ES2615177T3 - LED backlight system for luminous sign - Google Patents

Abstract

A backlighting system (100) for an illuminated sign comprising: an enclosure including a front lettering face and a rear section; a plurality of panels each including (104): a plurality of light emitting diodes ("LEDs") (106) affixed to the panel, wherein the distance each LED is from the lettering face of the enclosure divided by the distance between the subject LED and the nearest adjacent LED provides a ratio of less than 1.4, and an integrated circuit (108); and a cable wherein the cable physically connects adjacent panels and characterized in that the plurality of panels are each affixed to one or more rails (110).

Description

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DESCRIPTION

LED backlight system for luminous sign Background

The present exemplary embodiments refer to a backlight system. Find particular application in conjunction with the sign industry. A particular application for said backlight system is a light sign, and will be described with particular reference thereto. However, it will be appreciated that the present example embodiment can also be arranged for other similar applications.

At the present time, large luminous signs currently use fluorescent lamps and ballasts as lighting systems. These types of systems are labor intensive and costly to maintain. Frequently the lamps need to be replaced in a year or two at most. Given a typical location of the light sign and the size of the lamps, it is often necessary to use a truck with a lift basket or other equipment not readily available to repair the sign. Alternatives previously proposed for a backlight system for a light sign include a linear array of light emitting diodes or a perimeter lighting apparatus. However, for several reasons, these options have not obtained any significant commercial success as an alternative to the aforementioned fluorescent backlight system.

US 6,167,648 discloses a sign that can be illuminated that includes a number of illumination modules arranged on an electrical circuit so that they can be disconnected, removed individually and adjusted position between the conductors. Preferably, the illumination modules can slide over the conductors while remaining in electrical contact to provide illumination where specifically required. The connections between the modules and the conductors can be such that the modules slide over the conductors. Said connectors can be snap fit on connectors or they can be insertable tips inside helical springs around the conductors so that the compression of the springs increases the diameter of the springs to allow them to slide over the conductors and the lack of compression allow the springs to grip the tips firmly.

US 2003/0031032 discloses a module of light emitting diodes for fixing to a surface of a sign, which includes a mounting plate having upper and lower surface, a plurality of light emitting diodes mounted on the upper surface of the mounting plate, a housing having upper and lower surface, a first electrical connector fixed to the lower surface of the mounting plate and electrically connected to the plurality of light emitting diodes, a second electrical connector fixed to the upper surface of the housing for coupling with the first electrical connector, a third electrical connector fixed to the housing and electrically connected to the second electrical connector, and a power source to provide a voltage to the third electrical connector. Since the lower surface of the mounting plate is placed on the upper surface of the housing, the first electrical connector is coupled with the second electrical connector for electrically connecting the plurality of light emitting diodes to the third electrical connector. Alternatively, the mounting plate could be integrally formed as part of the housing, and the first and second electrical connectors omitted.

US 6,505,956 discloses a reel LED lighting system that has a plurality of nidged circuit cards, each circuit card having a plurality of light emitting diodes scattered on one side thereof, the diodes being electrically connected between positive and negative terminals of their respective circuit card, the circuit cards being electrically connected in parallel between sf and structurally connected in series with each other by a plurality of pairs of flexible conductors connecting the positive and negative terminals of the circuit boards , the structural series connection providing a chain of circuit boards and conductors, the chain being specially wound around a coil of a reel for each dispersion inside and fixed to a lighting housing.

US 2005/0231943 discloses a channel letter illumination system in accordance with the present invention comprising a channel letter housing with a translucent channel letter cover. A plurality of lighting units electrically connected to the channel letter housing are mounted and the conductors provide an electrical signal to each of the units. Each of the units comprises a lighting unit housing and a printed circuit board (PCB) mounted inside said housing. The PCB has a plurality of light emitting elements, such as light emitting diodes, with the electrical signal applied to the light emitting elements causing them to generate light substantially out of the housing. The PCB conducts and dissipates heat from the light emitting elements, traditionally the unit comprises a space between most of the PCB and the housing of the lighting unit to allow heat from the PCB to dissipate into the surrounding environment. A mounting mechanism is included for each unit to the channel letter housing.

US 2005/0207151 discloses an LED light engine that includes a flexible electric cable and a plurality of LEDs. The flexible electrical cable includes a first, second and third electrical conductors and an electrical insulator that covers the electrical conductors. The conductors are arranged substantially parallel to each other

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having an insulating material between them. A first LED that includes a first cable is electrically connected to the first electrical conductor and a second cable of the first LED is electrically connected to the second conductor. A second LED includes a first cable electrically connected to the second electrical conductor and a second cable electrically connected to the third electrical conductor. A third LED includes first and second cables electrically connected to the second conductor. The third LED stands between the first LED and the second LED. US 2005/0122293 discloses an LED string that is formed from link units connected by pairs of wires in the electrical circuit. At least one pair of cables is connected to a link unit to form external power cables. Each link unit is made of a PCB tray in the housing, and the LEDs mounted on the PCB in electrical connection with the cable pairs. A cured water-tight resin inside the housing tray encloses the printed circuit board, the connection point of the cable pair to the PCB and the lower half of the light emitting diode elements.

Short description

Aspects of the invention are defined in the appended claims. The present invention discloses a backlight system for a light sign comprising: an enclosure that includes a front labeling face and a rear section; a plurality of panels including each panel: a plurality of light emitting diodes ("LEDs") fixed to the panel, in which the distance at which each LED from the labeling face of the enclosure divided by the distance between the subject LED and the nearest adjacent LED provides a ratio of less than 1.4, and an integrated circuit; and a cable in which the cable physically connects adjacent panels and characterized in that the plurality of panels are fixed to each of one or more rails.

