U.S. patent application number 11/453470 was filed with the patent office on 2006-11-02 for light display structures.
This patent application is currently assigned to AGILIGHT, INC.. Invention is credited to William R. Ratcliffe.
Application Number | 20060245191 11/453470 |
Document ID | / |
Family ID | 34826745 |
Filed Date | 2006-11-02 |
United States Patent
Application |
20060245191 |
Kind Code |
A1 |
Ratcliffe; William R. |
November 2, 2006 |
Light display structures
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.
Inventors: |
Ratcliffe; William R.;
(Thousand Oaks, CA) |
Correspondence
Address: |
KOPPEL, PATRICK & HEYBL
555 ST. CHARLES DRIVE
SUITE 107
THOUSAND OAKS
CA
91360
US
|
Assignee: |
AGILIGHT, INC.
|
Family ID: |
34826745 |
Appl. No.: |
11/453470 |
Filed: |
June 14, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10773353 |
Feb 5, 2004 |
|
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11453470 |
Jun 14, 2006 |
|
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Current U.S.
Class: |
362/246 ;
257/E33.072; 362/103; 362/800 |
Current CPC
Class: |
H01L 33/62 20130101;
H01L 2924/0002 20130101; H01L 2924/00 20130101; G09F 9/33 20130101;
H01L 2924/0002 20130101; H01L 33/60 20130101 |
Class at
Publication: |
362/246 ;
362/103; 362/800 |
International
Class: |
F21V 5/00 20060101
F21V005/00; F21W 121/06 20060101 F21W121/06; F21Y 101/02 20060101
F21Y101/02 |
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.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] 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
[0002] 1. Field of the Invention
[0003] The present invention relates generally to light display
structures and lighted commodities that include these
structures.
[0004] 2. Description of the Related Art
[0005] 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
[0006] 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
[0007] FIGS. 1A and 1B are top and side views of a light display
structure embodiment of the present invention and FIG. 1C is an
enlarged view of another embodiment for structure within the curved
line 1C of FIG. 1B;
[0008] FIG. 2 is an enlarged isometric view of the light display
structure of FIGS. 1A and 1B that illustrates additional light
display structure embodiments;
[0009] FIGS. 3A-3D are views along the plane 3-3 of FIG. 1B that
illustrate additional light display structure embodiments;
[0010] FIG. 4 is an isometric view of the light display structure
of FIG. 3C which emphasizes its flexible, elongate form;
[0011] FIGS. 5A and 5B are views of additional light display
structures that can be carried on the structure of FIG. 4;
[0012] FIGS. 6A-6C are enlarged plan views of another light display
structure embodiment;
[0013] FIGS. 7A and 7B are enlarged views along the plane 7-7 of
FIG. 6B that illustrate additional light display structure
embodiments;
[0014] views along the plane 5-5 of FIG. 4B that illustrate
additional light display structure embodiments;
[0015] FIG. 8 is an enlarged view similar to FIG. 6B that
illustrates additional light display structure embodiments;
[0016] FIG. 9 is an enlarged view along the plane 9-9 of FIG. 8
that illustrates additional light display structure
embodiments;
[0017] FIG. 10A is a top view of another light display structure
embodiment embodiments;
[0018] FIG. 10B is a view along the plane 10B-10B of FIG. 10A;
[0019] FIG. 10C is a top view of another light display structure
embodiment;
[0020] FIG. 10D is a view along the plane 10D-10D of FIG. 10C;
[0021] FIG. 11 is a plan view of another light display structure
embodiment;
[0022] FIGS. 12A-12D are enlarged views of structural embodiments
within the curved line 12 of FIG. 11;
[0023] FIGS. 13A-13D are views that illustrate assembly of another
light display structure embodiment;
[0024] FIG. 14A is a plan view of another light display structure
embodiment;
[0025] FIG. 14B is a view along the plane 14B-14B in FIG. 14A;
[0026] FIG. 15A shows plan and side views of another light display
structure embodiment;
[0027] FIG. 15B is an isometric view which shows the embodiment of
FIG. 15A arranged in an array of similar embodiments; and
[0028] FIGS. 16-21 show light display structure embodiments in
association with different articles of merchandise
DETAILED DESCRIPTION OF THE INVENTION
[0029] FIGS. 1-21 illustrate advantageous light display structure
embodiments that can be economically fabricated and assembled.
