WO2007119908A1

WO2007119908A1 - Led module assembly for signboard and method for manufacturing signboard using the same

Info

Publication number: WO2007119908A1
Application number: PCT/KR2006/003282
Authority: WO
Inventors: Joung-Woong Cho
Original assignee: Joung-Woong Cho
Priority date: 2006-04-13
Filing date: 2006-08-21
Publication date: 2007-10-25
Also published as: KR100666166B1

Abstract

A light emitting diode (LED) module assembly for a signboard according to the present invention comprises LED circuit boards, each having a printed circuit board (PCB) with a plurality of interlocking holes and a plurality of LED devices mounted on the PCB; base holders, each having an upper surface with a plurality of interlocking protrusions being fit into the interlocking holes of the LED circuit boards, and side surfaces with at least one bracket having a through hole; a plurality of coupling rods, each having both ends coupled to the side surfaces of the base holders for connecting adjacent base holders to each other on the same plane; and connectors coupled to terminals of adjacent LED circuit boards for electrically connecting the adjacent LED circuit boards to each other.

Description

LED MODULE ASSEMBLY FOR SIGNBOARD AND METHOD FOR MANUFACTURING SIGNBOARD USING THE SAME

Technical Field

[1] The present invention relates to a light emitting diode (LED) module assembly for a signboard, and more particularly, to an LED module assembly for a signboard, by which LED module components can be easily assembled and steps for manufacturing a signboard can be reduced. Also, the present invention relates to a method for manufacturing a signboard using the LED module assembly. Background Art

[2] Typically, signboards are illuminated using various lighting means in the night to increase the discrimination and advertising effect of the signboards. Conventional lighting means mainly uses general lamps such as fluorescent lamps or neon lamps, but recently lighting means adopting LED is widespread. The LED has advantages of a long life and high effectiveness, and thus is widely used from various lighting devices to display devices.

[3] Also, such an LED is used as a lighting device for a signboard. FIG. 1 shows the conventional surface mount devices (SMD) type of LED lighting module for a signboard. As illustrated, the conventional LED lighting module includes a case 1 and an LED circuit board 2 received in the case 1.

[4] The case 1 has a support edge 3 formed in an inner side thereof, where the LED circuit board 2 rests, and a plurality of supports 4 to contact with a lower surface of the received LED circuit board 2 for supporting the LED circuit board 2.

[5] Also, the LED circuit board 2 includes a printed circuit board (PCB), a plurality of

LED devices 5 surface-mounted on the PCB, various resistance devices and lead-in wires. Power terminals 6 are provided at both ends of the LED circuit board 2 for power supply, and when the LED circuit board 2 is connected to the case 1, the power terminals 6 are exposed through openings 7 formed at both ends of the case 1.

[6] FIG. 2 is a cross-sectional view illustrating the conventional LED lighting module.

As shown in FIG. 2, the LED circuit board 2 is combined to the case 1, and the assembled LED lighting module is installed at a desired location corresponding to an advertising copy of a signboard to be manufactured. In other words, the LED lighting module is fixed at a proper location of a signboard frame 8, and typically the case 1 is attached to the signboard frame 8 using a double-sided tape or an adhesive, and thus the LED lighting module is fixed to signboard frame 8. Subsequently, the LED lighting module is electrically interconnected to adjacent LED lighting modules using connectors 9.

[7] Here, several tens to several hundreds of the LED lighting modules may be arranged according to the advertising copy and the size of the signboard. In the conventional method for manufacturing a signboard, the LED lighting modules are separately installed to each signboard frame and connected with the connectors. Such a procedure results in an increase in the cost of manufacturing signboard and delay of manufacturing time.

[8] Another problem of the prior art is about heat radiation of the LED module. That is, the case 1 surrounds the LED circuit board 2, which makes it difficult to radiate heat generated from the LED device out. Excessive heat may damage the circuits and reduce effectiveness of the LED device. Disclosure of Invention Technical Problem

[9] The present invention is designed to solve the problems of the prior art, and therefore it is an object of the present invention to provide an LED module assembly for a signboard having such a structure that an LED circuit board is easily assembled.

