plurality of printed circuit boards coupled to the housing. Each of the plurality of printed circuit boards can have a plurality of pixels, each pixel includes a plurality of lighting elements, wherein the plurality of lighting elements are contained in a single LED. The highway variable message sign further comprises a glazing adjacent to the plurality of lighting elements, and a mask attached to the housing and adjacent to the glazing. The mask can have a plurality of apertures aligned with the plurality of pixels at an offset, wherein each pixel is aligned at a different one of the plurality of apertures. The highway variable message sign can further comprise a structural return having a first end attached to the mask.
Various embodiments of the highway variable message sign with apertures include a highway variable message sign with apertures comprising a housing, a plurality of circuit boards coupled to the housing. In some embodiments, each of the plurality of circuit boards have a plurality of pixels. In some embodiments, each of the plurality of pixels comprise a grouping of lighting elements. In some embodiments, the grouping of lighting elements can be contained in a single package, for example, in a tricolor LED or a RGB LED. In some embodiments, each of the plurality of circuit boards have a plurality of groupings of lighting elements, wherein each of the plurality of groupings of lighting elements contain at least two lighting elements arranged vertically. In some embodiments, the at least two lighting elements arranged vertically can be two amber LEDs. In many embodiments, the vertical arrangement or layout of the lighting elements can limit color shifting or chromatic aberration. In some embodiments, the vertical arrangement of the lighting elements can limit color shifting when viewed from the left or the right side of the lighting elements or the highway variable message sign. The highway variable message sign further comprises a glazing attached to the mask and adjacent to the lighting elements and a mask attached to the housing and adjacent to the glazing, the mask having a plurality of apertures aligned with the plurality of groupings of lighting elements, wherein each of the plurality of apertures has a vertical axis that is longer than a horizontal axis.
In some embodiments, each of the plurality of pixels in any highway variable message sign can comprise two columns of lighting elements. For example, a pixel can comprise 6 LEDs such that there are two columns of three LEDs, and each of the three LEDs can be the same or different colors.
Some embodiments of the highway variable message sign with apertures include a highway variable message sign with apertures comprising a mask with a plurality of apertures, wherein at least one of the plurality of apertures has a vertical axis that is greater than a horizontal axis, a housing having the mask on a front face, a glazing between the mask and an interior of the housing, and a printed circuit board with a group of lighting elements, the group of lighting elements aligned with that at least one of the plurality of apertures.
Various embodiments include a highway variable message sign with apertures comprising a housing and a sign face. In some embodiments, a number of circuit boards are in the housing. Each of the circuit boards can have a number of groupings of lighting elements. In some embodiments, the at least three lighting elements can be contained in a single package, such as a tricolor LED or a RGB LED. In some embodiments, each of the groupings of lighting elements contains at least two lighting elements arranged vertically. In some embodiments, each of the groupings of lighting elements contains at least three lighting elements arranged in a vertical line. Each of the at least two or three lighting elements can be the same or different colors.
In some embodiments, a mask can be attached to the housing and/or next to the glazing. In some embodiments, a mask can be a dark, opaque, sheet of material with optical apertures for the light to shine through that provides contrast between the illuminated portion of the sign and the background of the sign. The mask can be aligned with the groupings of lighting elements, wherein each of the apertures has a vertical axis that is longer than a horizontal axis. In some embodiments, the mask can be aligned with the groupings of lighting elements, wherein each of the apertures has a vertical axis that is equal to the horizontal axis.
Turning to the figures,
Adjacent to printed circuit board 20 is a glazing 42. In some embodiments, glazing 42 can be next to and/or located over the lighting elements. In various embodiments, glazing 42 can be sheet of transparent material that covers the interior of the sign from the elements. In many embodiments, the glazing can be clear. In some embodiments, glazing 42 can be transparent. In many embodiments, glazing 42 can be approximately 0.1 to approximately 0.3 inch thick. In some embodiments, glazing 42 can be approximately 0.25 inch thick. In some embodiments, glazing 42 can be approximately 0.125 inch thick. In many embodiments, glazing 42 can have a minimum ultraviolet (UV) coating of approximately 80 percent. In some embodiments, glazing 42 comprises polycarbonate, acrylic, glass, or other similar materials. In some embodiments, glazing 42 can have an ultimate tensile strength of approximately 9,000 pounds per square inch (psi) to approximately 10,000 psi, a tensile strain at yield of approximately 4 percent to approximately 8 percent, and a tensile modulus of approximately 320,000 psi to approximately 360,000 psi. In some embodiments, glazing 42 can have a flexural modulus of approximately 320,000 psi to approximately 360,000 psi and an impact strength of approximately 12 ft-lbs/inch to approximately 16 ft-lbs/inch. In further embodiments, glazing 42 can have a heat deflection temperature under load value of approximately 265° Fahrenheit (F) to approximately 275° F. under 264 psi to approximately 285° F. to approximately 290° F. under 66 psi. In some embodiments, glazing 42 can have an average initial light transmittance average of 88 percent, a change in light transmittance of less than approximately 5 percent after 5 years of exposure, and a change in yellowness index of less than approximately 5 percent after 5 years of exposure. In many embodiments, the coefficient of thermal expansion of glazing 42 can be approximately 3.7×10−5 inch per inch per ° F. to approximately 3.8×10−5 inch per inch per ° F.