[0030] Attention is initially directed to FIGS. 1A and 1B which
illustrate a display structure embodiment 20 for energizing at
least one light-emitting element 22. The structure includes first
and second spaced elongate conductors 24 and 25 and at least one
support member in the form of a spacer that is coupled and
positioned to support the spaced conductors.
[0031] 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.
[0032] 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
FIG. 1A. In another embodiment, the wall may have a substantially
parabolic shape to enhance redirection of the light.
[0033] In the structure embodiment of FIGS. 1A and 1B, each spacer
26 defines first and second walls 32 and 33 that diverge with
increasing distance from one side of their aperture 28 and third
and fourth walls 34 and 35 that diverge with increasing distance
from another side of their aperture 28. In one embodiment, the
spacer may include a base 38 that defines the aperture 28 and the
walls extend upward from the base.
[0034] As shown in FIG. 1B, the display structure may include a
polymer (e.g., a thermoplastic or a thermosetting polymer)
insulator 40 that encloses the second conductor 25. In this case,
the insulator preferably defines an opening 41 positioned to
facilitate contact between the light-emitting element and the
second conductor 25. The spacers 22 are positioned to space the
first and second conductors apart locally while the insulator 40
insures they do not contact elsewhere.
[0035] Although the light display structures of the invention may
carry various light-emitting elements, the structure 20 of FIGS. 1A
and 1B is especially suited to carry a light-emitting diode (LED)
which is received in the aperture 28 with its cathode in contact
with the second conductor 25 and its anode in contact with the
first conductor 24.
[0036] 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 FIG. 1A, the light radiates
from the junction so that some light rays 46 issue directly away
from the spacer 26B and other light rays 48 are redirected by the
walls 32-34 to also radiate away from the spacer 26B.
[0037] As shown in FIG. 1C, another display structure may apply
(e.g., by printing, transfer printing, silkscreening) an insulator
50 on the second conductor 25. The insulator is arranged (e.g., by
masking or by ablating) to define a gap or aperture 52 into which
the LED is received, i.e., the insulator 50 is configured to permit
coupling of the LED to the second conductor.
[0038] The enlarged isometric view 60 of FIG. 2 supplements FIGS.
1A and 1B. It shows a strip 62 that facilitates fabrication of the
spacers (26 in FIGS. 1A and 1B). The strip can be easily molded
from a polymer and has a base 38 that defines apertures 28 and
walls 30 that extend upward from the base. For example, the walls
may include the first and second walls 32 and 33 that diverge with
increasing distance from one side of their aperture 28 and the
third and fourth walls 34 and 35 that diverge with increasing
distance from another side of their aperture 28. Although not
required, the diverging walls preferably abut at their ends that
are proximate to their respective aperture. The walls terminate in
a back wall 63 and a top wall 64.
[0039] 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.
[0040] The strip 62 may be formed with a notch 68 that facilitates
separation of one spacer from an adjoining spacer. As shown in FIG.
2, various other strip embodiments may be formed. For example, the
spacer structure 70 defines two wall structures that face
oppositely to be operative with apertures 28A and 28B. In an
assembly process, spacers can be easily broken from the strip 62
(with aid, for example, from the notch 68) and spaced along the
first and second conductors as shown in FIGS. 1A and 1B.
[0041] 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, FIG.