[10] Another object of the present invention is to provide an LED module assembly capable of facilitating a heat radiation of an LED circuit board.

[11] Another object of the present invention is to provide an LED module assembly that is integrally manufactured in the factory and installed rapidly and conveniently to a signboard on the spot.

[12] Another object of the present invention is to provide a method for manufacturing a signboard using the above-mentioned LED module assembly. Technical Solution

[13] In order to achieve the above-mentioned objects, there is provided a LED module assembly for a signboard, comprising: LED circuit boards, each including a printed circuit board (PCB) and a plurality of LED devices mounted on the PCB, the PCB having a plurality of interlocking holes; base holders, each having a plurality of interlocking protrusions formed on an upper surface thereof, the interlocking protrusions fitting into the interlocking holes of the LED circuit board; means for coupling the base holders to each other on the same plane; and connectors for electrically connecting terminals of the adjacent LED circuit boards to each other.

[14] Preferably, the coupling means comprises a plurality of coupling rods having both ends coupled to side surfaces of the base holders for coupling adjacent base holders to each other.

[15] More preferably, the coupling means further comprises a plurality of coupling grooves formed on the side surfaces of the base holder, the coupling groove having a bottleneck portion, and the coupling rod has neck portions formed at both ends thereof such that the neck portions are coupled to the coupling grooves.

[16] Alternately, the coupling means may comprise a plurality of coupling protrusions formed on the side surfaces of the base holder, the coupling protrusion having a neck portion, and the coupling rod has coupling grooves formed at both ends thereof such that the coupling grooves are coupled to the coupling protrusions.

[17] Preferably, the coupling means comprises: a plurality of coupling protrusions formed on a side surface of one of the base holders; and a plurality of coupling grooves formed on a side surface of another one of the base holders such that the coupling protrusions fit into the coupling grooves.

[18] According to the invention, the base holder further comprises openings formed on side surfaces thereof for heat radiation.

[19] Also, a bracket having a through hole may be formed on at least one side surface of the base holders.

[20] Preferably, the base holder has a plurality of another interlocking holes formed in the bottom thereof, and wherein the assembly further comprises a fixing member including a base bracket having a plurality of through holes, and a protruded portion protruding upwards from the base bracket and coupled to the interlocking holes formed at the bottom of the base holder.

[21] Also, the base holder has side surfaces inclined with regard to each other on the plane.

[22] Preferably, the side surfaces of the base holder have rounded surfaces.

[23] Preferably, the base holders are made of metal.

[24] According to a preferred embodiment, the invention may comprises a metal plate interposed between the base holder and the LED circuit board.

[25] According to another aspect of the invention, there is provided a method for manufacturing a signboard, comprising the steps of: preparing a plurality of LED circuit boards, each LED circuit board comprising a PCB having a plurality of interlocking holes and a plurality of LED devices mounted on the PCB, a plurality of base holders having a plurality of interlocking protrusions formed on an upper surface thereof, means for coupling the base holders to each other on the same plane, and a plurality of connectors for electrically connecting the LED circuits boards to each other; arranging the base holders according to an advertising copy and coupling adjacent base holders to each other by the coupling means; fitting the interlocking protrusions of the base holders into the interlocking holes of the LED circuit boards; electrically connecting terminals of adjacent LED circuit boards using the connectors; and fixing brackets formed on at least one side surface of the base holders to a signboard frame.

[26] Preferably, a plurality of coupling grooves are formed in the side surfaces of the base holders, each coupling groove having a bottleneck portion, and both ends of a coupling rod having neck portions are fit into the coupling grooves. [27] More preferably, a plurality of coupling protrusions are formed on the side surface of one of the base holders, and the coupling protrusions fitting into a plurality of coupling grooves formed on the side surface of another one of the base holders.

Brief Description of the Drawings

[28] The present invention will be more fully described in the following detailed description, taken accompanying drawings, however, the description proposed herein is just a preferable example for the purpose of illustrations, not intended to limit the scope of the invention. In the drawings:

[29] FIG. 1 is an exploded perspective view of a conventional LED lighting module.

