Light display structures
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.
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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 INVENTION1. 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 INVENTIONAdvantageous 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
views along the plane 5-5 of
Attention is initially directed to
In particular and as indicated by a spacer 26A, the spacers each define an aperture 28 to receive the light-emitting element as it contacts the first and second conductors 24 and 25. The spacer 26A illustrates the aperture 28 while the spacer 26B illustrates reception of the light-emitting element 22 into the aperture. Each spacer 26 also defines at least one light redirector 30 that is positioned to redirect light away from its respective light-emitting element 22.
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 in
In the structure embodiment of
As shown in
Although the light display structures of the invention may carry various light-emitting elements, the structure 20 of
In operation of the light display structure 20, a voltage is applied between the first and second conductors 24 and 25 which energizes the LED and causes light to be emitted from its light-emitting junction 44. As shown in
As shown in
The enlarged isometric view 60 of
A light-emitting element 22 in the form of an LED is shown in the process of being received into an aperture 28. Joining elements 65 and 66 are preferably formed of conductive materials (e.g., conductive epoxy, solder, reflow solder) and are provided to join the diode's anode to the first conductor 24 and the diode's cathode to the second conductor 25. 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's junction 44 and at least a portion of that light is redirected latterly away from the conductors 24 and 25 by the walls 30.
The strip 62 may be formed with a notch 68 that facilitates separation of one spacer from an adjoining spacer. As shown in
The first and second conductors 24 and 25 and their spacers 26 may be enclosed with various substantially-transparent structures to form elongate radiating elements. For example,
In
In
Structures such as those of
Transparent or translucent decorative
In particular,
In one light display embodiment, the light-emitting elements are LEDs which radiate light from their light-emitting junctions 44. When a voltage is placed across the first and second conductors, the LEDs are energized and light rays 106 are radiated from the junction 44 and redirected laterally from the plane of the spacer 102 by the cup-shaped wall 104 as shown in
The first conductors 24 of
The cup-shaped wall 104 of
In contrast to the spacer 102, however, the spacer 110 defines a cup-shaped wall 112 that has a flat shape rather than the concave shape of the wall 104 of
As shown in
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 in
The resistivity and cross section of the resistive member 136 are configured to realize a predetermined resistance which will provide the specified forward current when a selected supply voltage is applied via the first and second conductors 24 and 25. 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 the resistive member 136 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 the resistive member 136 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.
As shown in
The light display embodiments of
The light display structure embodiments shown in
The spacers (e.g., 26, 102) shown in various ones of the figures, the insulator 40 of
In an exemplary display embodiment, the photoluminescent films 126 of
To facilitate energization of the light source 202A, first and second conductors 211 and 212 are respectively dispensed along the upper and lower surfaces of the substrate 204 with the first conductor contacting the upper electrode 207 and the second conductor 212 contacting the lower electrode 208. In one forming embodiment, this may be quickly accomplished with conventional wire bonding processes and equipment. For example, the first conductor 211 can be rapidly dispensed along the substrate 204 to a point adjacent the aperture 205.
A first bond 221 is then formed at the substrate adjacent the aperture 205 after which the first conductor continues to be dispensed. A second bond 222 is then formed and attached to the upper electrode 207 after which the first conductor continues to be dispensed. A third bond 223 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 the second conductor 212 to the substrate 204 and the lower electrode 208. 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., the bonds 221, 222 and 223 may be balls formed by melting of gold wire or may be wedge contacts formed with ultrasonic processes). In other embodiments of the first and second conductors 211 and 21-2, segments of these conductors may be printed-circuit paths formed with conventional printed circuit processes. In one embodiment, for example, only those segments of the first conductor 211 of
From
The light wire 200 can be environmentally protected with an applied overcoat 228 formed, for example, of heat-shrinkable tubing, a polymer sleeve or a conformal coat. Prior to the overcoat, each LED 206 can be surrounded by a protective coat 229 of a substantially transparent material (e.g., epoxy). This coat may be configured with an index of refraction that enhances emission of the light 226. The coat and the overcoat are especially suitable if the LEDs have not been passivated.
In another light source embodiment, a resistive member 230 (similar to resistive member 136 introduced with respect to
In another light source embodiment, the resistive member may be inserted between the lower electrode 208 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 of
It is noted that
The light source 202C is similar to the light source 202A of
The first conductor 211 can be installed with a wire bonding process similar to that introduced with reference to
When the light wire 242 and heat sink 250 are assembled together, they are then received within the globe 260 and base 261 of the light bulb 240 of
Each of the ground planes 272 abuts the back of the substrate 271 and is in contact with lower electrodes of a respective set 273 of the LEDs 206. That is, the LEDs are grouped in sets 273 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 of switches 274 that can selectively couple that ground plane to a voltage potential (e.g., ground). Each light source 202D is similar to the light source 202C of
In
In a first operational phase of the segmented display 270, the switch 274 of one of the ground planes 272 is closed to couple that ground plane to a first voltage potential (e.g., ground). At this time, all of the other switches 274 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 the LEDs 206 of the ground plane whose switch 274 is closed. LEDs in the other sets 273 will not be energized because their respective switches 274 are open. Accordingly, a selected number is displayed by the LEDs associated with the closed switch.