Brief description of the drawings

FIGURE 1 is a front view of an embodiment of a backlight system for a light sign described herein,

FIGURE 2 is a front view of a panel that can be used as part of the backlight system as described herein;

FIGURE 3 is a front view of a basic plate that can be included as part of a panel; FIGURES 4 and 5 are side views of a panel that includes a cover mold; FIGURE 6 is a front view of another example of the backlight system;

FIGURE 7 is an example of a backlight system described herein in conjunction with the light sign frame;

FIGURE 8 is a side view of an example of a column of panels that are collapsible;

FIGURE 9 is a partial view of a backlight system that includes the collapsible panel column

of FIGURE 8;

FIGURE 10 is another example of the backlight system that includes a rectangular embodiment of the panels;

FIGURE 11 is a front view than another example of a panel that can be used in the backlight system disclosed herein;

FIGURE 12 is a column of the panels disclosed herein;

FIGURE 13 is an example of a column of panels as shown in FIGURE 12, which are wound in such a way that it can be easily packaged;

FIGURE 13a is an example of a column of panels as shown in FIGURE 12 that fold over each other;

FIGURE 14 is an example of two columns of panels that stack one column on top of another column; FIGURE 15 is an additional example of a panel;

FIGURES 16-19 represent alternatives of how power can be supplied to a panel as well as between panels in the same column and between different columns of panels;

FIGURES 20 and 21 illustrate alternatives of how the backlight system disclosed herein can be used on double-sided signs;

FIGURES 22A-F represent several supports that can be used with the backlight system panels;

FIGURE 23 is an example of a light sign that includes a backlight system as disclosed herein;

FIGURE 24 is an example of a light sign that includes a double matrix backlight system as described herein;

FIGURE 25 is a rectangular panel that includes a cover mold;

FIGURE 26A illustrates a three LED module that is coupled to a bridge, according to an example; FIGURE 26B illustrates a modular electrical connection of the lighting system, according to an example; FIGURE 26C illustrates a connection element to allow a second light module to be attached to the lighting system, according to an example;

FIGURE 26D illustrates a simple matrix lighting system, according to an example; FIGURE 26E illustrates a double matrix lighting system, according to an example; FIGURE 27A illustrates a six LED module, according to an example;

FIGURE 27B illustrates a simple matrix using the module of six LEDs, according to an example;

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FIGURE 27C illustrates a double matrix using the six LED module, according to an example; FIGURE 28A illustrates an alternative six LED module lighting system, according to an example; FIGURE 28B illustrates an optional cable passage through the realization of the lighting system of the six LED module, according to an example;

FIGURE 28C illustrates a simple matrix using the alternative six LED module, according to an example;

FIGURE 28D illustrates a double matrix using the alternative six LED module, according to an example;

FIGURE 29A illustrates an alternative six-LED module lighting system, according to an example; FIGURE 29B illustrates the electrical connectivity of the six LED module of FIGURE 29A, according to an example;

FIGURE 29C illustrates a simple matrix using the six LED module of FIGURE 29A, according to an example;

FIGURE 29D illustrates a double matrix using the six LED module of FIGURE 29A, according to an example;

FIGURE 30A illustrates a three LED module with a joint fixing joint, according to an example;

FIGURE 30B illustrates an embodiment of the three LED module for delivery, according to an example; FIGURE 30C illustrates a simple matrix using the three LED module, according to an example; FIGURE 30D illustrates a double matrix using the three LED module, according to an example; FIGURE 31A illustrates a top view of the LED panel in the form of a fabric, according to an example;

FIGURE 31B illustrates a bottom view of an LED panel in the form of a framework, according to an example;

FIGURE 32 illustrates a top view of a cover mold LED module in the form of a framework, according to an example;

FIGURE 33A illustrates a top view of an LED module in the form of a framework, according to an example;

FIGURE 33B illustrates a bottom view of an LED module in the form of a framework, according to an example;

FIGURE 33C illustrates an exploded view of an LED module in the form of a framework, according to an example;

FIGURE 34A illustrates a top view of a PCB assembly used with an LED panel, according to an example;

FIGURE 34B illustrates a bottom view of the PCB assembly used with an LED panel, according to an example.

Detailed description

In the description of various embodiments of the backlight system, equal elements of each embodiment are described by using the same or similar reference numbers.

An embodiment disclosed herein includes a plurality of panels comprising the backlight system. Each panel includes a plurality of LEDs. Preferably, the LEDs are separated from each other on the same panel and in the same way in relation to the LEDs on adjacent panels so that the backlight system will exhibit lighting qualities similar to those of a fluorescent backlight system. The LED backlight system will present uniformity, brightness and color reproduction consistent with that of a fluorescent backlight system.

Referring to FIGURE 1, a front view of the backlight system, 100, for a light sign is illustrated. The system 100 shown includes a frame 102 and a plurality of panels 104. The panels 104 are fixed to the frame 102 in a plurality of rows as shown. Alternatively, panels 104 may be attached to frame 102 in a plurality of columns instead of rows. Individual panels 104 are not limited to any particular size. Since typically a sign box is square or rectangular, a particularly useful panel size is 30.5 cm x 30.5 cm [1 foot x 1 foot]. The manufacturers of luminous signs can find this panel of desirable size because it can be used to make lighting systems for luminous signs of various sizes. Typically, the light sign has a sign surface that has a sign area less than about 18.6 m2 [200 square feet]. In various embodiments of the sign, the surface area of the sign can vary from about 0.362 m2 to about 18.6 m2 [from about 4 to about 200 square feet]. Alternatively, if a flexible material (for example a vinyl-based material, etc.) is used for the face of the display case, the surface area of the sign may be much larger than 18.6 m2 [200 square feet].

