US20060245191A1 - Light display structures - Google Patents

Abstract

Useful light display structures are configured so that they can be economically fabricated and assembled. The light display structures generally comprise a plurality of light-emitting elements that are coupled between first and second conductors with the addition of other structures (e.g., spacers, light redirectors, substrates, wire bonds, tabs, posts, ground planes and blocks) that support or augment the conductors.

Description

CROSS REFERENCES TO RELATED APPLICATIONS
• This application is a continuation-in-part of U.S. application Ser. No. 10/773,353 which was filed Feb. 5, 2004.
BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• The present invention relates generally to light display structures and lighted commodities that include these structures.
• 2. Description of the Related Art
• A variety of light display structures have been provided in response to the advantageous features of light-emitting diodes (e.g., low voltage, low heating, low maintenance, color diversity and long life). These structures, however, have generally been complex and expensive to produce.
BRIEF SUMMARY OF THE INVENTION
• Advantageous light display structure embodiments are formed with light-emitting elements. The drawings and the following description provide an enabling disclosure and the appended claims particularly point out and distinctly claim disclosed subject matter and equivalents thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIGS. 1A and 1B are top and side views of a light display structure embodiment of the present invention andFIG. 1C is an enlarged view of another embodiment for structure within thecurved line1C ofFIG. 1B;
• FIG. 2 is an enlarged isometric view of the light display structure ofFIGS. 1A and 1B that illustrates additional light display structure embodiments;
• FIGS. 3A-3D are views along the plane3-3 ofFIG. 1B that illustrate additional light display structure embodiments;
• FIG. 4 is an isometric view of the light display structure ofFIG. 3C which emphasizes its flexible, elongate form;
• FIGS. 5A and 5B are views of additional light display structures that can be carried on the structure ofFIG. 4;
• FIGS. 6A-6C are enlarged plan views of another light display structure embodiment;
• FIGS. 7A and 7B are enlarged views along the plane7-7 ofFIG. 6B that illustrate additional light display structure embodiments;
• views along the plane5-5 ofFIG. 4B that illustrate additional light display structure embodiments;
• FIG. 8 is an enlarged view similar toFIG. 6B that illustrates additional light display structure embodiments;
• FIG. 9 is an enlarged view along the plane9-9 ofFIG. 8 that illustrates additional light display structure embodiments;
• FIG. 10A is a top view of another light display structure embodiment embodiments;
• FIG. 10B is a view along theplane10B-10B ofFIG. 10A;
• FIG. 10C is a top view of another light display structure embodiment;
• FIG. 10D is a view along theplane10D-10D ofFIG. 10C;
• FIG. 11 is a plan view of another light display structure embodiment;
• FIGS. 12A-12D are enlarged views of structural embodiments within thecurved line12 ofFIG. 11;
• FIGS. 13A-13D are views that illustrate assembly of another light display structure embodiment;
• FIG. 14A is a plan view of another light display structure embodiment;
• FIG. 14B is a view along theplane14B-14B inFIG. 14A;
• FIG. 15A shows plan and side views of another light display structure embodiment;
• FIG. 15B is an isometric view which shows the embodiment ofFIG. 15A arranged in an array of similar embodiments; and
• FIGS. 16-21 show light display structure embodiments in association with different articles of merchandise
DETAILED DESCRIPTION OF THE INVENTION
• FIGS. 1-21 illustrate advantageous light display structure embodiments that can be economically fabricated and assembled.
• Attention is initially directed toFIGS. 1A and 1B which illustrate adisplay structure embodiment20 for energizing at least one light-emittingelement22. The structure includes first and second spacedelongate conductors24 and25 and at least one support member in the form of a spacer that is coupled and positioned to support the spaced conductors.
• In particular and as indicated by aspacer26A, the spacers each define anaperture28 to receive the light-emitting element as it contacts the first andsecond conductors24 and25. Thespacer26A illustrates theaperture28 while thespacer26B illustrates reception of the light-emittingelement22 into the aperture. Each spacer26 also defines at least onelight redirector30 that is positioned to redirect light away from its respective light-emittingelement22.
• In particular, the light redirector may be configured in any of various forms (e.g., a reflective wall or a refractive wall) that will direct at least a portion of the light away from the spacer. For simplicity, the light redirector will subsequently be referred to as a wall which may be flat in one embodiment. In another embodiment, it preferably has a concave shape as shown inFIG. 1A. In another embodiment, the wall may have a substantially parabolic shape to enhance redirection of the light.
• In the structure embodiment ofFIGS. 1A and 1B, each spacer26 defines first andsecond walls32 and33 that diverge with increasing distance from one side of theiraperture28 and third andfourth walls34 and35 that diverge with increasing distance from another side of theiraperture28. In one embodiment, the spacer may include a base38 that defines theaperture28 and the walls extend upward from the base.
• As shown inFIG. 1B, the display structure may include a polymer (e.g., a thermoplastic or a thermosetting polymer)insulator40 that encloses thesecond conductor25. In this case, the insulator preferably defines anopening41 positioned to facilitate contact between the light-emitting element and thesecond conductor25. Thespacers22 are positioned to space the first and second conductors apart locally while theinsulator40 insures they do not contact elsewhere.
• Although the light display structures of the invention may carry various light-emitting elements, thestructure20 ofFIGS. 1A and 1B is especially suited to carry a light-emitting diode (LED) which is received in theaperture28 with its cathode in contact with thesecond conductor25 and its anode in contact with thefirst conductor24.
