TITLE
MONOLITHIC ILLUMINATED ELEMENT Background of the Invention
[0001] The present invention is related to illuminated elements, such as signs letters and indicia, which can be readily manufactured and which appear as a monolithically illuminated element.
[0002] The manufacture Qf illuminated elements is well known in the art. Most common are neon signs and signs formed from channel lighting. Each of these has been, and continues to be, widely utilized in commerce. Both neon signs and channel lighting based signs have limitations when large illuminated elements are desired and particularly when it is the desire of the artisan to create the illusion of a monolithic illuminated element which appears to be completely illuminated without pixilation. Large signs are difficult to form from neon due to the fragile nature of the resulting sign. Large signs manufactured by channel lighting are expensive to manufacture and illumination is typically restricted to the face of the sign and therefore are not capable of presenting a monolithic image.
[0003] To date there is not a commercially viable monolithic illuminated element even though this desire has been present for many years. The present invention provides an illuminated element which solves this long felt desire in the art Objects of the Invention [0004] It is an object of the invention to provide a monolithic illuminated element, and method for making a monolithic illuminated element, which appears to be completely and equally illuminated over the entirety of the element.
[0005] It is another object of the present invention to provide a method for manufacturing a large illuminated element without requiring the necessity for large neon tubes or channel lighting techniques.
[0006J A particular feature of the present invention is the ability to manufacture the illuminated elements with readily available techniques and from readily available materials. [0007] These, and other advantages, are realized in an illuminatable element of the present invention, The illurainatable element has a thermo-formed lens in the shape of a preformed mold. A panel in the shape of the lens is attached to the lens A multiplicity of LEDs is mounted on the panel between the panel and lens.
[ODOS] Yet another advantage is provided in a process for manufacturing an illuminatable element. The process includes forming a sculpted mold in a predetermined shape. A plastic sheet is place on the sculpted mold and heating to conform the sheet to the sculpted mold thereby forming a lens. LEDs arc attached to a planar panel wherein the planer panel has a shape corresponding to the predetermined shape, The lens is secured to the panel with the LEDs between the panel and the lens. Brief Description of the Drawings [0009] Fig. 1 illustrates a three-dimensional computer sculpted mold.
[0010] Fig. 2 illustrates thermoforming a replica of the three-dimensional computer sculpted mold of Fig. 1.
[0011] Fig. 3 illustrates a panel computer cut in the approximate shape of the three- dimensional computer sculpted mold. [0012] Fig. 4 illustrates an exploded view of the monolithic illuminated element. [0013] Fig. 5 illustrates a cross-sectional view of a monolithic illuminated element. [0014] Fig. 6 illustrates a technique for attaching a monolithic illuminated element to a surface. [0015] Fig. 7 illustrates another technique for attaching a monolithic illuminated element to a surface.
Detailed Description of the Invention
[0016] The present invention is specific to a monolithic illuminated element which will be described with reference to the figures representing an integral part of the instant application. [0017] As illustrated hi Fig. 1, a three-dimensional mold, 1, is formed b the desired shape of the element by a cutting element, 2. For the purposes of illustration a letter "R" is to be formed without limit thereto and in the present application the term "letter" will be used to indicate any shape of the element without regard for the actual shape. The mold can be formed by any cutting element including computer-guided ablation or cutting techniques, by casting techniques, by stereo lithography techniques, or by standard techniques involving cutting and filing elements Any shape capable of being vacuum thermofoππed can be utilized for the mold.
[OOIS] As illustrated in Fig. 2, the thermo-formed rendition of the mold, 3, is then formed which acts as a lens. While not 1 united thereto the lens can be made from polyester glycol, polycarbonate or any plastic capable of being vacuum or drape formed over a mold. A particularly preferred material is polyester glycol (PETG) sold by Sheffield Plastics Inc. as VrVAK®. The lens is trimmed to remove edges and excess material to form a plastic letter, 12. [0019] As shown in Fig. 3, a planer pane! is cut in a separate step in the shape of the letter. The panel provides rigidity to the finished structure and provides a surface for attaching mounting pieces to the finished product. The panel may be an aluminum panel or an aluminum composite. Without limit aluminum can be in the form of a solid panel, aluminum honeycomb, or an aluminum composite such as an aluminum polypropylene layered structure. A particularly preferred panel is a laminated, corrugated plastic core provided as Alumalite by Laminators Inc..
[002ft] With reference to Fig. 3, light emitting diodes (LEDs), 5, are mounted to the panel in the approximate shape of the panel. While not limited thereto the LEDs are preferably surface mounted lambertian or bat-wing LEDs with about a 120° viewing angle. A particularly preferred LED is a surface mounted LED (SML) provided as Luxeon by Lumileds Lighting. The LEDs are preferably separated by about 2 cm. [0021] The lens is then secured to the panel by any method typically employed in such arrangements with mating protrusions and voids being engaged in a snap-fit arrangement being most preferred.
[0022] An illumination element, 11, is shown in cross-section in Fig. 5. In Fig. 5, a light- shaping film, 6, is preferably included between the panel and lens, 7, to reduce the number of LEDs required to get near equal illumination over the entirety of the lens. The light-shaping film may be bowed towards the lens. The light-shaping film may be a plastic film or a coextruded composite. A particularly preferred light-shaping film holographic film is marketed as LSD by POC Physical Optics Corporation.
[0023] An optional gasket, such as a teardrop gasket, 10, may be used to seal the interior of the element from moisture. [0024] As shown in Fig. 6, the element can be mounted io a surface by rivets, screws, nails and the like, 8, passing through the panel and engaging with the surface upon which the light is to be mounted. An alternative method is illustrated in Fig. 7 wherein mating clasp, 9, can be used wherein one portion is attached to the surface and the mating portion is attached to the panel. The mating portion may be slightly indented to insure that the element is flush with the surface. [0025] Energizing LEDs is well known, as are control mechanisms for controlling a group of LEDs in whole or individually. A particular advantage of LEDs is the ability to be energized by direct current (DC) which is inherently safer and which operates at a lower temperature than alternating current (AC). Both of these features are advantageous as would be realized by one of skill in the art. [0026] The depth of the letters, measured as the longest distance from the surface upon which the sign is mounted, is not particularly limited but it is preferably about 4 to about 5 cm.
[0027] The invention has been described with particular emphasis QΠ the preferred. embodiments without limit thereto. One of ordinary skill in the art could realize alternative embodiments and configurations which are within the scope of the invention as set forth in the claims appended hereto.