CN118898955A - LED backlighting system for cabinet signage - Google Patents

Abstract

An LED backlight system for a cabinet sign may include a plurality of panels. Each panel includes a plurality of light emitting diodes ("LEDs") connected to the panel. The diode has a box sign depth factor of less than about 1.4. The integrated circuit may also be located on the panel. The wiring physically connects adjacent panels.

Description

LED backlighting system for cabinet signage

Background Art

The present exemplary embodiment relates to a backlight system. It finds particular application in conjunction with the signage industry. One particular application for such a backlight system is a cabinet sign, and will be described with specific reference thereto. However, it will be found that the present exemplary embodiment is also amenable to other similar applications.

Currently, larger box signs typically use fluorescent bulbs and ballasts as their lighting system. These types of systems are labor intensive and expensive to maintain. The bulbs typically need to be replaced every one or two years at most. Given the typical location of box signs and the size of the bulbs, frequent use of a crane truck or other non-off-the-shelf equipment is required to service the signs. Previously proposed alternatives to box sign backlighting systems include linear LED arrays or perimeter lighting. However, for a variety of reasons, these options have not achieved any significant commercial success as alternatives to the fluorescent backlighting systems described above.

Summary of the invention

A backlight system for a cabinet sign and a method of making the sign are described herein. The system may include a plurality of panels. Each panel includes a plurality of light emitting diodes ("LEDs") connected to the panel. The LED layout spacing pattern has a cabinet sign depth factor of less than about 1.4. Integrated circuits may also be located on the panels. Wiring physically connects adjacent panels. A cabinet sign including the above-described backlight system is also disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an embodiment of a backlight system for a box sign described herein;

FIG2 is a front view of a panel that may be used as part of the backlight system described herein;

FIG3 is a front view of a core panel that may be included as part of a panel;

4 and 5 are side views of a panel including an overmold;

FIG6 is a front view of another embodiment of a backlight system;

FIG. 7 is an embodiment of the backlight system and the frame of the box sign described herein;

FIG8 is a side view of an embodiment of a foldable panel array;

FIG9 is a partial diagram of a backlight system including the column of foldable panels from FIG8;

FIG10 is another embodiment of a backlight system including a rectangular embodiment of a panel;

FIG. 11 is a front view of another embodiment of a panel that can be used in the backlight system disclosed herein;

Fig. 12 is a panel column disclosed in the article;

FIG. 13 is an embodiment of the panel array shown in FIG. 12 rolled into an easily packaged shape;

FIG. 13A shows an embodiment of a column of panels as shown in FIG. 12 folded one on top of the other;

FIG. 14 is an embodiment of two columns of panels stacked one on top of the other;

FIG15 is an additional embodiment of a panel;

16-19 describe alternatives for how power may be provided to panels and between panels in the same column and between panels in different columns;

20 and 21 show alternatives of how the backlighting system disclosed herein may be used in a double-sided sign;

22A-22F various brackets that may be used with the panels of a backlight system;

FIG. 23 is an embodiment of a cabinet sign including a backlight system disclosed herein;

FIG24 is an embodiment of a cabinet sign including a dual array backlight system disclosed herein;

Fig. 25 is a rectangular panel including an overmolding;

FIG26A shows a three-LED module connected to a bridge according to an exemplary embodiment;

FIG. 26B shows the module electrical connections of the lighting system according to an exemplary embodiment;

26C shows a connection element that allows a second lighting module to be connected to a lighting system according to an exemplary embodiment;

FIG26D illustrates a single array illumination system according to an exemplary embodiment;

FIG26E shows a dual array illumination system according to an exemplary embodiment;

FIG27A shows a six-LED module according to an exemplary embodiment;

FIG27B shows a single array utilizing six LED modules according to an exemplary embodiment;

FIG. 27C shows a dual array utilizing six LED modules according to an exemplary embodiment;

FIG. 28A illustrates an alternating six LED module lighting system according to an exemplary embodiment;

FIG. 28B illustrates an alternative wiring arrangement through an embodiment of a six LED module lighting system according to an exemplary embodiment;

FIG. 28C shows a single array utilizing alternating six LED modules according to an exemplary embodiment;

FIG28D shows a dual array utilizing alternating six LED modules according to an exemplary embodiment;

FIG. 29A illustrates an alternating six LED module lighting system according to an exemplary embodiment;

FIG. 29B illustrates the electrical connectivity of the six LED module in FIG. 29A according to an exemplary embodiment;

FIG. 29C illustrates a single array utilizing the six LED modules of FIG. 29A according to an exemplary embodiment;