Such an approach can be used to allow the face of the showcase to withstand excessive wind loads.

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Alternatively, as shown in FIGURE 11, the panels 104 may be rectangular in shape. The panels 104 are not limited to any particular shape or size. The panels 104 are represented in rectangular and square shapes due to the reason that it is believed that these are the desirable shapes for sign makers. Panels that have other shapes can be manufactured, if desired by an end user. Panels of different shapes and sizes can also be used on the same luminous sign.

In one embodiment, panel 104 may be a printed wiring card. The printed wiring card may be one selected from a group of a printed circuit card, a metal-based printed circuit card, and a flexible circuit. The flexible circuit may include a substrate plate. Two examples of preferred materials for the substrate plate include aluminum or plastic. Flexible circuits are available at least from the following sources: Minco of Minneapolis, MN, Allflex Inc. of Northfield, MN, and Unifilex Circuits of San Jose, CA. In another embodiment, the printed wiring card may include the LEDs connected together with a cable in the form of a strip and then the strip is fixed to a substrate. Typically, the substrate can be made of aluminum or plastic.

As shown in FIGURE 2, each panel 104 includes a plurality of light emitting diodes ("LEDs") 106. The LEDs 106 can be arranged in any particular pattern on the panel 104. Also, the number of LEDs 106 on each panel It may vary or it may be uniform. In a particular embodiment, each LED 106 is not separated more than 10.2 cm [4 inches] from one or more adjacent LEDs. In another embodiment, the separation of the LEDs can be determined by a depth factor of the sign box. This is the ratio of the distance at which the LED of the signage face of the light sign ("depth") is divided by the distance between the nearest adjacent LEDs and the subject LED. For example, if the subject LED is separated 10.2 cm [4 inches] from the nearest adjacent LED and the depth of the LED below the sign is 10.2 cm [4 inches], the factor is 1. In another example if the distance between adjacent LEDs remains the same but, the depth is changed to 10.7 cm [5 inches], the factor is 1.25. In a further example, the adjacent LEDs are approximately 15.2 cm [6 inches] apart between sf and the depth is approximately 20.3 cm [8 inches], the depth factor of the sign box is approximately 1, 33.

In a particular embodiment, a preferred factor is less than about 1.4. In another particular embodiment, the factor may vary from about 1.25 to about 0.5. In a further embodiment, the LEDs can be randomly or uniformly separated from each other. In another embodiment, each LED is substantially equally separated from its adjacent LEDs.

Any suitable type of LED can be used in conjunction with panel 104. Examples of typical types of LEDs that can be used include surface mount LEDs and through hole LEDs. Panel 104 is not limited to a particular number of LED 106. Any desired number of LEDs can be used. A typical panel 104 may have any between four (4) to twelve (12) LEDs associated with it.

In addition to various types of LEDs that are suitable, LED 106s must not have any specific power requirements. In a particular LED application 106 the power may be 1 W or 0.5 W. As for panel 104, in a particular embodiment it is preferred that the light emitted by LEDs 106 on panel 104 has a brightness of up to about 1500 nits (candles per square meter), measured on the outer surface of the signage face of the sign.

Panel 104 may also include one or more integrated circuits 108. Integrated circuits 108 may be used to control LEDs 106 on panel 104. In addition to panel 104 that includes circuit 108, panel 104 may include one or more protection elements of the LED. These are elements that can protect the LED diode that makes physical contact with another tangible item. In one example, the protection element may comprise a ring-shaped cone on the surface of the panel 104 in which the LED 106 is in the center of the lowered part of the cone. In a second embodiment, the protective element may be a clear plastic cover on the top of the diode of each LED.

Also illustrated in FIGURE are 2 panels 104 that can be fixed to one or more rails 110. The rails can be constructed from any material that is known to be suitable for use as a heat sink; Non-limiting examples include aluminum and natural graphite. The panels 104 can be fixed by any known fixing technique. As illustrated the panels 104 are fixed by the use of screws 112. Optionally, the panels 104 can be fixed to rails 110 or can be fixed in an adjustable way to rails 110, as shown. The rails 110 can be fixed to the frame 102 by any known fixing technique. In another embodiment, the panels 104 may include one or more integral or fixed beams that coincide with a portion of rails 110 and allow the panels 104 to move easily along the rails 110.

As illustrated, the rails 110 can be fixed in an adjustable manner to the frame 102 by using a clamp element, 114. Alternatively, other adjustable fasteners can be used instead of the clamp member 114 or fixed fasteners can be used instead of the clamp element 114. The panels 104 can be uniformly separated or randomly separated. In a particular embodiment the separation between any two adjacent panels 104 adjustablely fixed on the same rail 110 may

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adjust to a desired distance. Panel 104 may also include one or more terminals 116. The terminals may be used to connect two (2) adjacent panels 104 together.

A front view of an embodiment of an optional component of panel 104 is shown in FIG. 3. As illustrated in panel 104, it may include a basic plate 105. Optionally, the basic plate 105 includes one or more openings 118. Preferably, the openings 118 are sized and separated so that they do not detract from the structural integrity of the panel 104 but at least improve the ability of the panel 104 to transfer heat to the outside from the LEDs and optionally also the resistance of a basic plate 105. The openings 118 can be oriented uniformly or randomly on panel 104. Examples of preferable building materials for the basic plate 105 include steel, steel alloys, aluminum, aluminum alloys, natural graphite, extruded plastic, any other material that can be used as a heat sink and have sufficient structural integrity, and combinations thereof.