[30] FIG. 2 is a cross-sectional view illustrating the assembled LED lighting module of

FIG. 1. [31] FIG. 3 is an exploded perspective view of an LED module assembly in accordance with a preferred embodiment of the present invention. [32] FIG. 4 is a plan view illustrating an assembled LED module assembly in accordance with a preferred embodiment of the present invention. [33] FIG. 5 is a cross-sectional view illustrating an assembled LED module assembly in accordance with a preferred embodiment of the present invention. [34] FIG. 6 is a cross-sectional view illustrating an assembled LED module assembly in accordance with another preferred embodiment of the present invention. [35] FIG. 7 is a plan view illustrating an assembled LED module assembly in accordance with still another preferred embodiment of the present invention. [36] FIG. 8 is a plan view illustrating a component of the LED module assembly in accordance with another preferred embodiment of the present invention. [37] FIG. 9 is an exploded perspective view illustrating components of the LED module assembly in accordance with further another preferred embodiment of the present invention. [38] FIG. 10 is a plan view illustrating an assembled LED module assembly of FIG. 9 of the present invention. [39] FIG. 11 is a perspective view illustrating an example of a fixing member fixing a base holder to a signboard frame in accordance with another preferred embodiment of the present invention. [40] FIG. 12 is a cross-sectional view illustrating an assembled LED module assembly using the fixing member of FIG. 11.

Best Mode for Carrying Out the Invention [41] FIG. 3 is an exploded perspective view of an LED module assembly in accordance with a preferred embodiment of the present invention.

[42] Referring to FIG. 3, the LED module assembly for a signboard of the present invention includes an LED circuit board 10 having LED devices for emitting light corresponding to an advertising copy, a plurality of base holders 20 connected to the LED circuit board 10 for supporting the LED circuit board 10, and a plurality of coupling rods 30 for coupling adjacent base holders 20 to each other.

[43] As mentioned above, the LED circuit board 10 includes a printed circuit board

(PCB) and a plurality of the LED devices 11 surface-mounted on the PCB and has various resistance devices and lead-in wires. Power terminals 12 are formed at both ends of the LED circuit board 10 for power supply. The power terminals 12 have terminal pins 13 that are inserted into connectors (See 9 of FIG. 1). The configuration of the LED circuit board is well known and the detailed description thereof is herein omitted.

[44] According to the present invention, a plurality of the LED circuit boards 10 may be used according to the advertising copy, and preferably, the LED circuit board 10 may be formed in the shape of a lengthwise rectangle so that a plurality of LED circuit boards 10 are arranged parallel to each other.

[45] And, the LED circuit board 10 has a plurality of interlocking holes 14, and the LED circuit board 10 is connected to the base holder 20 by means of the interlocking holes 14 as mentioned below.

[46] The base holder 20 serves as a support for supporting the LED circuit board 10, and has side surfaces 21 and an upper surface 22. A plurality of interlocking protrusions 23 are formed on the upper surface 22 of the base holder 20 to be inserted into the interlocking holes 14 of the LED circuit board 10. As illustrated, each of the interlocking protrusions 23 has a rounded head 23a formed at the top, of which size is larger than the diameter of the interlocking hole 14, and thus the interlocking protrusions 23 are inserted into the interlocking holes 14 in a press-fit manner.

[47] Preferably, the length of the base holder 20 is equal to the length of the LED circuit board 10, but not limited, the length of the base holder 20 may be shorter or longer than the length of the LED circuit board 10.

[48] According to the present invention, the base holder 20 is coupled to adjacent base holders on the same plane using coupling means. Preferably, the coupling means includes coupling grooves 24 formed on the side surfaces 21 of the base holder 20 and coupling rods 30 being fit into the coupling grooves 24.

[49] A plurality of the coupling grooves 24 of the base holder 20 are preferably formed at the edge where the side surfaces 21 and the upper surface 22 meet. Each of the coupling grooves 24 has a bottleneck portion.