• In operation of thelight display structure20, a voltage is applied between the first andsecond conductors24 and25 which energizes the LED and causes light to be emitted from its light-emittingjunction44. As shown inFIG. 1A, the light radiates from the junction so that somelight rays46 issue directly away from thespacer26B and otherlight rays48 are redirected by the walls32-34 to also radiate away from thespacer26B.
• As shown inFIG. 1C, another display structure may apply (e.g., by printing, transfer printing, silkscreening) aninsulator50 on thesecond conductor25. The insulator is arranged (e.g., by masking or by ablating) to define a gap or aperture52 into which the LED is received, i.e., theinsulator50 is configured to permit coupling of the LED to the second conductor.
• The enlargedisometric view60 ofFIG. 2 supplements FIGS.1A and1B. It shows astrip62 that facilitates fabrication of the spacers (26 inFIGS. 1A and 1B). The strip can be easily molded from a polymer and has a base38 that definesapertures28 andwalls30 that extend upward from the base. For example, the walls may include the first andsecond walls32 and33 that diverge with increasing distance from one side of theiraperture28 and the third andfourth walls34 and35 that diverge with increasing distance from another side of theiraperture28. Although not required, the diverging walls preferably abut at their ends that are proximate to their respective aperture. The walls terminate in aback wall63 and atop wall64.
• A light-emittingelement22 in the form of an LED is shown in the process of being received into anaperture28. Joiningelements65 and66 are preferably formed of conductive materials (e.g., conductive epoxy, solder, reflow solder) and are provided to join the diode's anode to thefirst conductor24 and the diode's cathode to thesecond conductor25. This operation insures electrical continuity between the first and second conductors and their respective contacts of the LED. When a voltage is imposed between the conductors, the LED is energized and light is radiated from the diode'sjunction44 and at least a portion of that light is redirected latterly away from theconductors24 and25 by thewalls30.
• Thestrip62 may be formed with anotch68 that facilitates separation of one spacer from an adjoining spacer. As shown inFIG. 2, various other strip embodiments may be formed. For example, thespacer structure70 defines two wall structures that face oppositely to be operative withapertures28A and28B. In an assembly process, spacers can be easily broken from the strip62 (with aid, for example, from the notch68) and spaced along the first and second conductors as shown inFIGS. 1A and 1B.
• The first andsecond conductors24 and25 and their spacers26 may be enclosed with various substantially-transparent structures to form elongate radiating elements. For example,FIG. 3A (a view along the plane3-3 ofFIG. 1B) shows them enclosed in athermoplastic shrink tube80 andFIG. 3B shows them enclosed by a thermoplastic molded cover82 (the spacer'sback wall63 is indicated in each of these figures). InFIG. 3C, thecover82 has been modified to acover84 that defines a mounting surface85 that can abut, for example, a floor or wall.
• InFIG. 3D, thecover82 ofFIG. 3B has been modified to acover86 that defines a pair ofprotrusions87 in addition to defining the mounting surface85 ofFIG. 3C (the protrusions appear as outward-extending ribs when envisioned in theelongate structure90 ofFIG. 4 which is described below). Because of the flexible nature of these protrusions or ribs, they flex and absorb the pressure of an impinging object (e.g., a pedestrian's shoe) to thereby prevent damage to light-emitting elements within (as shown inFIG. 2).
• InFIG. 3E, thecover82 ofFIG. 3B has been modified to a cover88 that defines a mounting flange89 which can facilitate attachment (e.g., with adhesive, with mechanical elements such as rivets or by sewing) to various objects (e.g., footwear, clothing apparel and architectural mountings).
• Structures such as those ofFIGS. 3A-3E can be used to form elongate light display structures such as thestructure90 ofFIG. 4 which can be bent into various forms and which radiates light laterally when a voltage is placed across the first andsecond conductors24 and25.
• Transparent or translucent decorativeFIG. 92 can be molded in various forms that slide onto (or snap over) thestructure90 as shown inFIG. 5A. Alternatively, a decorativeFIG. 94 can include a hinged member95 (a non-engaged position is shown in broken lines) which facilitates its installation over thestructure90 as shown inFIG. 5B.
• FIGS. 6A-6C illustrate anotherdisplay structure embodiment100 for carrying at least one light-emittingelement22. As shown particularly inFIG. 6A, aspacer102 is shaped to define an array ofapertures22 and also to define an array of cup-shapedwalls104 that each surround a respective one of the apertures.FIG. 6B shows an array of light-emittingelements22 that are each received in a respective one of the apertures.FIG. 6B also shows a plurality offirst conductors24 that each contact a first side of a selected group of the light-emittingelements22. These conductors are also shown inFIG. 7A which is an enlarged view along the plane7-7 ofFIG. 6B.
• In particular,FIG. 7A shows thespacer102 positioned to space the first andsecond conductors24 and25 with a light-emitting element received in an aperture to contact the first and second conductors. Thesecond conductor25 may comprise a plurality of elongate conductors (similar to thefirst conductors24 inFIG. 6B) or may comprise a conductive sheet that contacts all of the light-emitting elements ofFIG. 6B.
• In one light display embodiment, the light-emitting elements are LEDs which radiate light from their light-emittingjunctions44. When a voltage is placed across the first and second conductors, the LEDs are energized andlight rays106 are radiated from thejunction44 and redirected laterally from the plane of thespacer102 by the cup-shapedwall104 as shown inFIG. 7A.
• Thefirst conductors24 ofFIG. 6B are shown to have a linear form but this is one of many possible embodiments.FIG. 6C, for example, shows a firstelongate conductor24A which is configured to contact various selected light-emitting elements that do not lie along a linear path. These elements can be selected so that the radiated light forms various figures (e.g., a letter, a number or a word) frofm the array of light-emitting elements.
• The cup-shapedwall104 ofFIG. 7A is shown to have a concave shape which may be substantially parabolic to enhance the redirected radiation.FIG. 7B is similar toFIG. 7A with like elements indicated by like reference numbers. Similar to thespacer102 ofFIG. 7A, aspacer110 is positioned to space the first and second conductors and it defines an array of apertures to each receive a respective one of the light-emittingelements22 as it contacts respective ones of the first and second conductors.