As shown in FIGURE 4, the panel 104 may include a thin ceramic coating 120 that encapsulates the basic plate 105. The panel 104 may also include a cover mold 122. Preferably, the cover mold 122 is made of a resistant material. meteorologically and has a transparent upper surface. Examples of materials that can be used to make the cover mold 122 include silicone, epoxy, or a plastic extrusion. Plastic extrusion can be formed from thermoplastic elastomers (thermoconductors or non-thermoconductors), polyvinyl chloride, acrylic, polyethylene (high density or low density), polypropylene, polystyrene and ABS. The cover mold 122 may be fixed to an upper surface of the panel 104 or, alternatively, may be fixed to a lateral or lower surface of the panel 104, as shown in FIGURE 5. Additionally, the panel 104 may include one or more optional feet 125 . Preferably, the feet 125 extend separated from the panel 104 from a lower side of the panel 104. Preferably, the cover mold 122 does not cover an upper surface of the LEDs 106.

Specific preferred combinations of panel 104 and cover mold 122 include a printed circuit board panel and a plastic or silicone cover mold, a metal coated circuit card and a plastic or silicone cover mold, and a circuit flexible on an aluminum or plastic substrate and a plastic or silicone cover mold. The plastic can be a thermoplastic elastomer or other suitable polymer that can be formed as a plastic.

In a method of applying a cover mold material to the panel 104, the panel 104 may include openings and pins may be used to keep the panel 104 in a fixed position during the covering molding process. If desired in a second embodiment, the openings used may be filled in a molding step of the separate cover or the holes may be filled with a filler.

Alternatively, panels 104 can be encapsulated together in a plastic lace housing. The housing may include front and rear connection sections that can be used as an enclosure to protect the card. It is preferred that the front section of the housing includes openings aligned with the LEDs 106 for the emission of the light generated by the LEDs 106.

The cover mold 122 or the housing can be used to connect a plurality of panels 104 having a one-dimensional matrix to form a panel having a two-dimensional matrix. For example, the coverage of two or more panels 104R, such as that shown in Figure 10, may be molded to form a composite panel having the LEDs arranged in two dimensions. The resulting panel will have an orientation similar to that of panel 104L, shown in Figure 12. Alternatively, a housing can be used to form a plurality of panels 104R having a one-dimensional matrix in a two-dimensional matrix. Said housing encapsulates two or more panels to align the LEDs 106 in the direction of the width and length of the housing.

An arrangement 130 of panels 104 that does not comprise part of the claimed invention is illustrated in Figures 6 to 9. As shown, a plurality of panels 104 are arranged in columns. Adjacent panels 104 in each column are fixed by one or plus 126 flexible strips. Preferably the flexible strips 126 mechanically connect adjacent panels 104. Optionally, flexible strips 126 can also electrically connect adjacent panels 104. Preferably the flexible strips 126 have sufficient flexibility so that the strips 126 can be used to bend the panels 104 of the system 100 over each other, as illustrated in FIGURE 8. In a particular example, the panels 104 can be sent in one folded orientation as shown in FIGURE 13A. In the embodiment shown in FIGURE 6, a fold can take place between row 104A of panels 104 and row 104B of panels 104 and another fold can take place between row 104B of panels 104 and row 104C of panels 104. Such as shown, a connector 128 is used to secure the end panel 104 of each column to a support 124. Two non-limiting examples of suitable materials for flexible strip 126 are a ribbon cable and a Mylar flexible connection. These example materials can also be used to supply the feed between adjacent panels. In case the strip 126 includes a cable, the cable may optionally be either a two-conductor cable or a three-conductor cable.

The supports 124 can be fixed to the frame 102 of a light sign. One or more of the arrangements 130 may be used to form the system 100 for a light sign. Alternatively, as shown in FIGURE 9,

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flexible strips 126 may be used to secure panels 104 to support 124. In another alternative example, flexible strips 126 may be used to secure panels 104 to frame 102 instead of support 124.

An alternative embodiment of panels 104R is depicted in FIGURE 10. In FIGURE 10, the panel 104R has a rectangular shape and the LEDs 106 are arranged in a single presentation line along the length of the panel 104R. This can also be referred to as an arrangement of LED 106 in a single-dimensional pattern, while in FlGURA 2, LEDs 106 are arranged in a two-dimensional pattern.

As shown in FIGURE 10, the panels 104R may move in the direction of the double arrow A along the lanes 110 to any desired point along the lanes 110. In the illustrated embodiment, each lane 110 includes a recess for coupling an interlocking element 129. As shown the interlocking element 129 includes a screw sized to fit the recess 127. In an alternative embodiment, the recess 127 can be sized to couple the foot of the similar panel 104R, but without be limited to, at the foot 125 represented in FIGURE 5.

Each pair of panels 104R may include a support between means of adjacent panels 104R. The support may be a unit element that connects adjacent panels 104R. Each 104R panel may include a receiving element for the support. Additionally, the support may have a recess so that it is capable of receiving another panel 104R to align a plurality of panels in a manner similar to that shown in Figure 14. Alternatively, a part of the support may be fixed to each of the panels 104R and match a complementary part of the support on the adjacent panel 104R. Also, the support can include an articulation so that a fold relative to the two adjacent panels can be formed. Finally, the supports can be removable; so that the support can be removed from a panel or that the support can be separated into two (2) sections.