[50] The coupling rod 30 is coupled to the coupling groove 24, and the coupling rod 30 has neck portions 31 formed at both ends thereof, corresponding to the bottleneck portion of the coupling groove 24. Thus, when one end of the coupling rod 30 is inserted into the coupling groove 24, the bottleneck portion is interlocked to the neck portion. Since the coupling rod 30 has the neck portions 31 formed at both ends thereof, the other end of the coupling rod 30 is inserted into the coupling groove 24 of another base holder, and thus adjacent base holders are connected to each other.

[51] Although the coupling grooves 24 are formed in the base holder 20 and the neck portions 31 are formed at both ends of the coupling rod 30 in the present embodiment, it may not be limited in this regard. For example, in alternative embodiments, coupling protrusions having neck portions may be formed on the base holder 20 and coupling grooves may be formed at both ends of the coupling rod 30. Further, alternatively, screw holes may be formed in the side surfaces of the base holder, and screw threads may be formed at both ends of the coupling rod such that the screw threads are engaged with the screw holes. Furthermore, the base holder may be coupled to the coupling rod in a press-fit method or a locking method, and it should be understood the above-mentioned coupling methods are included within the spirit and scope of the present invention.

[52] And, at least one bracket 26 is formed on the side surface 21 of the base holder 20, and the bracket 26 has a through hole 26a. The bracket 26 is used to fix the base holder 20 to the signboard frame.

[53] The base holder 20 may be manufactured by injection molding a synthetic resin or plastic, and may be preferably made of metal such as aluminum for improvement of heat radiation. If the base holder 20 is made of metal, it is preferred that an insulating layer (not shown) is formed on the upper surface 22 of the base holder 20 or an insulating tape is attached to the upper surface 22 of the base holder 20.

[54] Further, a plurality of openings 25 are formed on the side surfaces 21 of the base holder 20, enabling air passage for cooling.

[55] Below is described a method for manufacturing a signboard using the LED module assembly of the above-mentioned configuration.

[56] The method for manufacturing a signboard according to the present invention is mainly divided into a step for assembling an LED module assembly and a step for installing the LED module assembly to a signboard.

[57] In the manufacture of the LED module assembly, first, the base holders 20 are arranged according to a draft of an advertising copy to be manufactured and adjacent base holders 20 are connected to each other using the coupling rods 30. An example of interconnection of the base holders 20 is illustrated in FIG. 4.

[58] Then, the LED circuit board 10 is mounted on the upper surface 22 of the base holder 20. In other words, as shown in FIG. 5, the interlocking protrusions 23 of the upper surface 22 of the base holder 20 are fit into the interlocking holes 14 of the LED circuit board 10, and thus assembly of the LED circuit board 10 is completed.

[59] Subsequently, terminals 12 of adjacent LED circuit boards 10 are electrically connected by means of the connector (See 9 of FIG. 1), and thus the LED module assembly is completed. If necessary, current may be supplied to the assembly for test.

[60] The completed LED module assembly may be immediately installed to the signboard. In other words, as shown in FIG. 5, the LED module assembly is directly joined to the signboard frame 100 such that a fastener 40 such as a screw is inserted into the through hole 26a of the bracket 26 of the base holder 20, and thus the LED module assembly is fixed in a simple manner. If necessary, the completed LED module assembly may be carried in parts and installed to the signboard, and after installation, the parts of the LED module assembly may be completely connected to each other by the connectors.

[61] Although the embodiment shows the base holder 20 is fixed to the signboard frame by the brackets 26, the present invention may not be limited in this regard, and the base holder 20 may be fixed to the signboard frame in other various methods. FIG. 11 is a perspective view illustrating a fixing member 60 fixing the base holder 20 to the signboard frame 100 in accordance with another embodiment of the present invention.

[62] The fixing member 60 includes a base bracket 61 and a protruded portion 62 protruding upwards from the base bracket 61. The base bracket 61 has a plurality of through holes 61a, preferably formed at opposite ends thereof. As described below, the protruded portion 62 has a rounded head having a diameter slightly larger than that of interlocking holes (27 of FIG. 12) formed at the bottom of the base holder 20, and thus the protruded portion 62 is inserted into the interlocking hole 27 in a press-fit method.