• In contrast to thespacer102, however, thespacer110 defines a cup-shapedwall112 that has a flat shape rather than the concave shape of thewall104 ofFIG. 7A. Also thespacer110 spaces the first and second conductors apart without completely filling the space between these conductors. Instead, thespacer110 comprises a sheet that is formed to define the cup-shapedwall112 and to contact thesecond conductor25 locally and contact thefirst conductor24 in other regions.
• FIG. 8 illustrates another light-emittingstructure120 which is similar to thestructure100 ofFIG. 6B with like elements indicated by like reference numbers. Thestructure120, however, includes a substantially-transparent sheet122 formed of a suitable polymer (e.g., mylar). Thefirst conductors24 can be bonded to thesheet122 and the sheet is then placed to bring these conductors into contact with their respective light-emittingelements22.
• As shown inFIG. 9 (a view along the plane9-9 ofFIG. 8), thesheet122 and itsfirst conductors24 may be locally shaped to formdimples124 that enhance contact between the conductors and their respective light-emittingelements22. In another light-emitting structure embodiment, thesheet124 may carry photoluminescent films126 (e.g., phosphor films, conjugated polymer, organic phosphor). In operation of this embodiment,light rays128 from the light-emittingelement22 are redirected by the cup-shaped wall (104 inFIG. 8) to strike the phosphor films. In response to this excitation, the luminescent films emitlight rays130. Different luminescent films may be used to selectively display different colors.
• Semiconductor LEDs have been configured to emit light with a variety of wavelengths and, generally, the forward voltage drop of these LEDs increases as the wavelength decreases. For example, red, yellow and green LEDs typically exhibit forward voltage drops in the respective ranges of 1.8-2.0 volts, 2.0-2.2 volts and 2.2-2.5 volts. In addition, each LED typically has a specified forward current that is recommended to enhance LED performance parameters (e.g., intensity, dissipation and lifetime).
• Accordingly, it may be desirable to insert a resistive member between the LEDs of the light display structures and their associated first and second conductors. This is exemplified inFIG. 2 where a resistive member136 (e.g., a resistive film such as a thin film resistor, a thick film resistor, conductive paste, conductive epoxy) is inserted between the anode of theLED22 and the first conductor24 (the insertion is indicated byinsertion arrow138—e.g., the member can be carried over the anode). Alternatively, the resistive member may be inserted between the cathode of theLED22 and thesecond conductor25.
• The resistivity and cross section of theresistive member136 are configured to realize a predetermined resistance which will provide the specified forward current when a selected supply voltage is applied via the first andsecond conductors24 and25. An exemplary green LED, for example, is specified to have a forward voltage drop of 2.8 volts and a forward current of 20 milliamps. For this particular LED, the resistivity and cross section of theresistive member136 would preferably be configured to provide a resistance that increases through the range of 10 to 100 ohms when the selected supply voltage increases through the range of 3.0 to 4.8 volts.
• In general, the resistivity and cross section of theresistive member136 are chosen to realize the specified forward current in response to a provided supply voltage. To enhance conductivity between elements, conductive films may be carried on the anode and cathode surfaces and also inserted between the resistive member and its associated one of the first and second conductors.
• FIGS. 10A-10D illustrate other light display embodiments of the present invention. In particular,FIG. 10 A shows alight display embodiment140 in which the first andsecond conductors24 and25 are arranged (e.g., side by side) to facilitate the insertion ofwire bonds142 that couple a selected one of the anode and cathode surfaces (wherein the anode surface has been selected inFIG. 10A) ofLEDs22 to thefirst conductor24.
• As shown inFIG. 10B, a resistive member136 (introduced inFIG. 2) is preferably inserted between theLED22 and thewire bond142. In addition, the LED's anode and cathode (and the resistive member136) may be joined to thewire bond136 and thesecond conductor25 withconductive elements65 and66 (also introduced inFIG. 2).
• FIG. 10C illustrates alight display embodiment160 that is similar to theembodiment140 ofFIG. 10A with like elements indicated by like reference numbers. In this embodiment, however, thefirst conductor24 is modified to aconductor164 which defines a plurality oftabs166. Each of theLEDs22 is then coupled between thesecond conductor25 and a respective one of thetabs166.FIG. 10D is similar toFIG. 10B except that theconductor164 and itstab166 is substituted for thefirst conductor24 and thewire bond142.
• The light display embodiments ofFIGS. 10A-10D may also be enclosed with various substantially-transparent structures to form elongate radiating elements. InFIGS. 3A-3D, for example, they can be substituted for the light display embodiments ofFIGS. 1A-1C and2 (which are represented inFIGS. 3A-3D by first andsecond conductors24 and25 and a spacer's back wall63).
• The light display structure embodiments shown inFIGS. 1-10D are simple and comprise few parts so that they can be economically fabricated from various polymers and quickly assembled. They lend themselves for realization in a variety of forms. For example, they can be realized in elongate display structures wherein light is directed laterally from the elongate shape or sheet-like display structures wherein light is directed laterally from the sheet. The descriptions of these embodiments include walls which are light redirectors that may be configured in various forms (e.g., reflective or refractive walls).
• The spacers (e.g.,26,102) shown in various ones of the figures, theinsulator40 ofFIG. 1B, thetube80 ofFIG. 3A, thecover82 ofFIG. 3B and thetransparent sheet122 ofFIGS. 8 and 9 can be fabricated from various insulators such as polymers (e.g., polyimide and mylar). The first and second conductors (24 and25 inFIG. 2) may be formed from various conductive metal foils (e.g., copper and silver). The spacers may also be fabricated in colors that enhance the light redirected from their respective LEDs.