Optionally, one end of the panels 104R may include a socket for connection of a power supply to the panel 104R. A second end of panel 104R may include an electrical connector for adding adjacent panels 104R in the horizontal direction of the backlight system.

Another example of a panel that is not part of the claimed invention in the form of a frame 104L is illustrated in Figure 12. Panel 104L may be of any desired dimension, such as, but not limited to, approximately 30.5 cm (12 inches) wide (represented as a "W") and a height from approximately 10.2 cm (4 inches) to approximately 15.2 cm (6 inches) (represented as "H"). Preferably, the LEDs 106 are separated by at least about 5.1 cm (2 inches), but not more than 15.2 cm (6 inches) apart from an adjacent LED 106. Preferably, adjacent panels 104L are connected by flexible strips 126. Optionally, panels 104L can be connected to a bus, not shown. It is also preferred that the plurality 134 of panels 104L can be folded on top of each other as shown in FIGURE 13A, or rolled in a convenient packaging form and transported to a desired location. As shown, a convenient form is the substantially cylindrical winding of the plurality 134 illustrated in FIGURE 13.

In a particular example of the system 100 that includes panels 104L, it is preferred that the LEDs 106 be equally separated from each other. For example, each LED can be separated approximately 10.2 cm (4 inches) from an adjacent LED. Optionally, the 10.2 cm (4 inch) separation is also applied to adjacent LEDs 106 on adjacent panels 104L. Adjacent panels 104L can be arranged either horizontally or vertically between each other. The dimensions of a panel, long on one side (for example, 22.9 cm [nine inches]), short on the other (for example less than 12.7 cm [five inches]) can provide an easier fit with a rectangular luminous sign and, by adjusting the orientation or arrangement, can be adapted with a larger number of signaling boxes of varying heights and widths.

In another example of system 100 that includes panels 104L, panels 104L can be stacked on top of each other as shown in FIGURE 14. In a particular example, it is preferred that panels 104L be stacked with a displacement ratio between sf of so that the light emitted from the LEDs 106 on a lower panel 104L is not blocked by the upper panel 104L. This technique can be used to increase the density of the LEDs in a particular area of the light sign or over all the lighting areas of the light sign. The panels 104L can be arranged in a stacked configuration by various techniques, such as rails, support cables, or pressure fit features. A lower surface of the upper of the panels 104L may have a snap-in element and the upper surface of the lower panel 104L may have a complementary snap-in element. Optionally, one or more of the panels 104L may include a separator. The separator can be integral or fixed to panel 104L. In an example of stacked panels 104L, it is preferred that panels 104L do not contact each other. In this embodiment, the separator may include a small piece of plastic that is used to maintain a preferred distance between the upper and lower panels 104L.

FIGURES 31A and 31B show a top view 500 and a bottom view 502 of a PCB assembly 508 used in the frame of the LED panel 104L. FIGURE 32 shows a top view of a plurality of framed LED panels 104L as illustrated in FIGURE 12 above. FIGURE 33A illustrates a view

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FIG. 33B illustrates a bottom view of cover mold 122. FIG. 33C illustrates an exploded view of cover mold 122 with PCB assembly 508 and flexible strips 126. FIGURES 34A and 34B illustrate a top and bottom view 520 and 530 of the PCB assembly 508 shown in FIGURES 31A and 31B above.

As illustrated in FIGURE 17, a power supply 144 can be used to supply the power to one (1) or more panel columns by means of the use of division connectors 146. Alternatively, IDC (insulator offset connector may be used ) 136 and quick connect cables 148 between the columns for supplying power from a column of panels 104L to the next panel 104L, as shown in FIGURE 18. As shown in FIGURES 16 and 17, the current is transported in both sides of panel 104L. Alternatively, the current can be transported only on one side of the panel 104L and the IDC 136 can be located on the side of the panel 104L that carries the current for power supply to another column of panels 104L. If desired, a flexible strip 162 can be attached to the other side of the panel 104L for the support as shown in FIGURE 19. Alternatively, the cable between adjacent panels can be soldered to each panel. For a particular system, combinations of IDC and welding can be used. In another embodiment, the feed can be supplied on both sides of panel 104L as shown in FIGURE 15. Panel 104L in FIGURE 15 may include one or more IDC 136. An additional optional feature is mounting points 138, if Panel mounting 104L is desired for the particular application.

In a certain example, a simple power supply can be used to supply power to a sufficient number of columns or rows of panels 104 to illuminate up to approximately 1.86 m2 (20 square feet) of surface area of the signage face. It is further preferred that the power supply be used to provide power to at least about 1.30 m2 (14 square feet) of surface area of a labeling face. The examples for a backlight system described herein are applicable to both 12V and 24V systems. Also the system 100 can function as a constant voltage applied to each card, constant current applied to each panel, or power supply. of constant tension.

In a particular example, LEDs 106 on panel 104L can be electrically connected together and mounted on panel 104l using flexible circuits or cables. The entire panel 104L can be fitted with a cover mold 122. In one approach, the use of cables as part of the mechanical support for the system 100 can assist in the arrangement when removed from the package and when secured to a backplate of the sign . In addition, the cables can provide trouble-free assembly, providing a redundant electrical connection to the power supply. For example, one of the two cables can be cut without breaking the electrical junctions, thereby providing additional flexibility in the placement or rotation of the panel for the start of a new row. The modules can be structured to allow an overlap of the panels to provide gaps in the material so that the LEDs from the lower panel shine through the face of the light sign.