In front of glazing 42 is a mask 44. In many embodiments, mask 44 can provide contrast and some protection from the elements, including lowering the solar heat gain inside the housing, and can limit the output light of lighting elements, such as LEDs 22, 24, 26, 28, 30, 32, 34, 36, 38, to a particular direction to avoid distracting drivers who do not need to view the sign. Furthermore, mask 44 can limit the color shifting or chromatic aberration that drivers can experience because of the physical separation of the color diodes or different colored lighting elements, such as LEDs 22, 24, 26, 28, 30, 32, 34, 36, 38. In many embodiments, mask 44 can be aluminum and finished with a fluropolymer-based coating system. In some embodiments, mask 44 is finished with a resin, such as a KYNAR 500 resin. In some embodiments, mask 44 can be approximately 0.055 inch thick to approximately 0.070 inch thick. In some embodiments, mask 44 can be approximately 0.080 inch thick to approximately 0.099 inch thick. In many embodiments, mask 44 can have a minimum thickness of approximately 0.063 inch. In other embodiments, mask 44 can have a minimum thickness of approximately 0.090 inch. In some embodiments, the lighting elements do not protrude through mask 44. In some embodiments, the lighting elements do not protrude through mask 44, and the lighting elements are not flush with mask 44. Mask 44 has a plurality of apertures 46, 48, 50 aligned with LEDs 22, 24, 26, 28, 30, 32, 34, 36, 38. In some embodiments, an aperture can be an opening used to limit the light exiting an optical system. In some embodiments, the aperture can be a non-circular ellipse. In other embodiments, the aperture can be stadium shape or an oblong oval with semicircles at each end and straight sides. In other embodiments, the aperture can be any oblong shape. In another embodiment, the aperture can be circular.
As shown in
Sign 10 can also include a controller and environmental monitoring and control equipment. The environmental control systems include filters that have to be replaced, fans to blow air through the sign and in some cases air conditioners or heat exchangers. In some embodiments, a control system such as the control system in U.S. Pat. No. 8,446,293, which is incorporated by reference herein, can be used.
In many embodiments, each PCB 20 can be uniform and can have the same number of rows of pixels as columns of pixels. In many embodiments, the number of apertures, pixels and/or lighting elements can be in factors of eight. For example, in some embodiments, each PCB 20 can have 16 rows of pixels and 16 columns of pixels. As another example, each PCB 20 can have 8 rows of apertures and 8 columns of apertures 46 as shown in the upper left-hand PCB 20 of
Between columns 54, 56, 58, 60, 62 are structural returns 64, 66, 68, 70 that hold PCBs 20. Structural returns 64, 66, 68, 70 are thin enough to fit between columns 54, 56, 58, 60, 62 while allowing the distances between the centers of neighboring pixels between PCBs to remain consistent with the distances between the centers of neighboring pixels on a same PCB. In embodiments with one PCB 20, structural returns can be optional. Structural returns 64, 66, 68, 70 can provide support to mask 44 and can withstand wind loading according to various highway sign safety requirements. In some embodiments, one or more structural returns 64, 66, 68, 70 can be bent another 90 degrees.
In some embodiments, a sheet of glazing 42 (as shown in
In some embodiments, glazing 42 can be attached to mask 44 by rivets, screws, welds, fasteners, adhesives, and/or tapes. In various embodiments, glazing 42 can be floated, by placing rubber seals between glazing 42 and mask 44. In some embodiments, a bead of silicon can be used to form a weather-tight seal between glazing 42 and mask 44. In many embodiments, glazing 42 can be attached to mask 44 by a two sided tape 74. For example, tape 74 can be an ultra high bond tape or very high bond tape, such as VHB™ tape from 3M. In some embodiments, tape 74 can be approximately 0.12 inch to approximately 0.13 inch thick. In some embodiments, tape 74 can be approximately 0.125 inch thick. Tape 74 can seal the surface of mask 44 to the surface of glazing 42, and can leave an air gap between glazing 42 and mask 44. In some embodiments, tape 74 can be a thermal expansion intermediator. Tape 74 can be an intermediating layer between glazing 42 and mask 44 and expand to compensate for distinct coefficients of thermal expansion of glazing 42 and mask 44. In some embodiments, tape 74 is a thermal intermediator and can allow or compensate for the differences in the coefficients of thermal expansion of mask 44 and glazing 42. For example, in some embodiments, as the temperature increases, glazing 42 can expand or increase in size more rapidly than mask 44. Tape 74 is pliable or flexible enough that it can allow for the difference in expansion without damaging mask 44 or glazing 42, and while maintaining a seal and adhesion. In some embodiments, tape 74 has a coefficient of thermal expansion that can allow for thermal insulation and/or thermal isolation of glazing 42 from mask 44. The glazing 42 has through holes 75 through which pins 72 pass. In one embodiment, structural returns 64, 66 are formed by bending the edges of mask 44 inward.