• In an exemplary display embodiment, thephotoluminescent films126 ofFIG. 9 may include conjugate polymers and organic phosphors that are excited, for example, by blue LEDs to thereby cause the redirectedlight rays130 to be substantially white.
• FIG. 11 illustrates another light display structure in the form of a flexiblelight wire200 which can provide an extensive set oflight source embodiments202 that are spaced along asubstrate204 which is preferably formed from a flexible material (e.g., a polymer).FIG. 12A is an enlarged view of thearea12 inFIG. 11 andFIG. 12B is a sectioned side view of the structure ofFIG. 12A. These figures show that anembodiment202A of the light source is formed with the aid ofapertures205 in thesubstrate204. Received within each aperture is a light-emitting element which, in this embodiment, is anLED206 that has a light-emittingjunction44 defined by abutted upper andlower electrodes207 and208 (a more general designation of the structures previously referred to as anode and cathode).
• To facilitate energization of thelight source202A, first andsecond conductors211 and212 are respectively dispensed along the upper and lower surfaces of thesubstrate204 with the first conductor contacting theupper electrode207 and thesecond conductor212 contacting thelower electrode208. In one forming embodiment, this may be quickly accomplished with conventional wire bonding processes and equipment. For example, thefirst conductor211 can be rapidly dispensed along thesubstrate204 to a point adjacent theaperture205.
• Afirst bond221 is then formed at the substrate adjacent theaperture205 after which the first conductor continues to be dispensed. Asecond bond222 is then formed and attached to theupper electrode207 after which the first conductor continues to be dispensed. Athird bond223 is then formed and attached to the substrate adjacent the aperture.
• Having formed and attached the first, second and third bonds, the first conductor is subsequently pulled down to the next aperture and the wire bonding process continued. A similar wire bonding process is used to rapidly install thesecond conductor212 to thesubstrate204 and thelower electrode208. Each LED will then be energized when a voltage potential is placed across the first and second conductors.
• Various wire bonding processes may be used (e.g., thebonds221,222 and223 may be balls formed by melting of gold wire or may be wedge contacts formed with ultrasonic processes). In other embodiments of the first andsecond conductors211 and21-2, segments of these conductors may be printed-circuit paths formed with conventional printed circuit processes. In one embodiment, for example, only those segments of thefirst conductor211 ofFIGS. 12A and 12B between thebonds221 and223 are formed with wire bonding processes and the other segments of the first conductor are formed with printed circuit processes. The second conductor can be formed with a similar combination of processes.
• FIGS. 12C and 12D show anotherlight source embodiment202B that is similar to thelight source202A ofFIGS. 12A and 12B with like elements indicated by like reference numbers. In contrast, however, aportion225 of theupper electrode207 is broken away to expose a portion of thelower electrode208. This permits thesecond conductor212 to be moved from its location inFIG. 12B (i.e., adjacent the lower substrate surface) to join thefirst conductor211 adjacent the upper substrate surface. InFIG. 12C, accordingly, thesecond conductor212 is now wire bonded to the upper substrate surface and to the exposed portion of thelower electrode208.
• FromFIGS. 11-12D, it is thus apparent that the structures of thelight wires202A and202B facilitate a rapid, economical fabrication process. Once fabricated and installed, an energy source (e.g., battery) can be placed across the first andsecond conductors211 and212 to simultaneously energize eachLED206 along the light wire so that it emits light226 as shown inFIGS. 12B and 12D. Thesubstrate204 may be formed of a variety of materials such as a laminated film or an extruded polymer (e.g., thermoplastic or thermosetting polymer). Flexibility of the substrate will enhance the flexibility of thelight wire200 ofFIG. 11.
• Thelight wire200 can be environmentally protected with an appliedovercoat228 formed, for example, of heat-shrinkable tubing, a polymer sleeve or a conformal coat. Prior to the overcoat, eachLED206 can be surrounded by aprotective coat229 of a substantially transparent material (e.g., epoxy). This coat may be configured with an index of refraction that enhances emission of the light226. The coat and the overcoat are especially suitable if the LEDs have not been passivated.
• In another light source embodiment, a resistive member230 (similar toresistive member136 introduced with respect toFIG. 2) is inserted inFIG. 12B between asecond bond222 and theupper electrode207 of theLED206 as indicated byinsertion arrow232. The resistive member facilitates control of the emittedlight226. As previously disclosed, for example, it facilitates control over the forward voltage drop and/or the forward current of the LED to thereby alter and enhance the appearance of the emittedlight226.
• In another light source embodiment, the resistive member may be inserted between thelower electrode208 of the LED and its respective bond. Alternatively, resistive members can be inserted to abut each of the upper and lower electrodes. In other light source embodiments, resistive members may be inserted in similar manners in the light source embodiment ofFIGS. 12C and 12D. In these latter embodiments, the resistive members will abut the upper electrode and/or the exposedportion208 of the lower electrode.
• It is noted thatFIGS. 12B and 12D show theLED206 and thesubstrate204 to have substantially-similar heights or thicknesses. In other light display embodiments, however, they may differ. For example, the thickness of thesubstrate204 may be reduced so that theLED junction44 is above the substrate which may enhance emission of the light226.
• FIGS. 13A-13D illustrate another light display structure in the form of a light bulb240 (shown in 3 orthogonal views inFIG. 13D) which is formed with alight wire242 that provides a set oflight sources202C that are spaced along a polymer substrate244 (shown, for example, inFIG. 13A). Thepolymer substrate244 is similar in composition to thepolymer substrate204 inFIG. 11 but its form differs as it has a cross-like shape which includeslegs245 that couple to alonger leg246. Afirst conductor211 runs through some of thelight sources202C and is coupled to anorthogonal conductor247 which runs through the otherlight sources202C.