[63] In this case, as shown in FIG. 12, the fixing member 60 is already installed in the signboard frame 100 according to the advertising copy. That is, screws 70 are inserted into the through holes 61a of the base bracket 61, and thus the fixing member 60 is joined to the signboard frame 100.

[64] Next, the protruded portion 62 of the fixing member 60 is fit into each of a plurality of the interlocking holes 27 formed at the bottom of the base holder 20, and thus the LED module assembly is installed in the signboard frame.

[65] As such, after the LED module assembly is installed in the signboard frame, an outer frame is assembled, and therefore the manufacture of the signboard is completed in a simple manner.

[66] FIG. 6 is a cross-sectional view illustrating an assembled LED module assembly in accordance with another embodiment of the present invention. Here, the same reference numerals as in the previously illustrated drawings indicate components of the same function. [67] As illustrated, the LED module assembly of the present embodiment includes a base holder 20, an LED circuit board 10 attached on an upper surface of the base holder 20, and a metal plate 50 such as aluminum interposed between the base holder 20 and the LED circuit board 10. Thus, the metal plate 50 may rapidly radiate heat generated from the LED circuit board 10 during operation. Preferably, an additional insulating layer (not shown) may be interposed between the LED circuit board 10 and the metal plate 50.

[68] FIG. 7 is a plan view wherein base holders 120 of an LED module assembly are coupled to coupling rods 30 in accordance with another embodiment of the present invention. Here, the same reference numerals as in the previously illustrated drawings indicate components of the same function.

[69] As illustrated, the base holder 20 of the present embodiment has a pair of first side surfaces 121 and 122, each being parallel, and second side surfaces 123 and 124 inclined with regard to the first side surfaces 121 and 122. As described above, coupling grooves 24 are formed in the first side surfaces and the second side surfaces.

[70] According to the present embodiment, the side surfaces of the base holder include slanted side surfaces on the plane, and thus adjacent base holders may be connected to each other at various angles, corresponding to a desired advertising copy. Here, 'on the plane' is based on a planar projection as shown in FIG. 7.

[71] FIG. 8 is a plan view illustrating a base holder 220 used in an LED module assembly in accordance with another embodiment of the present invention. Here, the same reference numerals as in the previously illustrated drawings indicate components of the same function.

[72] The side surfaces of the base holder 220 of the embodiment include rounded surfaces 221 curved at a predetermined curvature. Thus, the coupling rods 30 are selectively coupled to a plurality of coupling grooves 24 formed in the rounded surfaces 221 so that the base holders are connected to each other at various angles.

[73] FIG. 9 is an exploded perspective view illustrating components of an LED module assembly in accordance with another embodiment of the present invention. Here, the same reference numerals as in the previously illustrated drawings indicate components of the same function.

[74] Referring to FIG. 9, adjacent base holders 320 and 321 are connected to each other on the same plane by a coupling means. According to the present embodiment, the coupling means includes a plurality of coupling protrusions 322 formed on the side surface 21 of the base holder 320 located at one side and a plurality of coupling grooves 324 formed in the side surface 21 of the base holder 321 at the other side.

[75] Each of the coupling protrusions 322 has a neck portion, and each of the coupling grooves 324 has a bottleneck portion being fit into the neck portion of the coupling protrusion 322. According to the embodiment, as shown in FIG. 10, a plurality of the base holders 320 and 321 may be arranged parallel such that the base holders 320 and 321 are located most adjacent to each other. Industrial Applicability

[76] The LED module assembly for a signboard according to the present invention connects the base holders to each other using the coupling rods, and then fits the LED circuit boards into the base holders, thereby performing a module assembly process in a simple and easy manner.

[77] And, the LED module assembly for a signboard according to the present invention fixes the LED module assembly to the signboard frame using the bracket in a simple manner, thereby eliminating ineffectiveness resulted from use of a double-sided tape or an adhesive in the prior art and improving connection reliability.

