Changeable message sign system with reconfigurable sign screen

A modular sign system for constructing outdoor changeable message signs with an exteriorly exposed sign screen of an adjustable size, the system comprising:

• a) a sign controller comprised of circuitry with a data output for providing message data to a selected number of individual display modules through said data output, said selected number being changeable as the sign screen is adjusted, said data including specific data for each display module;
• b) a plurality of interchangeable display modules, each display module comprising:
• i) a sealed weather resistant enclosure having a display side with a sign screen portion, the enclosure positionable next to other interchangeable display modules such that the screen portions are adjacent one another for defining the sign screen;
• ii) a submatrix of changeable pixel elements positioned within the open interior of the enclosure adjacent to the display side, the pixel elements viewable through the display side, the enclosures sized and the pixel elements arranged on each display module to provide an alphanumeric character height capability on each of said individual display modules of at least six inches;
• and
• iii) circuitry contained with the enclosure and connected to the pixel elements, said circuitry having a data input and being configured for retaining a display module address, for receiving the message data, for distinguishing the specific data corresponding to said display module address, and for operating the pixel elements in accordance with the specific data received from the sign controller, the circuitry sealed within the enclosure whereby each display module is independently protected from the weather and the sign controller circuitry and the individual module's circuitry further configured for providing alphanumeric characters which may extend across a plurality of adjacently positioned display module screen portions;
• c) a mounting track having a plurality of module positions for accommodating a desired number of display modules, the mounting track having a plurality of conductors for electrically connecting the sign controller to the display modules, the modules electrically connectable with each conductor upon installing a module in a particular module position.

A modular sign system for constructing changeable message signs with an exteriorly exposed sign screen of an adjustable size, the system comprising:

• a) a plurality of interchangeable sealed display modules, each display module comprising:
• i) a sealed enclosure having a display side with a sign screen portion, the enclosure positionable next to other interchangeable display modules such that the screen portions are adjacent one another for defining a sign screen;
• ii) a submatrix of changeable pixel elements positioned within the open interior of the enclosure adjacent to the display side, the pixel elements viewable through the display side;
• and
• iii) circuitry contained with the plastic enclosure and connected to the pixel for retaining a display module address, for receiving data from the sign controller, for operating the pixel elements in accordance with the data from the sign controller;
• b) a sign controller comprised of circuitry with a data output for providing data to the individual display modules, the data output line connectable to each of the individual display modules;
• and
• c) the enclosures sized and the pixels arranged on each display module to provide an alphanumeric character height capability on each of said individual display modules of at least six inches, the display module circuitry and the sign controller circuitry configured to provide alphanumeric characters from 6 inches to greater than 10 inches in height and further configured to provide alphanumeric characters whereby individual characters may extend across a plurality of adjacently positioned display module screen portions.

A module changeable sign with an adjustable screen size, the sign comprising:

• a) a sign controller comprised of a circuitry with a data output line for providing a message data to a selected number of individual display modules through said data output, said selected number being changeable as the sign screen is adjusted, said data including specific data for each display module;
• b) a plurality of interchangeable display modules positioned in a module matrix arrangement having a rectangular periphery defining a screen periphery, the module matrix arrangement having at least one row of modules and at least two columns of modules, the screen size adjustable by adding or subtracting either rows or columns of display modules respectively, each display module comprising:
• i) a front display side with a height of at least six inches and a width of at least six inches, the front display side defining a screen portion, the screen portion of each module in the matrix arrangement defining a sign screen, the sign screen not having a sign screen enclosure;
• ii) an array of changeable pixel elements positioned at the screen portion of each of said modules, the pixel elements sufficient in number to define at least one complete alphanumeric character at least five inches in height within each of said screen portions;
• and
• iii) circuitry contained with the enclosure and connected to the pixel elements, said circuitry having a data input and being configured for retaining a specific display module address, for receiving the message data, for distinguishing the specific data corresponding to said display module address, and for operating the pixel elements in accordance with the specific data received from the sign controller, the circuitry sealed whereby each display module is independently protected from the weather;
• c) a support structure supporting said matrix arrangement of modules.