• FIG. 13B illustrates an elongatemetallic heat sink250 in association with thelight wire242. This figure shows thelegs245 and thelonger leg246 in a fabrication process wherein they are being bent so that they can each run down a respective side of theheat sink250. As shown inFIG. 13C, this process has been continued until each of the legs (e.g., the legs245) are in contact with the sides of theheat sink250.
• Thelight source202C is similar to thelight source202A ofFIG. 12A with like elements indicated by like reference numbers. In contrast to thelight source202A, however, thelight source202C lacks thesecond conductor212 of thelight source202B. Instead, theheat sink247 abuts theelectrode208 of the LED to serve as an electrical connection to this electrode and to also provide a conduction path which transports heat away from thelight sources202C.
• Thefirst conductor211 can be installed with a wire bonding process similar to that introduced with reference toFIG. 12A. For example,FIG. 13C shows first, second andthird bonds221,222 and223 that can be successively installed to secure the first conductor respectively to one of thesubstrate legs245, theupper electrode207 and another of thesubstrate legs245.
• When thelight wire242 andheat sink250 are assembled together, they are then received within theglobe260 andbase261 of thelight bulb240 ofFIG. 13D. In this arrangement, theconductor211 is electrically connected to one of thebase261 and the bulb terminal262 (that is surrounded by the base) and theheat sink250 is electrically connected to the other. A voltage across the base and terminal is communicated via thefirst conductor211 and theheat sink250 to energize the LED in each of thelight sources202C. In response, each of the LEDs radiates the light226 shown inFIG. 13C. The lifetime of the LEDs is substantially enhanced because heat is rapidly carried away from them along the conduction path provided by theheat sink250.
• FIGS. 14A and 14B illustrate another light display structure in the form of asegmented display270 which is formed withlight wires271 that each provides a plurality oflight sources202D. The display is formed withfirst conductors211, asubstrate271, and a plurality of electrically conductive ground planes272. The substrate defines a plurality ofapertures205 and each of a plurality ofLEDs206 is received within a respective one of the apertures.
• Each of the ground planes272 abuts the back of thesubstrate271 and is in contact with lower electrodes of arespective set273 of theLEDs206. That is, the LEDs are grouped insets273 and each of the ground planes contacts lower electrodes of LEDs in its respective one of the sets. Each ground plane is associated with a respective one ofswitches274 that can selectively couple that ground plane to a voltage potential (e.g., ground). Eachlight source202D is similar to thelight source202C ofFIG. 13C except that the substrate,245 is replaced with thesubstrate271 and theheat sink250 is replaced by aground plane272.
• InFIG. 14A, thefirst conductors211 bear the designations of A through G. As shown, each of these conductors can be wire bonded to thesubstrate271 and wire bonded to the upper electrode of a respective LED in each of thesets273. In each set, the LEDs are arranged as segments of a number. The conductor labeled A is wire bonded to theupper LED206 in each of thesets273, the conductor labeled B is wire bonded to an upperleft LED207 in each of thesets273 and so on for the rest of theconductors211.
• In a first operational phase of thesegmented display270, theswitch274 of one of the ground planes272 is closed to couple that ground plane to a first voltage potential (e.g., ground). At this time, all of theother switches274 are open. A second voltage potential is placed upon a first selected group of the conductors A-G to thereby energize a selected group of theLEDs206 of the ground plane whoseswitch274 is closed. LEDs in theother sets273 will not be energized because theirrespective switches274 are open. Accordingly, a selected number is displayed by the LEDs associated with the closed switch.
• In a second operational phase of thesegmented display270, theswitch274 of a different one of the ground planes272 is closed and the remainder of theother switches274 are open. The second voltage potential is placed upon a second selected group of the conductors A-G. The second selected group of conductors is not necessarily the same as the first selected group. Accordingly, the selected number that is displayed by the LEDs associated with the closed switch is not necessarily the same as the earlier displayed number.
• Additional operational phases are conducted for each of the remaining ground planes after which the entire process is rapidly repeated. Although each of these operational phases is quite brief (e.g., a fraction of a second), each displayed number will appear to be continuous because of the rapid repetition and the retinal retention of light in the human eye.
• In another light display embodiment, thesubstrate271 is formed of a flexible polymer and the ground planes272 is formed of flexible and electrically conductive material to enhance flexibility of thesegmented display270. Such embodiments are useful in applications in which it is desired to conform the display to a curved surface.
• FIG. 14B is a view along theplane14B-14B ofFIG. 14A. This sectional view shows one of the ground planes272 abutting the back of thesubstrate271 and one of theLEDs206 within anaperture205. In another light display embodiment, thesurface272S of theground plane272 is configured with a reflective surface that provides a high degree of reflection while maintaining electrical conductivity. The reflective surface may, for example, be realized with a color (e.g., white) and/or a finish (e.g., gloss finish) that enhances light reflection. This reflective ground plane enhances the intensity of the emittedlight226 of theLED206.
• In another light display embodiment, areflective member275 is inserted between theground plane272 and theLED206 as indicated byinsertion arrow276. The reflective member is configured as described above in order to reflectively enhance the emittedlight226.