3A (a view along the plane 3-3 of FIG. 1B) shows them enclosed in a
thermoplastic shrink tube 80 and FIG. 3B shows them enclosed by a
thermoplastic molded cover 82 (the spacer's back wall 63 is
indicated in each of these figures). In FIG. 3C, the cover 82 has
been modified to a cover 84 that defines a mounting surface 85 that
can abut, for example, a floor or wall.
[0042] In FIG. 3D, the cover 82 of FIG. 3B has been modified to a
cover 86 that defines a pair of protrusions 87 in addition to
defining the mounting surface 85 of FIG. 3C (the protrusions appear
as outward-extending ribs when envisioned in the elongate structure
90 of FIG. 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
in FIG. 2).
[0043] In FIG. 3E, the cover 82 of FIG. 3B has been modified to a
cover 88 that defines a mounting flange 89 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).
[0044] Structures such as those of FIGS. 3A-3E can be used to form
elongate light display structures such as the structure 90 of FIG.
4 which can be bent into various forms and which radiates light
laterally when a voltage is placed across the first and second
conductors 24 and 25.
[0045] Transparent or translucent decorative FIG. 92 can be molded
in various forms that slide onto (or snap over) the structure 90 as
shown in FIG. 5A. Alternatively, a decorative FIG. 94 can include a
hinged member 95 (a non-engaged position is shown in broken lines)
which facilitates its installation over the structure 90 as shown
in FIG. 5B.
[0046] FIGS. 6A-6C illustrate another display structure embodiment
100 for carrying at least one light-emitting element 22. As shown
particularly in FIG. 6A, a spacer 102 is shaped to define an array
of apertures 22 and also to define an array of cup-shaped walls 104
that each surround a respective one of the apertures. FIG. 6B shows
an array of light-emitting elements 22 that are each received in a
respective one of the apertures. FIG. 6B also shows a plurality of
first conductors 24 that each contact a first side of a selected
group of the light-emitting elements 22. These conductors are also
shown in FIG. 7A which is an enlarged view along the plane 7-7 of
FIG. 6B.
[0047] In particular, FIG. 7A shows the spacer 102 positioned to
space the first and second conductors 24 and 25 with a
light-emitting element received in an aperture to contact the first
and second conductors. The second conductor 25 may comprise a
plurality of elongate conductors (similar to the first conductors
24 in FIG. 6B) or may comprise a conductive sheet that contacts all
of the light-emitting elements of FIG. 6B.
[0048] 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 FIG. 7A.
[0049] The first conductors 24 of FIG. 6B are shown to have a
linear form but this is one of many possible embodiments. FIG. 6C,
for example, shows a first elongate conductor 24A 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.
[0050] The cup-shaped wall 104 of FIG. 7A is shown to have a
concave shape which may be substantially parabolic to enhance the
redirected radiation. FIG. 7B is similar to FIG. 7A with like
elements indicated by like reference numbers. Similar to the spacer
102 of FIG. 7A, a spacer 110 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-emitting elements 22 as it
contacts respective ones of the first and second conductors.
[0051] 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 FIG. 7A. Also the spacer 110
spaces the first and second conductors apart without completely
filling the space between these conductors. Instead, the spacer 110
comprises a sheet that is formed to define the cup-shaped wall 112
and to contact the second conductor 25 locally and contact the
first conductor 24 in other regions.
[0052] FIG. 8 illustrates another light-emitting structure 120
which is similar to the structure 100 of FIG. 6B with like elements
indicated by like reference numbers. The structure 120, however,
includes a substantially-transparent sheet 122 formed of a suitable
polymer (e.g., mylar). The first conductors 24 can be bonded to the
sheet 122 and the sheet is then placed to bring these conductors
into contact with their respective light-emitting elements 22.