A modular changeable message sign with an adjustable screen size, the sign comprising:

• a) a plurality of interchangeable sealed display modules positioned in a matrix arrangement having a rectangular periphery, said matrix arrangement not being constrained within a sign screen enclosure whereby additional display modules may be added to the matrix to increase the sign screen size without opening or entering an enclosure, each display module comprising:
• i) a front display side with a height of at least six inches and a width of at least six inches, the front display side defining an exteriorly exposed screen portion, the screen portions of the plurality of display modules defining an exteriorly exposed sign screen;
• ii) an array of pixel elements positioned at the screen portion of each of said modules, the pixel elements sufficient in number to define at least one complete alphanumeric character within each of said screen portions;
• and
• iii) circuitry contained within the module and connected to the pixel elements for operating the pixel elements;
• b) a support structure positioned behind the matrix arrangement of modules, the matrix arrangement attached to said support structure;
• and
• c) a sign controller comprised of circuitry and configured for communicating with each of the display modules in the matrix, and are of sufficient size to be readable from at least 150 feet in front of the sign, the sign controller further configured for allowing additional display modules to be added to the matrix.

A combination highway sign and modular changeable message sign comprising:

• a) a static highway sign with an upright flat sign base and a support frame;
• b) a plurality of interchangeable sealed display modules positioned in a matrix arrangement on the front of the sign base, the matrix arrangement having a rectangular periphery, said matrix arrangement not being constrained within a sign screen enclosure whereby additional display modules may be added to the matrix to increase the sign screen size, each display module comprising:
• i) a front display side with a height of at least six inches and a width of at least six inches, the front display side defining an exteriorly exposed screen portion, the screen portions of the plurality of display modules defining an exteriorly exposed sign screen;
• ii) an array of light emitting diodes positioned at the screen portion of each of said modules, the pixel elements sufficient in number to define at least one complete alphanumeric character within each of said screen portions;
• and
• iii) circuitry contained within the module and connected to the pixel elements for operating the pixel elements, the circuitry sealed within the module whereby the module is weather resistant;
• b) a sign controller comprised of circuitry and configured for communicating with each of the display modules in the matrix, the sign controller further configured for allowing additional display modules to be added to the matrix.

A module changeable message sign with an adjustable screen size, the sign comprising:

• a) a plurality of interchangeable sealed display modules positioned in a matrix arrangement having a rectangular periphery, each display module comprising:
• i) a front display side with a height of at least six inches and a width of at least six inches, the front display side defining an exteriorly exposed screen portion, the screen portions of the plurality of display modules defining an exteriorly exposed sign screen, whereby the screen portions of each of the modules are not positioned behind a screen panel;
• ii) an array of pixel elements positioned at the screen portion of each of said modules, the pixel elements sufficient in number to define at least one complete alphanumeric character within each of said screen portions;
• iii) circuitry contained within the module and connected to the pixel elements for operating the pixel elements;
• b) a support structure with a front side and a back side, the matrix arrangement of modules supported by said support structure on said front side, said modules configured such that each individual module is removable and replaceable without opening a sign enclosure and without accessing the back of the support structure;
• c) a sign controller comprised of circuitry and configured for communicating with each of the display modules in the sign controller further configured for allowing additional display modules to be added to the matrix, and are of sufficient size to be readable from at least 150 feet in front of the sign.

A method for constructing changeable message signs, said method comprising the steps of:

• a) securing a mounting track to a support structure, the mounting track comprising a plurality of conductors and a plurality of fixed electrical connecting portions along the track;
• b) electrically connecting a sign controller to the conductors;
• c) selecting a desired number of interchangeable modules for a desired screen size, each module comprising a weatherized enclosure, a screen portion, a plurality of changeable pixel elements in the enclosure, circuitry for operating the pixel elements in the enclosure and an electrical connector connecting to the circuitry, said connector fixed with respect to the enclosure;
• and
• d) plugging the modules onto the track by engagement of each electrical connector of each module with the electrical connector engaged with an electrical connector portion of the mounting track, whereby an electrical connection between each electrical connector of each module and the conductors in the track is achieved, whereby each of said modules is structurally supported on said tracks by said plugging, and whereby the screen portions of the modules in the matrix arrangement is exteriorly exposed.