• As further shown inFIG. 14B, eachLED206 may be covered with a light-enhancingmember279. In one embodiment, this light-enhancing member may be a substantially transparent material (e.g., epoxy) that has an index of refraction that enhances the emittedlight226. In another embodiment, the light-enhancing member may be a holographic member that alters and enhances the appearance of the emittedlight226. For example, the holographic member may any of various polymers whose surface has been configured to diffuse light in manners that achieve a holographic effect. In each of thesets273 of LEDs, these holographic members may be oriented in different directions to obtain different holographic effects in the LEDs of that set.
• FIG. 15A illustrates side and front views of another light display structure in the form of anarray member280 which is formed withfirst conductors211, asubstrate282, aconductive block283 and a plurality of insulated metallic pins284. Theblock283 contacts the lower surface of thesubstrate282 and the lower electrode of each ofLEDs206 that are received in theapertures205 of thesubstrate282. Theinsulated pins284 extend through the substrate and the block so that they are accessible at each side of the combined substrate and block.
• Eachfirst conductor211 can be installed with a wire bonding process similar to that introduced with reference toFIG. 12A. For example, the first, second and third bonds ofFIG. 12A can be used in a similar manner to successively secure afirst conductor211 to one of thepins284, the upper surface of thesubstrate282, and to the upper electrode of a corresponding one of theLEDS206.Light sources202E are thus formed which are each similar to thelight source202C ofFIG. 13D except that thesubstrate244 is replaced with thesubstrate282 and theheat sink250 is replaced by theconductive block283.
• In operation of thearray member280, a first potential is applied to theblock283 and a second potential is applied to a selected one of thepins284. Accordingly, a selected one of theLEDs206 is energized. In a display embodiment, each of the LEDs is associated with a phosphor film which causes its emitted light to have a selected color. For example, the LEDs inFIG. 15A are indicated with letters R, G and B indicating that they emit red, green and blue light when the second potential is applied to their respective ones of thepins284. Because green light is generally not as intense as the other colors, two of the LEDs are structured to emit green light as they are simultaneously energized.
• The structure of thearray member280 ofFIG. 15A is particularly suited for use in alight display array290 that is shown inFIG. 15B. The array is formed by arranging a plurality of thearray members280 in an array relationship which is indicated bybroken lines292. Although only onearray member280 is shown inFIG. 15B, each of the spaces defined by thebroken lines292 would be filled with a respective one of the array members.
• Because of the structure shown inFIG. 15A, thearray members280 can be tightly arranged inFIG. 15B with theirpins284 each available at the rear of the array and they're LEDs forming a lighted array at the front of the array. Heat from the LEDs is quickly carried away by the conduction path formed by theblocks283. Various light patterns can be displayed by placing potentials on selected ones of thepins284. Theblocks283 may be formed from any material (e.g., a metal) that is electrically and thermally conductive.
• Other embodiments of thearray member280 are formed by those which include areflective back member294 which is inserted (as exemplified by insertion arrow295) between theblock283 and itsLEDs206 to thereby redirect any light that emits from the back sides of the LEDs. The reflection substantially enhances the light intensity visible to a viewer of the array member. Although shown having a size similar to that of thesubstrate282, there may, for example, be smaller back films that are each inserted between theblock283 and a respective one of the LEDs.
• Another array member embodiment includes anopaque overlay296 which is positioned (as indicated by positioning arrow297) over thesubstrate282. The overlay defines apertures similar to theapertures205 of thesubstrate282 and these apertures are positioned to each pass light emitted from respective one of theLEDs206. Various overlay embodiments may be formed with masking processes (e.g., silk screening or the use of decals). Theoverlay296 is configured to enhance the appearance of the array member.
• Yet another array member embodiment includes epoxy coatings298 (one is indicated by a broken-line ellipse) that are positioned over eachLED206. Each coating may include light dispersing particles formed of reflective material (e.g., titanium oxide and silver) so that it disperses the light emitted from its respective LED. This embodiment particularly enhances the appearance of the array member.
• In still another array member embodiment, the broken-line ellipse298 represents a holographic lens which is positioned proximate to theLEDs206 to further enhance the appearance of thearray member280.
• It is noted that various structures have been described above inFIGS. 12A-15B to enhance emitted light of LEDs. These include substantially transparent material (e.g., epoxy) configured with a selected index of refraction, substantially transparent material configured with light dispersing particles formed of reflective material (e.g., titanium oxide and silver), phosphor films which cause the emitted light to have a selected color, and holographic members whose surface has been configured to diffuse light in manners that achieve holographic effects. These light-enhancing structures may be used in conjunction with (e.g., disposed proximate to) any of the light display embodiments described above.
• Light display embodiments of the invention are particularly suited for combination with articles of merchandise (i.e., goods which may be offered for sale) to form commodities (i.e., economic goods, articles of commerce) such as the lighted commodity embodiments illustrated inFIGS. 16-21. In general, the light display structures shown in these lighted commodity embodiments may be formed with light display structure embodiments exemplified by those illustrated inFIGS. 1-15A. Although the lighted commodities are shown in the form of exemplary objects (e.g., a Christmas tree), they may generally be arranged in any desired graphic or textual form.