System 100 can be used on double-sided light signs as shown in FIGURE 20 and FIGURE 21. In FIGURE 20, two (2) columns of panels 104L are mounted back to back. Snap fit connectors can be used to mount 104L panels in opposition back to back. Alternatively, as illustrated in FIGURE 21, opposing panels 104L can be separated by a desired distance D.

When panel 104L is mounted to a back plate, if maintenance of LEDs 106 on panel 104L perpendicular to the front surface of the light sign is a problem, a 150 grille can be used to maintain the location of panels 104L. Variants of lane 150 are illustrated in FIGURES 22A-F. In FIGURE 22A, lane 150 is depicted as a flat bar applied across all panels 104L in a panel column. In one example, the grind 150 may consist of two flat bars; one mounted at each end of panels 104L on a particular column of panels 104L. A third example is shown in FIGURE 22C. The grains 150 may consist of two flat bars that are applied to two adjacent panels 104L in a column of panels. In the final example, depicted in FIGURES 22D-F, the rail 150 may comprise a support. Preferably, the support includes a base 152 and two vertical arms 154. In the example shown in FIGURE 22E, panel 104L is mounted on a sliding track in each of arms 154. As in FIGURE 22F, two adjacent panels 104L can be connected together. A first panel is fixed along an upper section of each of the arms 154 of the 150 grille and a second panel 104L is fixed along the base 152 of the 150 grille.

The grains 150 can be made of any suitable material for alignment of the panels 104L. In one example, the grains 150 are constructed of plastic. However, other construction materials may also be suitable. Additionally, the grains 150 can be attached to the back plate if desired.

In an alternative example, panel 104L can be formed by a connector between vertically adjacent panels 104R. The connector can be an integral part of any one of both vertically adjacent 104R panels. Additionally, each panel may include one or more passways to pass a cable from a panel 104R vertically adjacent to another panel 104R vertically adjacent. Also, the connector can be a unit element or a multi-piece unit. Finally, the connector can include a mode articulation

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that between two adjacent panels 104R, a first panel may move located in a non-parallel manner with respect to the second panel.

The system 100 as described above has a particular advantageous application such as the lighting system of light signs with a surface area of less than 18.6 m2 (200 square feet). In another example, the use of the system 100 in the light sign will maximize uniformity and will not require the same depth between the signal and the light source as a light sign that uses a fluorescent light source.

Additionally, the system 100 will reduce the construction costs of the sign by reducing the installation time of the backlight system inside the showcase. LEDs will also typically have a much longer life expectancy than fluorescent lamps, which will reduce maintenance costs. Additionally, the system 100 is simple to install and is flexible to adapt to different sizes of luminous signs. In addition to the system 100 it is adaptable to showcases sized differently, the system 100 can be arranged at various distances from the signage face of the light sign. Also, system 100 is suitable for those types of luminous signs that have a substrate plate for mounting system 100 and for signs that do not include a substrate plate. Consequently, system 100 is suitable for light signs on one side and double side.

Also, panels 104 of system 100 may use serial / parallel architecture. Additionally, adjacent columns of panels 104 may have the benefit of connections to connect and ready between the columns. The connections of connection and ready between the columns may comprise panels 104 that include one or more of an insulating displacement connector or one or more butt splices.

As for the individual panels, in one example, each panel may include two (2) separate series of LED strings. Alternatively, each panel may include at least two (2) separate controllers per panel for separate series of LED strings, intermingled on the panel. This will have the benefit that the failure of an LED will not be detected on the front of the sign because the LEDs each form spatially intermingled chains so that an area of the face of the sign will not be significantly impacted.

FIGS. 23 and 24 are illuminated signs that include a partial view of the signage face so that the backlight system for each sign is shown. In FIGURE 23, the sign 200 includes a simple array of panels 104L to illuminate a labeling face 202. The panels 104L are arranged in vertical columns as shown in FIGURE 12. FIGURE 24 includes a matrix backlight system double in which panels 104L are arranged as illustrated in FIGURE 14. If desired, a double matrix can be used if it is desired to increase the intensity of the light used to illuminate the labeling face 202.

FIGURE 25 is an illustration of a panel 104L that includes a plurality of LED 106 and a cover mold 122. The panel 104L also includes a housing 160 around the outer edges of the panel 104L and cover mold 122.

The backlight system 100 may be substantially lacking in optics. System 100 may optionally not include any of the following items: (1) phosphor panel, (2) a gloss enhancement film, (3) a diffuser, and (4) a light tube. Additionally, the system 100 may not include a fluorescent lamp and / or ballast.

The system 100 also offers a unique advantage with packaging and storage, because the system 100 can be folded or rolled into end-user options. This makes the system 100 easy to package and transport to an end user and in the same way, the system 100 is convenient for the end user to store once it has been delivered.

Additionally, a particular example of system 100 may have a cut-off definition of no more than about 3, more preferably, no more than about 2, and even more preferably no more than about 1.

FIGURE 26A illustrates an alternative example, in which two modules 202 are coupled to a bridge 204 to provide flexible lighting systems having the desired size and light output in particular. The bridge 204 can be constructed of substantially any suitable material such as a plastic or other similar material. Each module 202 can be coupled to the bridge 204 through a recessed part that can accept a mechanical flange connector or equivalent from the bridge. In one approach, the bridge may include electrical connectors to facilitate the supply of power and / or electrical control signals to modules 202. In addition, the bridge may include a connector 212 to accommodate an additional module.