A method for field constructing changeable message signs at the point of usage, said method comprising the steps of:

• a) securing a mounting track to a support structure at the point of usage, the mounting track comprising a plurality of conductors and a plurality of fixed electrical connecting portions along the track;
• b) electrically connecting a sign controller to the conductors;
• c) selecting a desired number of interchangeable modules for a desired screen size, each module comprising a weatherized enclosure, a screen portion, a plurality of changeable pixel elements in the enclosure, circuitry for operating the pixel elements in the enclosure and an electrical connector connecting to the circuitry, said connector fixed with respect to the enclosure;
• d) plugging the modules onto the track by engagement of each electrical connector of each module with the electrical connector engaged with an electrical connector portion of the mounting track, whereby an electrical connection between each electrical connector of each module and the conductors in the track is achieved, whereby each of said modules is structurally supported on said tracks by the plugging of the modules onto the track, and whereby the screen portions of the modules in the matrix arrangement is exteriorly exposed;
• and
• e) providing data from the sign controller to each individual module whereby a desired message may be displayed on the sign screen.

A method for field reconfiguring the screen size of a changeable outdoor message sign readable from at least 300 feet, said message sign having a plurality of exteriorly exposed display modules positioned in a matrix arrangement defining a sign screen, each module removably connected to a mounting track on a support structure, and in data communication with a sign controller, the method comprising the steps of:

• a) altering the number of display modules attached to the mounting track on the support structure for a new number of modules on said mounting track;
• b) readdressing each of the new number of modules;
• and
• c) providing data from the sign controller to each individual module by way of the module addresses for activating pixel elements in each module whereby a desired message may be displayed on the sign screen.

A method of manufacturing outdoor highway signs readable at a distance of at least 200 feet comprising the steps of:

• a) providing a plurality of display modules, each with a viewable screen at least six inches in height and six inches in width, a mounting structure, and a sign controller;
• b) transporting the display modules, the mounting structure, and the sign controller to a use location;
• c) assembling the display modules on the mounting structure at the use location with each display module exteriorly exposed;
• d) putting each display module in communication with the sign controller at the use location;
• and
• e) addressing each display module with respect to its position on the mounting structure.

A method of modifying a nonchangeable outdoor sign to a changeable outdoor sign, the method comprising the steps of:

• a) providing a plurality of interchangeable display modules, each module having a weatherized enclosure with a screen portion at least six inches in height and six inches in width, changeable pixels adjacent the screen portion inside the display module, sealed circuitry for operating the pixels inside the display module;
• b) attaching the plurality of display modules on a sign panel of a preexisting roadway sign in a matrix arrangement without a sign enclosure containing the display modules, whereby each of the display modules is exteriorly exposed and whereby the collective screen portions of the display modules form a changeable sign screen;
• c) connecting the display modules to a sign controller;
• and
• d) operating the controller to provide changeable messages for display on the sign screen.

A method of manufacturing a field modifiable and changeable message sign at a desired location, the method comprising the steps of:

• a) providing a plurality of interchangeable display modules, each module having a weatherized enclosure with a screen portion at least six inches in height and six inches in width, changeable pixel elements adjacent the screen portion inside the display module, and sealed circuitry for operating the pixels;
• b) positioning a sign mounting structure adapted for receiving display modules at a desired location;
• c) attaching the plurality of display modules on the mounting structure in a matrix arrangement without a sign enclosure containing the display modules, whereby each of the display modules is exteriorly exposed, and whereby the collective screen portions form a sign screen;
• d) connecting a sign controller to the plurality of display modules;
• and
• e) operating the sign controller to provide a changeable message on the sign screen.

A method of manufacturing a changeable message sign for outdoor usage in response to a customer request, the method comprising the steps of:

• a) maintaining in inventory;
• b) selecting from inventory to create a sign of a desired size, a plurality of preconstructed display modules, each module being interchangeable and having a weatherized enclosure with a screen portion at least six inches in height and six inches in width, changeable pixel elements adjacent the screen portion inside the display module, and sealed circuitry for operating the pixels, each display module individually addressable;
• c) attaching a mounting track to a sign structure, said mounting track adapted to receive a variable number of display modules and further adapted to allow variable positioning of the display modules;
• d) arranging the plurality of display modules on the mounting track in a matrix arrangement to form a sign screen, without a sign enclosure enclosing or containing the sign screen;
• e) putting a sign controller in communication with the display modules;
• and
• f) addressing each of the display modules in accordance with their respective positions in the matrix arrangement.