• FIG. 16, for example, shows a lightedcommodity embodiment300 that is particularly suited for forming lighted signs. It includes apanel302 andlight display structures303 and304 carried on the panel. The display structures are formed with first and second conductors (22 and24 inFIG. 1A), spacers (26 inFIG. 1A) and light-emitting elements (22 inFIG. 1A). For simplicity of illustration, the first and second conductors of thedisplay structure303 are shown as a single line, the spacers are not explicitly shown and the light-emitting elements are indicated as dots with light rays radiating therefrom. Thedisplay structure304 is only indicated by broken lines to indicate that it is not currently selected. In an important feature of the invention, the display structures are nearly invisible when not illuminated.
• In an exemplary form, thedisplay structure303 is shaped to spell the word “open” and thedisplay structure304 is shaped to spell the word “closed”. The letters of these words are preferably formed by a single display structure but, for clarity of illustration, the conductors between letters are not shown. In an exemplary use of thecommodity300, a power source (e.g., a battery or a permanent power source) would be switched to illuminate, at different times, a selected one of thedisplay structures303 and304 to indicate the present status of something associated with the sign (e.g., a business).
• Thepanel304 is preferably formed from any of a variety of translucent plastics (e.g., acrylic) which will receive and spread a portion of the light emitted by thedisplay structures303 and304 to thereby present a pleasing effect to the lighted sign. To further enhance the lighted sign, thecommodity300 may include a reflecting sheet306 (e.g., a white sheet of paper, plastic or other thin material) positioned on one side of thepanel300 to thereby spread and redirect emitted light back through the panel.
• FIG. 17 is a view along the plane17-17 inFIG. 16 which shows another commodity embodiment in which an edge of thepanel302 is shaped to define achannel307 which receives anotherdisplay structure308. Thechannel307 anddisplay structure308 may run along a portion of or all of the perimeter of thepanel302. The channel can be shaped in forms (e.g., a parabola) that facilitate passage of emitted light through thepanel302 to thereby further enhance the appearance of the lighted sign. In addition, a reflective sheet309 (similar to the reflective sheet306) may be positioned to cover the groove and further redirect light through the panel. Although thereflective sheets306 and309 are slightly spaced from thepanel302 inFIGS. 16 and 17 to better delineate them, they would generally abut the panel.
• Another lighted commodity embodiment is shown with front, side and back views of the lightedsign310 ofFIG. 18. This sign includes apanel311 and amessage312 that is carried on either thefront side314 of the panel or on theback side315. Similar to thepanel304 ofFIG. 16, thepanel311 may be formed from any of a variety of translucent plastics (e.g., acrylic) which will receive and spread a portion of the light emitted by alight display structure316 which is preferably carried on theback side315.
• Although themessage312 is indicated by an exemplary text “message”, it may be in the form of any message structure such as text, graphics or combinations of text and graphics. Although the message is shown on thefront side314, it may be carried on theback side315 in other embodiments.
• The light from thelight display structure316 is spread throughout thepanel311 and enhances the appearance of themessage312. Accordingly, this light display structure is arranged in a form (e.g., the serpentine form ofFIG. 18) that effectively illuminates thepanel311. A diffusingsheet318 may be inserted between thepanel311 and thedisplay structure316 to diffuse the structure's light and further enhance the appearance of the lightedcommodity310.
• Another lightedcommodity embodiment320 is shown inFIG. 19 to be a shoe322 and a light display structure that is carried on the shoe. For example, the shoe includes atongue323 and alight display structure324 that is carried on the tongue. For another example, the shoe has abody325 and a light display structure326 that is carried on the body. It is noted that the laces of the shoe322 are schematically shown over the tongue and on the body.
• Thetongue323 and its associateddisplay structure324 may be removably coupled to thebody325 with first and second fasteners321 (e.g., engagable snaps) to facilitate its replacement with another tongue that carries a different display structure. The fasteners may also be part of first and second electrical paths associated with abattery328 that powers thedisplay structure324. A switch329 (e.g., a pressure-activated switch) may be inserted between the battery and the display structure to provide a means of activating (i.e., energizing) the display (e.g., by interrupting at least one of the electrical paths).
• InFIG. 19, anotherlight display structure330 is carried on aremovable body portion332. In particular, theexample arrow334 is associated with a portion of the boundary between thebody325 and thebody portion332 and indicates that this portion can be removably coupled to the body with a fastener in the form of azipper334. This fastener facilitates the replacement of this body portion with another body portion that carries a different display structure.
• FIG. 20 illustrates another lightedcommodity embodiment340 which is formed with a clothing item342 (in particular, a T shirt) and alight display structure344 that is carried on the clothing item.
• Another lightedcommodity embodiment350 is shown inFIG. 21 to be formed with a container342 (in particular, a bottle) and alight display structure344 that is carried on the container.
• As disclosed above, various light display structure embodiments include conductors having path segments formed with wire bonding processes. It is to be understood that, in other embodiments of these light display structures, some or all conductor path segments may be formed with wire bonding processes and some or all conductor path segments may be formed with printed circuit processes. An exemplary example was disclosed in which those path segments of thefirst conductor211 ofFIGS. 12A and 12B between thebonds221 and223 are formed with wire bonding processes and the other path segments of the first conductor are formed with printed circuit processes.
• Although not explicitly shown in all of the lighted commodity embodiments ofFIGS. 16-21, their light display structures may be activated with a battery (e.g., thebattery328 ofFIG. 19) and this activation may be accomplished with a switch (e.g., theswitch329 ofFIG. 19). Alternatively, they may be activated with other power sources (e.g., permanent power sources) that are spaced away from the lighted commodity embodiments.
• The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the appended claims