Center 76 of the aperture is offset from the center of the line segment formed by the LEDs. In some embodiments, center 76 can be located within the bottom third of the line segment formed by the LEDs. In other embodiments, center 76 can be located below the bottom LED in the line segment formed by the LEDs. Other shaped apertures can be used and also can be offset similarly. In some embodiments, to display a full color range, each aperture 48, 50 of the sign has a red, a green, and a blue LED 22, 24, 26. In some embodiments, the red, green, and blue LEDs 22, 24, 26 can be in any order. In other embodiments, the red, green, and blue LEDs 22, 24, 26 can be in the order of red green blue from top to bottom of the pixel defined by the aperture.
In many embodiments, the line of LEDs 22, 24, 26 can be as close to each other as possible depending on manufacturing tolerances to allow for color blending. In many embodiments, LEDs in a single pixel are no further apart from each other than 1 diameter of an LED bulb. In some embodiments, LEDs in a single pixel are no further apart from each other than half a diameter of an LED bulb. In some embodiments, each pixel of the plurality of pixels can comprise only two lighting elements, for example two amber or yellow LEDs. In many embodiments, each pixel of the plurality of pixels comprise three LEDs. In another embodiment, some systems may use four LEDs with different colors. For example, in some embodiments, a pixel comprises four LEDs, including a red LED, a green LED, a blue LED, and a yellow LED. In another example, a pixel can comprise four LEDs, including a red LED, a green LED, a blue LED, and a tricolor LED. In another embodiment, a pixel comprises three tricolor LEDs. In yet another embodiment, a pixel comprise two red LEDs, a green LED, and a blue LED. In other embodiments, a pixel can comprise more than three LEDs and can comprise any combination of LEDs or other lighting element colors. In another embodiment, a pixel comprises only one LED, namely a tricolor LED.
In some embodiments, width 78 can be approximately equal to the diameter of the LED bulb. In some embodiments, the width 78 of the aperture can be large enough to encompass at least the full angular beam of the light output from LEDs 22, 24, 26. In other embodiments, the width 78 of the aperture can be large enough to encompass approximately half of the full angular beam of the light output from LEDs 22, 24, 26 when measured at the aperture or mask 44. In many embodiments, a narrow viewing or beam angle can be used to decrease motorist distraction. For example, a beam angle 95 (
The aperture is offset from the center of the line segment formed by LEDs 22, 24, 26, where the center is based on the position of LED 24 as noted above, because the sign is located above the motorist. In some embodiments, the motorist viewing angle can be when the line of sight resides within the LED's cone of vision. The motorist viewing angle is such that the aperture might no longer be offset from the center of the line segment formed by the line of LEDs 22, 24, and 26, and such that mask 44 does not cut off the view of LEDs 22, 24, 26. A larger aperture that is not offset can provide less contrast than a smaller, offset aperture. For example, an aperture with larger major and minor axes would provide less contrast than a smaller but offset aperture. Because the aperture is offset, it is possible that top 80 of aperture 48 may impede the cone of light from the top LED 22, 28 when viewing straight on. However, in many embodiments, a motorist may not be viewing the sign from above or straight on, so the offset has no effect on the readability of the sign. The aperture provides room for returns and allows the face to be manufactured. In one embodiment, the sign may have only two or one lighting element per aperture 48, 50. The lighting elements may all be the same color, a single color, or only two colors may be used. If the lighting elements are all the same color or the single color, the single color can be amber, in one embodiment. The disclosure is not limited any particular number of color of lighting elements or to fine pitch signs.
Thus there has been described a highway variable message sign with apertures that limits the output light to the drivers needing to see the sign and therefore not distracting drivers who do not need to see the sign.
While the disclosure has been described in conjunction with specific embodiments thereof, it is evident that many alterations, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alterations, modifications, and variations in the appended claims.
Additional examples of such changes have been given in the foregoing description. Accordingly, the disclosure of embodiments of highway variable message sign with apertures is intended to be illustrative of the scope of highway variable message signs with apertures and is not intended to be limiting. For example, in one embodiment, a highway sign may have one or more features of
The highway variable message sign discussed herein may be implemented in a variety of embodiments, and the foregoing discussion of these embodiments does not necessarily represent a complete description of all possible embodiments. Rather, the detailed description of the drawings, and the drawings themselves, disclose at least one preferred embodiment of a highway variable message sign with apertures, and may disclose alternative embodiments of the highway variable message sign with apertures.
Replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims.
Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and/or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and/or limitations in the claims under the doctrine of equivalents.
The present application is a continuation-in-part of U.S. patent application Ser. No. 12/888,241, entitled “Fine Pitch Full Color Variable Message Sign,” filed on Sep. 22, 2010, and claims priority to U.S. Provisional Patent Application No. 62/110,507, entitled “Multiple Sign Controller,” filed on Jan. 31, 2015, both of which are hereby incorporated by reference.
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| Parent | 12888241 | Sep 2010 | US |
| Child | 14802440 | US |