[78] Furthermore, the LED module assembly for a signboard according to the present invention exposes other portions except for the base holder to air, thereby improving a heat radiation effect, and in the case that the base holders are made of metal, the LED module assembly may further improve a heat radiation effect.

Claims

[1] A LED module assembly for a signboard, comprising:

LED circuit boards, each including a printed circuit board (PCB) and a plurality of LED devices mounted on the PCB, the PCB having a plurality of interlocking holes; base holders, each having a plurality of interlocking protrusions formed on an upper surface thereof, the interlocking protrusions fitting into the interlocking holes of the LED circuit board; means for coupling the base holders to each other on the same plane; and connectors for electrically connecting terminals of the adjacent LED circuit boards to each other.

[2] The LED module assembly according to claim 1, wherein the coupling means comprises a plurality of coupling rods having both ends coupled to side surfaces of the base holders for coupling adjacent base holders to each other.

[3] The LED module assembly according to claim 2, wherein the coupling means further comprises a plurality of coupling grooves formed on the side surfaces of the base holder, the coupling groove having a bottleneck portion, and wherein the coupling rod has neck portions formed at both ends thereof such that the neck portions are coupled to the coupling grooves.

[4] The LED module assembly according to claim 2, wherein the coupling means further comprises a plurality of coupling protrusions formed on the side surfaces of the base holder, the coupling protrusion having a neck portion, and wherein the coupling rod has coupling grooves formed at both ends thereof such that the coupling grooves are coupled to the coupling protrusions.

[5] The LED module assembly according to claim 1, wherein the coupling means comprises: a plurality of coupling protrusions formed on a side surface of one of the base holders; and a plurality of coupling grooves formed on a side surface of another one of the base holders such that the coupling protrusions fit into the coupling grooves.

[6] The LED module assembly according to claim 1, wherein the base holder further comprises openings formed on side surfaces thereof for heat radiation.

[7] The LED module assembly according to claim 2, wherein a bracket having a through hole is formed on at least one side surface of the base holders.

[8] The LED module assembly according to claim 1, wherein the base holder has a plurality of another interlocking holes formed in the bottom thereof, and wherein the assembly further comprises a fixing member including a base bracket having a plurality of through holes, and a protruded portion protruding upwards from the base bracket and coupled to the interlocking holes formed at the bottom of the base holder.

[9] The LED module assembly according to claim 1, wherein the base holder has side surfaces inclined with regard to each other on the plane.

[10] The LED module assembly according to claim 1, wherein the side surfaces of the base holder have rounded surfaces.

[11] The LED module assembly according to claim 1, wherein the base holders are made of metal.

[12] The LED module assembly according to claim 1, further comprising a metal plate interposed between the base holder and the LED circuit board.

[13] A method for manufacturing a signboard, comprising the steps of: preparing a plurality of LED circuit boards, each LED circuit board comprising a PCB having a plurality of interlocking holes and a plurality of LED devices mounted on the PCB, a plurality of base holders having a plurality of interlocking protrusions formed on an upper surface thereof, means for coupling the base holders to each other on the same plane, and a plurality of connectors for electrically connecting the LED circuits boards to each other; arranging the base holders according to an advertising copy and coupling adjacent base holders to each other by the coupling means; fitting the interlocking protrusions of the base holders into the interlocking holes of the LED circuit boards; electrically connecting terminals of adjacent LED circuit boards using the connectors; and fixing brackets formed on at least one side surface of the base holders to a signboard frame.

[14] The method for manufacturing a signboard according to claim 13, wherein a plurality of coupling grooves are formed in the side surfaces of the base holders, each coupling groove having a bottleneck portion, and wherein both ends of a coupling rod having neck portions are fit into the coupling grooves. [15] The method for manufacturing a signboard according to claim 13, wherein a plurality of coupling protrusions are formed on the side surface of one of the base holders, and the coupling protrusions fitting into a plurality of coupling grooves formed on the side surface of another one of the base holders.