[0053] As shown in FIG. 9 (a view along the plane 9-9 of FIG. 8),
the sheet 122 and its first conductors 24 may be locally shaped to
form dimples 124 that enhance contact between the conductors and
their respective light-emitting elements 22. In another
light-emitting structure embodiment, the sheet 124 may carry
photoluminescent films 126 (e.g., phosphor films, conjugated
polymer, organic phosphor). In operation of this embodiment, light
rays 128 from the light-emitting element 22 are redirected by the
cup-shaped wall (104 in FIG. 8) to strike the phosphor films. In
response to this excitation, the luminescent films emit light rays
130. Different luminescent films may be used to selectively display
different colors.
[0054] 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).
[0055] 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 FIG.
2 where a resistive member 136 (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 the LED 22 and
the first conductor 24 (the insertion is indicated by insertion
arrow 138--e.g., the member can be carried over the anode).
Alternatively, the resistive member may be inserted between the
cathode of the LED 22 and the second conductor 25.
[0056] 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.
[0057] 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.
[0058] FIGS. 10A-10D illustrate other light display embodiments of
the present invention. In particular, FIG. 10 A shows a light
display embodiment 140 in which the first and second conductors 24
and 25 are arranged (e.g., side by side) to facilitate the
insertion of wire bonds 142 that couple a selected one of the anode
and cathode surfaces (wherein the anode surface has been selected
in FIG. 10A) of LEDs 22 to the first conductor 24.
[0059] As shown in FIG. 10B, a resistive member 136 (introduced in
FIG. 2) is preferably inserted between the LED 22 and the wire bond
142. In addition, the LED's anode and cathode (and the resistive
member 136) may be joined to the wire bond 136 and the second
conductor 25 with conductive elements 65 and 66 (also introduced in
FIG. 2).
[0060] FIG. 10C illustrates a light display embodiment 160 that is
similar to the embodiment 140 of FIG. 10A with like elements
indicated by like reference numbers. In this embodiment, however,
the first conductor 24 is modified to a conductor 164 which defines
a plurality of tabs 166. Each of the LEDs 22 is then coupled
between the second conductor 25 and a respective one of the tabs
166. FIG. 10D is similar to FIG. 10B except that the conductor 164
and its tab 166 is substituted for the first conductor 24 and the
wire bond 142.
[0061] The light display embodiments of FIGS. 10A-10D may also be
enclosed with various substantially-transparent structures to form
elongate radiating elements. In FIGS. 3A-3D, for example, they can
be substituted for the light display embodiments of FIGS. 1A-1C and
2 (which are represented in FIGS. 3A-3D by first and second
conductors 24 and 25 and a spacer's back wall 63).
[0062] The light display structure embodiments shown in FIGS. 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).
[0063] The spacers (e.g., 26, 102) shown in various ones of the
figures, the insulator 40 of FIG. 1B, the tube 80 of FIG. 3A, the
cover 82 of FIG. 3B and the transparent sheet 122 of FIGS. 8 and 9
can be fabricated from various insulators such as polymers (e.g.,
polyimide and mylar). The first and second conductors (24 and 25 in
FIG. 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.
[0064] In an exemplary display embodiment, the photoluminescent
films 126 of FIG. 9 may include conjugate polymers and organic
phosphors that are excited, for example, by blue LEDs to thereby
cause the redirected light rays 130 to be substantially white.
[0065] FIG. 11 illustrates another light display structure in the
form of a flexible light wire 200 which can provide an extensive
set of light source embodiments 202 that are spaced along a
substrate 204 which is preferably formed from a flexible material
(e.g., a polymer). FIG. 12A is an enlarged view of the area 12 in
FIG. 11 and FIG. 12B is a sectioned side view of the structure of
FIG. 12A. These figures show that an embodiment 202A of the light
source is formed with the aid of apertures 205 in the substrate
204. Received within each aperture is a light-emitting element
which, in this embodiment, is an LED 206 that has a light-emitting
junction 44 defined by abutted upper and lower electrodes 207 and
208 (a more general designation of the structures previously
referred to as anode and cathode).
[0066] 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.