In a second operational phase of the segmented display 270, the switch 274 of a different one of the ground planes 272 is closed and the remainder of the other switches 274 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, the substrate 271 is formed of a flexible polymer and the ground planes 272 is formed of flexible and electrically conductive material to enhance flexibility of the segmented display 270. Such embodiments are useful in applications in which it is desired to conform the display to a curved surface.
In another light display embodiment, a reflective member 275 is inserted between the ground plane 272 and the LED 206 as indicated by insertion arrow 276. The reflective member is configured as described above in order to reflectively enhance the emitted light 226.
As further shown in
Each first conductor 211 can be installed with a wire bonding process similar to that introduced with reference to
In operation of the array member 280, a first potential is applied to the block 283 and a second potential is applied to a selected one of the pins 284. Accordingly, a selected one of the LEDs 206 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 in
The structure of the array member 280 of
Because of the structure shown in
Other embodiments of the array member 280 are formed by those which include a reflective back member 294 which is inserted (as exemplified by insertion arrow 295) between the block 283 and its LEDs 206 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 the substrate 282, there may, for example, be smaller back films that are each inserted between the block 283 and a respective one of the LEDs.
Another array member embodiment includes an opaque overlay 296 which is positioned (as indicated by positioning arrow 297) over the substrate 282. The overlay defines apertures similar to the apertures 205 of the substrate 282 and these apertures are positioned to each pass light emitted from respective one of the LEDs 206. Various overlay embodiments may be formed with masking processes (e.g., silk screening or the use of decals). The overlay 296 is configured to enhance the appearance of the array member.
Yet another array member embodiment includes epoxy coatings 298 (one is indicated by a broken-line ellipse) that are positioned over each LED 206. 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 ellipse 298 represents a holographic lens which is positioned proximate to the LEDs 206 to further enhance the appearance of the array member 280.
It is noted that various structures have been described above in
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 in
In an exemplary form, the display structure 303 is shaped to spell the word “open” and the display structure 304 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 the commodity 300, a power source (e.g., a battery or a permanent power source) would be switched to illuminate, at different times, a selected one of the display structures 303 and 304 to indicate the present status of something associated with the sign (e.g., a business).
The panel 304 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 the display structures 303 and 304 to thereby present a pleasing effect to the lighted sign. To further enhance the lighted sign, the commodity 300 may include a reflecting sheet 306 (e.g., a white sheet of paper, plastic or other thin material) positioned on one side of the panel 300 to thereby spread and redirect emitted light back through the panel.
Another lighted commodity embodiment is shown with front, side and back views of the lighted sign 310 of
Although the message 312 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 the front side 314, it may be carried on the back side 315 in other embodiments.
The light from the light display structure 316 is spread throughout the panel 311 and enhances the appearance of the message 312. Accordingly, this light display structure is arranged in a form (e.g., the serpentine form of
Another lighted commodity embodiment 320 is shown in
The tongue 323 and its associated display structure 324 may be removably coupled to the body 325 with first and second fasteners 321 (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 a battery 328 that powers the display structure 324. A switch 329 (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).
In
Another lighted commodity embodiment 350 is shown in
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 the first conductor 211 of
Although not explicitly shown in all of the lighted commodity embodiments of
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
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 of claim 1, wherein said first and second conductors are wire bonded to said first electrode and said exposed portion respectively.
3. The structure of claim 2, wherein said first and second conductors are wire bonded to said first substrate side.
4. The structure of claim 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 of claim 5, wherein said first and second conductors are wire bonded to said first and second electrodes.
7. The structure of claim 6, wherein said first and second conductors are wire bonded to said first and second substrate sides respectively.
8. The structure of claim 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 of claim 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 of claim 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 of claim 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 of claim 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 of claim 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 of claim 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 of claim 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 of claim 16, wherein said substrate defines at least one light redirector positioned to redirect light from a respective one of said diodes.
18. The structure of claim 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 of claim 16, further including at least one fastener that removably couples said substrate to said article.
20. The structure of claim 19, wherein said fastener is a zipper.
Type: Application
Filed: Jun 14, 2006
Publication Date: Nov 2, 2006
Applicant:
Inventor: William Ratcliffe (Thousand Oaks, CA)
Application Number: 11/453,470
International Classification: F21V 5/00 (20060101); F21W 121/06 (20060101); F21Y 101/02 (20060101);