Each module 202 includes a plurality of LEDs 203. In a representative embodiment, three LEDs are included for each module 202. The LEDs 203 can be separated a predetermined distance so that a fixed number of LEDs 203 are based in part on the length of the LEDs. modules 202. Since each module is removable from bridge 204, the lighting system can be easily disassembled and packaged for transport.

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Power can be supplied to LEDs 203 on modules 202 using a power input plug 206 on the end cover. The power input plug 206 of the end cover can be a male component and coupled to the module through a female power input connector 208. The power input plug 206 includes electrical contacts that couple to the female connector 208 to supply power when the power input plug 206 is plugged in. In this way, once the modules 202 have been mounted in a particular location, the power can be supplied through the connection between the power input plug 206 and the female connector 208.

Similarly, modules 202 can be coupled to an additional module 209 through a feed through 210. FIGURE 26B illustrates the connections of module 202 and module 209 through the modular power supply socket 210 and the corresponding female power input connector 208 located on the module 209. In this example, the modular power supply through jack 210 It is located on the opposite side of module 202 as the external power input. It should be appreciated, however, that the modular feed-through tap 210 can be located in substantially any location on module 202. The location of the modular feed pass-through 210 can refer to a desired configuration of modules 202 relative to each other. By allowing flexible connectivity between modules by providing associated power connectors in convenient locations, flexible design and fabrication of various desired lighting elements is facilitated.

FIGURE 26C illustrates how a second matrix 214 can be coupled to bridge 204 through connector 212. In one example, FIGURE 26D illustrates a simple matrix lighting system 220 that is created using a plurality of modules 202 and bridges 204 such as is shown in FIGURE 26a. FIGURE 26E illustrates a double matrix lighting system 224. In one approach, the lighting system 224 is created by coupling a plurality of second matrices 214 to a plurality of respective connectors 212.

FIGURE 27A illustrates an interlaced LED panel 230 that facilitates a single or double array of modules. The interlacing panel 230 includes a plurality of recesses 232, 234, 236, 238, 240, 242 and 244 that can accommodate a diverse interlacing module to provide additional light production for a system. Each recess 232-244 may include one or more connectors that protrude from the surface of each recess of the LED panel 230 and sit on the back of an LED panel that is stacked on top. An LED is located on each raised form 246, 248, 250, 252, 254 and 256. Power is provided to the interlacing panel 230 through feed lines 260 and 262 located on both sides of the panel 230 as described above in FIGURE 12. It should be appreciated that the LEDs can be separated substantially any distance between themselves and that said separation may not be uniform throughout the entire length of the panel.

FIGURE 27B shows a single matrix lighting system 270 employing a plurality of interlaced LED panels 230. The lighting system 270 includes five columns in which each column includes four interlocking panels 230. The power supply from each column is distributed through a power connector 272, 274, 276 and 278. In this way, a plurality can be connected of panels in substantially any configuration.

FIGURE 27C illustrates a lighting system 280 that includes a double array of interlaced LED panels 230. A second set of LED panels is stacked on top of the first set so that the back of the upper LED panels is coupled to the lower set of lEd panels through connectors located on the surface of each recess 232-244. The double matrix system 280 is similar to the single matrix system 270 in terms of connectivity. However, the system 280 also includes a second set of LED panels 230 which is placed in the recesses 232-244 of the single matrix system 270. The power for the second set of LED panels can be provided through two power lines 260 and 262. In one approach, the power is provided through the connectors from the lower set of LED panels to the upper set of LED panels so that the upper set of panels does not require that power lines be connected between them.

FIGURE 28A illustrates an I-shaped LED panel 290 that includes a first arm 310 and a second arm 312 positioned parallel to each other and connected by a crossing element 314. The first arm 310 includes three LEDs and two connectors 292 and 294. The second arm 312 includes three LEDs and two connectors 292 and 294. The first arm 310 and the second arm 312 are connected through the bridge 314 that includes a connector 300. The connectors can be used to allow stacking of the LED panels 290 with I shape to provide a double array of LED panels for a desired lighting system configuration. In one approach the connectors are a protrusion from the surface of the I-shaped LED panel that are seated in corresponding dimples on the back of the LED panels stacked on top of them.

Power is supplied to LED panel 290 through power lines 302 and 304. FIGURE 28B shows an alternative example in which power is supplied to LED panel 290 in the form of I through power lines 306 and 308. In this For example, the first arm 310 and the second arm 312 are connected through supply lines 306 and 308 respectively. In a different example, the power can be supplied to the top of the LED panels in a dual matrix configuration through the 292-300 connectors.

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FIGURE 28C illustrates a single-matrix lighting system 340 that includes a plurality of I-shaped LED panels 290. The single-matrix lighting system 340 includes five columns of I-shaped LED panels in which each column includes four I-shaped LED panels. It should be appreciated that substantially any number of LED panels can be configured in substantially any way. Each column of I-shaped LED panels is connected through coupling lines 342, 344, 346 and 348. Coupling lines 342-348 can be used to provide power and / or control signals from a group of LED panels with I form to another. FIGURE 28D illustrates a double matrix illumination system 350 that includes the single matrix illumination system 340 with an additional matrix of I-shaped light elements stacked on top of it. As explained above, the second upper matrix can be coupled to the lower matrix through connectors 292-300.

FIGURE 29A illustrates an H-shaped LED 360 panel. The LED 360 panel includes a first arm 362, a second arm 364 and a third arm 366. The first arm 362 and the second arm 364 are parallel to each other and are connected through the third arm 366 which is oriented perpendicular to the first and second arms 362 and 364. The first arm includes three LEDs and connectors 366 and 368. The second arm includes three LEDs and connectors 370 and 372. The third arm 366 includes a connector 374 located between the first arm 362 and the second arm 364.