[0067] 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.
[0068] 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.
[0069] 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 FIGS.
12A and 12B between the bonds 221 and 223 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.
[0070] FIGS. 12C and 12D show another light source embodiment 202B
that is similar to the light source 202A of FIGS. 12A and 12B with
like elements indicated by like reference numbers. In contrast,
however, a portion 225 of the upper electrode 207 is broken away to
expose a portion of the lower electrode 208. This permits the
second conductor 212 to be moved from its location in FIG. 12B
(i.e., adjacent the lower substrate surface) to join the first
conductor 211 adjacent the upper substrate surface. In FIG. 12C,
accordingly, the second conductor 212 is now wire bonded to the
upper substrate surface and to the exposed portion of the lower
electrode 208.
[0071] From FIGS. 11-12D, it is thus apparent that the structures
of the light wires 202A and 202B facilitate a rapid, economical
fabrication process. Once fabricated and installed, an energy
source (e.g., battery) can be placed across the first and second
conductors 211 and 212 to simultaneously energize each LED 206
along the light wire so that it emits light 226 as shown in FIGS.
12B and 12D. The substrate 204 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 the light wire 200 of
FIG. 11.
[0072] 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.
[0073] In another light source embodiment, a resistive member 230
(similar to resistive member 136 introduced with respect to FIG. 2)
is inserted in FIG. 12B between a second bond 222 and the upper
electrode 207 of the LED 206 as indicated by insertion arrow 232.
The resistive member facilitates control of the emitted light 226.
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 emitted light
226.
[0074] 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 FIGS. 12C and 12D. In
these latter embodiments, the resistive members will abut the upper
electrode and/or the exposed portion 208 of the lower
electrode.
[0075] It is noted that FIGS. 12B and 12D show the LED 206 and the
substrate 204 to have substantially-similar heights or thicknesses.
In other light display embodiments, however, they may differ. For
example, the thickness of the substrate 204 may be reduced so that
the LED junction 44 is above the substrate which may enhance
emission of the light 226.
[0076] FIGS. 13A-13D illustrate another light display structure in
the form of a light bulb 240 (shown in 3 orthogonal views in FIG.
13D) which is formed with a light wire 242 that provides a set of
light sources 202C that are spaced along a polymer substrate 244
(shown, for example, in FIG. 13A). The polymer substrate 244 is
similar in composition to the polymer substrate 204 in FIG. 11 but
its form differs as it has a cross-like shape which includes legs
245 that couple to a longer leg 246. A first conductor 211 runs
through some of the light sources 202C and is coupled to an
orthogonal conductor 247 which runs through the other light sources
202C.
[0077] FIG. 13B illustrates an elongate metallic heat sink 250 in
association with the light wire 242. This figure shows the legs 245
and the longer leg 246 in a fabrication process wherein they are
being bent so that they can each run down a respective side of the
heat sink 250. As shown in FIG. 13C, this process has been
continued until each of the legs (e.g., the legs 245) are in
contact with the sides of the heat sink 250.
[0078] The light source 202C is similar to the light source 202A of
FIG. 12A with like elements indicated by like reference numbers. In
contrast to the light source 202A, however, the light source 202C
lacks the second conductor 212 of the light source 202B. Instead,
the heat sink 247 abuts the electrode 208 of the LED to serve as an
electrical connection to this electrode and to also provide a
conduction path which transports heat away from the light sources
202C.
[0079] The first conductor 211 can be installed with a wire bonding
process similar to that introduced with reference to FIG. 12A. For
example, FIG. 13C shows first, second and third bonds 221, 222 and
223 that can be successively installed to secure the first
conductor respectively to one of the substrate legs 245, the upper
electrode 207 and another of the substrate legs 245.