Claims (20)

1. A display structure, comprising:

a substrate that has first and second substrate sides and defines a plurality of apertures that communicate with said first and second substrate sides;

a plurality of light-emitting diodes that each have a semiconductor junction between abutted first and second electrodes and that are each received within a respective one of said apertures wherein a portion of said first electrode is absent to thereby provide access to an exposed portion of said second electrode;

a first conductor that is coupled to said first substrate side and coupled to the first electrode of each of said diodes; and

a second conductor that is coupled to said first substrate side and coupled to the exposed portion of each of said diodes;

said diodes thereby energized by a potential between said first and second conductors.

2. The structure ofclaim 1, wherein said first and second conductors are wire bonded to said first electrode and said exposed portion respectively.

3. The structure ofclaim 2, wherein said first and second conductors are wire bonded to said first substrate side.

4. The structure ofclaim 1, further including, proximate to each of said diodes, a light-enhancing structure that is a selected one of a material with a selected index of refraction, a material configured with light dispersing particles, a material configured to diffuse light in a holographic effect, and a phosphor film.

5. A display structure, comprising:

a substrate that has first and second substrate sides and defines a plurality of apertures that communicate with said first and second substrate sides;

a plurality of light-emitting diodes that each have a semiconductor junction between abutted first and second electrodes and that are each received within a respective one of said apertures;

a first conductor that is coupled to said first substrate side and coupled to the first electrode of each of said diodes; and

a second conductor that is coupled to said second substrate side and coupled to the second electrode of each of said diodes;

said diodes thereby energized by a potential between said first and second conductors.

6. The structure ofclaim 5, wherein said first and second conductors are wire bonded to said first and second electrodes.

7. The structure ofclaim 6, wherein said first and second conductors are wire bonded to said first and second substrate sides respectively.

8. The structure ofclaim 5, further including, proximate to each of said diodes, a light-enhancing structure that is a selected one of a material with a selected index of refraction, a material configured with light dispersing particles, a material configured to diffuse light in a holographic effect, and a phosphor film.

9. A display structure, comprising:

a substrate that has first and second substrate sides and defines a plurality of apertures that communicate with said first and second substrate sides;

a plurality of light-emitting diodes that each have a semiconductor junction between abutted first and second electrodes and that are each received within a respective one of said apertures;

a conductor that is coupled to said first substrate side and coupled to the first electrode of at least one of said diodes; and

an electrically-conductive member that contacts the second electrode of at least one of said diodes;

said diodes thereby energized by a potential between said conductor and said member.

10. The structure ofclaim 9, wherein said member is a post, said substrate is wrapped about a portion of said post with said second substrate side contacting said post and said post contacts the second electrode of all of said diodes, and further including:

a terminal in contact with one of said conductor and said post;

a cylindrical base surrounding said terminal and in contact with the other of said conductor and said post; and

a glass globe extending from said base and surrounding said substrate and said diodes;

said diodes thereby energized by a potential between said terminal and said base.

11. The structure ofclaim 9, wherein:

said member is one of a plurality of ground planes that are positioned adjacent said second substrate side;

each of said ground planes contacts the second electrodes of a corresponding set of said diodes wherein said set is arranged as segments of a number; and

said conductor is one of a plurality of wires that are each coupled to the first electrode of a respective diode of each of said sets.

12. The structure ofclaim 11, further including a plurality of switches that are each arranged to couple a potential to a respective one of said ground planes.

13. The structure ofclaim 9, further including a plurality of insulated pins wherein:

said member is an electrically conductive block that contacts said second substrate side;

each of said pins extends through said block; and

said conductor is one of a plurality of wires that are each coupled to the first electrode of a respective one of said diodes and coupled to a respective one of said pins.

14. The structure ofclaim 13, further including:

phosphor films that are each carried over a respective one of said first electrodes to selectively display different colors; and

an opaque overlay positioned over said substrate with apertures arranged to correspond to respective ones of said diodes.

15. The structure ofclaim 9, further including, proximate to each of said diodes, a light-enhancing structure that is a selected one of a material with a selected index of refraction, a material configured with light dispersing particles, a material configured to diffuse light in a holographic effect, and a phosphor film.

16. The structure ofclaim 9, further including an article of merchandise wherein said conductor and said member are flexible wires and said substrate is a flexible polymer substrate that is carried by said article.

17. The structure ofclaim 16, wherein said substrate defines at least one light redirector positioned to redirect light from a respective one of said diodes.

18. The structure ofclaim 16, wherein said article is a selected one of a sign, a container, a clothing item, a shoe, a tongue of a shoe

19. The structure ofclaim 16, further including at least one fastener that removably couples said substrate to said article.

20. The structure ofclaim 19, wherein said fastener is a zipper.

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