The third arm 366 may include one or more feeding lines that are located within the arm body. The lower part of the third arm 366 may include a male power connector 376. The upper part of the third arm 366 may include a female power receptacle 378. In this form, the H-shaped LED panel can be coupled to one or more panels Various H-shaped LEDs through the male and female power connectors where the power is supplied to all LED panels. Said power supply is illustrated in FIGURE 29B. It should be appreciated that although the feed is supplied through the third arm 366, substantially any signal can be communicated. An example may be a control signal that uses a particular communication protocol.

FIGURE 29C illustrates a single-matrix lighting system 380 that includes a plurality of 360-shaped LED panels of H. The single-matrix lighting system 380 includes five columns of H-shaped LED panels in which each column includes four panels H-shaped LED It is to be appreciated that substantially any number of LED panels can be configured in substantially any way. Each column of H-shaped LED panels is connected through coupling lines 382, 384, 386 and 388. Coupling lines 382-388 can be used to provide power and / or control signals from a group of LED panels with H shape to another. FIGURE 29D illustrates a double-matrix lighting system 390 that includes the single-matrix lighting system 380 with an additional array of H-shaped lighting elements stacked on top of them. The second upper die can be coupled to the lower die through connectors 366-374. The lighting systems 380 and 390 can be divided into simple LED panels to facilitate compact transport from one location to another.

FIGURE 30A illustrates two modules 400 and 402 in which each includes three LEDs. Each module is composed of three capsules (one for each LED) on a single axis in which one arm connects each capsule to the adjacent one. Module 400 includes a male joint component 404 on a first side of the module and a female joint component 406 on a second side. The middle capsule houses a supply line 408. Module 400 is coupled to module 402 through male and female joint components 404 and 406 of module 400 to the corresponding male and female joint components of module 402. Connectors 410 and 412 are used to facilitate a double matrix lighting system in which a second set of LED modules is stacked on top of a first set and mechanically coupled thereto. FIGURE 30B illustrates the folding in two of a plurality of modules together to provide a more compact footprint for transport. Said bending is facilitated through the joints to couple two or more modules together.

FIGURE 30C illustrates a simple array lighting system 420 that includes a plurality of LED modules 400. The single array lighting system 420 includes five columns of LED modules in which each column includes four LED modules. It should be appreciated that substantially any number of LED modules can be configured in substantially any way. FIGURE 30D illustrates a double-matrix lighting system 440 that includes the single-matrix lighting system 420 with an additional array of LED modules stacked on top of it. The second upper matrix can be coupled to the lower matrix through connectors 410 and 412. The lighting systems 420 and 440 can be divided into simple LED modules to facilitate compact transport from one location to another.

The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others after reading and understanding the above detailed description. It is intended that the exemplary embodiment be interpreted as including all such modifications and alterations provided that they fall within the scope of the appended claims or the equivalents thereof.

Claims (15)

5 10 fifteen twenty 25 30 35 40 Four. Five fifty 55 60 1. Backlight system (100) for a light sign comprising: an enclosure that includes a front labeling face and a rear section; a plurality of panels including each panel (104): a plurality of light emitting diodes ("LEDs") (106) fixed to the panel, in which the distance at which each LED is from the labeling face of the enclosure divided by the distance between the object LED and the adjacent LED plus nearby provides a ratio of less than 1.4, and an integrated circuit (108); Y a cable in which the cable physically connects adjacent panels and characterized in that the plurality of panels are fixed to each of one or more rails (110). 2. The backlight system (100) of claim 1 wherein each panel (104) comprises a printed wiring card. 3. The backlight system (100) of claim 2 wherein the printed wiring card comprises at least one of a printed circuit board, a metal clad printed circuit board and a flexible circuit. 4. The system (100) of any of the aforementioned claims in which the LEDs (106) are equally separated. 5. The system (100) of any of the aforementioned claims further comprising a cover mold fixed to a panel, to be located the cover mold (122) between the LED (106) and a front surface of the sign. 6. The system (100) of claim 5 wherein an upper surface of the cover mold (122) is constructed from a weather-resistant transparent material. 7. The system (100) of any of the aforementioned claims wherein the LEDs (106) are arranged in a three-dimensional orientation. 8. The system (100) of any of the aforementioned claims further comprising that each LED (106) has a protective element aligned to protect the diode of each LED from physical contact. 9. The system (100) of any of the preceding claims wherein a brightness of the light emitted from the LEDs (106) on a panel (104) comprises up to 1500 candles per square meter measured on the outer surface of a face of signage of a luminous sign. 10. The backlight system (100) of any of the aforementioned claims wherein the wires define the relative separation of the light emitting diodes between adjacent panels (104). 11. The backlight system (100) of any of the aforementioned claims wherein the distance at which each LED (106) is from a display face of the display divided by the distance between the subject LED and the adjacent LED Closer provides a ratio from 1.25 to 0.5. 12. The backlight system (100) of any of the aforementioned claims further comprising one or more terminals on each panel (104) for connecting two adjacent panels together. 13. The backlight system of claim 1, wherein the panels are adjustablely supported on the one or more rails (110). 14. The backlight system of claim 1, wherein the one or more rails (110) are constructed from a material suitable for use as a heat sink. 15. The backlight system of claim 1, further including a frame (102) interconnecting at least two rails (110).