[0080] 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 FIG. 13D. In this arrangement, the
conductor 211 is electrically connected to one of the base 261 and
the bulb terminal 262 (that is surrounded by the base) and the heat
sink 250 is electrically connected to the other. A voltage across
the base and terminal is communicated via the first conductor 211
and the heat sink 250 to energize the LED in each of the light
sources 202C. In response, each of the LEDs radiates the light 226
shown in FIG. 13C. The lifetime of the LEDs is substantially
enhanced because heat is rapidly carried away from them along the
conduction path provided by the heat sink 250.
[0081] FIGS. 14A and 14B illustrate another light display structure
in the form of a segmented display 270 which is formed with light
wires 271 that each provides a plurality of light sources 202D. The
display is formed with first conductors 211, a substrate 271, and a
plurality of electrically conductive ground planes 272. The
substrate defines a plurality of apertures 205 and each of a
plurality of LEDs 206 is received within a respective one of the
apertures.
[0082] 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 FIG. 13C except that the substrate, 245 is replaced with the
substrate 271 and the heat sink 250 is replaced by a ground plane
272.
[0083] In FIG. 14A, the first conductors 211 bear the designations
of A through G. As shown, each of these conductors can be wire
bonded to the substrate 271 and wire bonded to the upper electrode
of a respective LED in each of the sets 273. In each set, the LEDs
are arranged as segments of a number. The conductor labeled A is
wire bonded to the upper LED 206 in each of the sets 273, the
conductor labeled B is wire bonded to an upper left LED 207 in each
of the sets 273 and so on for the rest of the conductors 211.
[0084] 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.
[0085] 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.
[0086] 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.
[0087] 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.
[0088] FIG. 14B is a view along the plane 14B-14B of FIG. 14A. This
sectional view shows one of the ground planes 272 abutting the back
of the substrate 271 and one of the LEDs 206 within an aperture
205. In another light display embodiment, the surface 272S of the
ground plane 272 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 emitted light 226 of the LED 206.
[0089] 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.
[0090] As further shown in FIG. 14B, each LED 206 may be covered
with a light-enhancing member 279. 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
emitted light 226. In another embodiment, the light-enhancing
member may be a holographic member that alters and enhances the
appearance of the emitted light 226. 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 the sets 273 of LEDs, these holographic members
may be oriented in different directions to obtain different
holographic effects in the LEDs of that set.
[0091] FIG. 15A illustrates side and front views of another light
display structure in the form of an array member 280 which is
formed with first conductors 211, a substrate 282, a conductive
block 283 and a plurality of insulated metallic pins 284. The block
283 contacts the lower surface of the substrate 282 and the lower
electrode of each of LEDs 206 that are received in the apertures
205 of the substrate 282. The insulated pins 284 extend through the
substrate and the block so that they are accessible at each side of
the combined substrate and block.
[0092] Each first conductor 211 can be installed with a wire
bonding process similar to that introduced with reference to FIG.
12A. For example, the first, second and third bonds of FIG. 12A can
be used in a similar manner to successively secure a first
conductor 211 to one of the pins 284, the upper surface of the
substrate 282, and to the upper electrode of a corresponding one of
the LEDS 206. Light sources 202E are thus formed which are each
similar to the light source 202C of FIG. 13D except that the
substrate 244 is replaced with the substrate 282 and the heat sink
250 is replaced by the conductive block 283.
[0093] 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 FIG. 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 the pins 284. 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.
[0094] The structure of the array member 280 of FIG. 15A is
particularly suited for use in a light display array 290 that is
shown in FIG. 15B. The array is formed by arranging a plurality of
the array members 280 in an array relationship which is indicated
by broken lines 292. Although only one array member 280 is shown in
FIG. 15B, each of the spaces defined by the broken lines 292 would
be filled with a respective one of the array members.
[0095] Because of the structure shown in FIG. 15A, the array
members 280 can be tightly arranged in FIG. 15B with their pins 284
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 the blocks
283. Various light patterns can be displayed by placing potentials
on selected ones of the pins 284. The blocks 283 may be formed from
any material (e.g., a metal) that is electrically and thermally
conductive.
[0096] 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.
[0097] 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.
[0098] 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.
[0099] 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.
[0100] It is noted that various structures have been described
above in FIGS. 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.
[0101] 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 FIGS. 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 in FIGS. 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.
[0102] FIG. 16, for example, shows a lighted commodity embodiment
300 that is particularly suited for forming lighted signs. It
includes a panel 302 and light display structures 303 and 304
carried on the panel. The display structures are formed with first
and second conductors (22 and 24 in FIG. 1A), spacers (26 in FIG.
1A) and light-emitting elements (22 in FIG. 1A). For simplicity of
illustration, the first and second conductors of the display
structure 303 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. The display structure 304
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.
[0103] 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).
[0104] 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.
[0105] FIG. 17 is a view along the plane 17-17 in FIG. 16 which
shows another commodity embodiment in which an edge of the panel
302 is shaped to define a channel 307 which receives another
display structure 308. The channel 307 and display structure 308
may run along a portion of or all of the perimeter of the panel
302. The channel can be shaped in forms (e.g., a parabola) that
facilitate passage of emitted light through the panel 302 to
thereby further enhance the appearance of the lighted sign. In
addition, a reflective sheet 309 (similar to the reflective sheet
306) may be positioned to cover the groove and further redirect
light through the panel. Although the reflective sheets 306 and 309
are slightly spaced from the panel 302 in FIGS. 16 and 17 to better
delineate them, they would generally abut the panel.
[0106] Another lighted commodity embodiment is shown with front,
side and back views of the lighted sign 310 of FIG. 18. This sign
includes a panel 311 and a message 312 that is carried on either
the front side 314 of the panel or on the back side 315. Similar to
the panel 304 of FIG. 16, the panel 311 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 a light display
structure 316 which is preferably carried on the back side 315.
[0107] 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.
[0108] 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 FIG. 18) that effectively
illuminates the panel 311. A diffusing sheet 318 may be inserted
between the panel 311 and the display structure 316 to diffuse the
structure's light and further enhance the appearance of the lighted
commodity 310.
[0109] Another lighted commodity embodiment 320 is shown in FIG. 19
to be a shoe 322 and a light display structure that is carried on
the shoe. For example, the shoe includes a tongue 323 and a light
display structure 324 that is carried on the tongue. For another
example, the shoe has a body 325 and a light display structure 326
that is carried on the body. It is noted that the laces of the shoe
322 are schematically shown over the tongue and on the body.
[0110] 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).
[0111] In FIG. 19, another light display structure 330 is carried
on a removable body portion 332. In particular, the example arrow
334 is associated with a portion of the boundary between the body
325 and the body portion 332 and indicates that this portion can be
removably coupled to the body with a fastener in the form of a
zipper 334. This fastener facilitates the replacement of this body
portion with another body portion that carries a different display
structure.
[0112] FIG. 20 illustrates another lighted commodity embodiment 340
which is formed with a clothing item 342 (in particular, a T shirt)
and a light display structure 344 that is carried on the clothing
item.
[0113] Another lighted commodity embodiment 350 is shown in FIG. 21
to be formed with a container 342 (in particular, a bottle) and a
light display structure 344 that is carried on the container.
[0114] 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 FIGS. 12A and 12B
between the bonds 221 and 223 are formed with wire bonding
processes and the other path segments of the first conductor are
formed with printed circuit processes.
[0115] Although not explicitly shown in all of the lighted
commodity embodiments of FIGS. 16-21, their light display
structures may be activated with a battery (e.g., the battery 328
of FIG. 19) and this activation may be accomplished with a switch
(e.g., the switch 329 of FIG. 19). Alternatively, they may be
activated with other power sources (e.g., permanent power sources)
that are spaced away from the lighted commodity embodiments.
[0116] 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
* * * * *