FIG. 29D shows a dual array utilizing the six LED modules of FIG. 29A according to an exemplary embodiment;

FIG30A shows a three-LED module with a clip-connected hinge according to an exemplary embodiment;

FIG. 30B illustrates an embodiment of a three-LED module for transportation according to an exemplary embodiment;

FIG30C shows a single array utilizing three LED modules according to an exemplary embodiment;

FIG30D shows a dual array utilizing three LED modules according to an exemplary embodiment;

FIG31A shows a top view of a grid-like LED panel according to an exemplary embodiment;

FIG31B shows a bottom view of a grid-form LED panel according to an exemplary embodiment;

FIG. 32 shows a top view of an overmold LED module in a grid format according to an exemplary embodiment;

FIG33A shows a top view of a grid-like LED module according to an exemplary embodiment;

FIG33B shows a bottom view of a grid-like LED module according to an exemplary embodiment;

FIG33C shows an exploded view of a grid-like LED module according to an exemplary embodiment;

FIG34A illustrates a top view of a PCB assembly utilizing an LED panel according to an exemplary embodiment;

34B shows a bottom view of a PCB assembly utilizing an LED panel according to an exemplary embodiment.

DETAILED DESCRIPTION

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

Here, the disclosed embodiments include a plurality of panels including a backlight system. Each panel includes a plurality of LEDs. Preferably, the LEDs are spaced apart from each other on the same panel, and similarly spaced apart from each other relative to LEDs on adjacent panels, so that the backlight system will present a lighting quality similar to that of a fluorescent backlight system. The LED backlight system will present uniformity, brightness, and color rendering consistent with that of a fluorescent backlight system.

Referring to FIG. 1 , a front view of a backlighting system 100 for a box sign is shown. The depicted system 100 includes a frame 102 and a plurality of panels 104. The panels 104 are connected to the frame 102 in a plurality of rows as shown. Alternatively, the panels 104 are connected to the frame 102 in a plurality of columns, rather than rows. The individual panels 104 are not limited to any particular size. Assuming that box signs are generally square or rectangular, a panel size of 1′× ^{1′ is specifically used. Manufacturers of box signs can find panels of this size that are desired because they can be used to make lighting systems for box signs of various sizes. Typically, box signs have a sign surface that has a sign area of approximately less than 200 square feet (ft 2} ). In various embodiments of the sign, the surface area of the sign can range from approximately 4 square feet (ft ² ) to approximately 200 square feet (ft ² ). Alternatively, if a flexible material (eg, vinyl, etc.) is utilized for the cabinet face, the surface area of the sign can be much larger than 200 sq. ft. This approach can be utilized to allow the cabinet face to withstand excessive wind loads.

Alternatively, as shown in FIG. 11 , the panel 104 may be rectangular in shape. The panel 104 is not limited to any particular shape or size. The panel 104 is described in rectangular and square shapes for reasons believed to be desirable for sign manufacturers. Panels having other shapes may be manufactured if desired by the end user. Furthermore, panels of different shapes and/or sizes may be used in the same box sign.

In one embodiment, panel 104 can be a printed wiring board. The printed wiring board can be one of the group selected from a printed circuit board, a metal composite printed circuit board, and a flexible circuit. The flexible circuit can include a backing plate. Two examples of preferred materials for the backing plate include aluminum or plastic. At least the following sources of flexible circuits are available: Minco of Minneapolis, MN, Allflex Inc. of Northfield, MN, and Uniflex Circuits of San Jose, CA. In another embodiment, the printed wiring board can include LEDs connected to wiring in the form of strips, which are then connected to a backing. Typically, the backing can be made of aluminum or plastic.

As shown in FIG. 2 , each panel 104 includes a plurality of light emitting diodes (“LEDs”) 106. The LEDs 106 may be arranged on the panels 104 in any particular pattern. Additionally, the number of LEDs 106 on each panel may be different or may be the same. In one particular embodiment, each LED 106 is no more than 4” from one or more adjacent LEDs. In another embodiment, the LED spacing may be determined by a case sign depth factor. This is the ratio of the distance of the LED from the sign face of the case sign (“depth”) divided by the distance between the nearest LED and the target LED. For example, if the target LED is 4” from the nearest LED and the depth of the LEDs below the sign is 4”, the factor is 1. In another example, if the distance between adjacent LEDs remains the same, but the depth is changed to 5”, the factor is 1.25. In a further example, adjacent LEDs are spaced approximately 6” apart from one another and the depth is approximately 8”, then the case sign depth factor is approximately 1.33.

In a specific embodiment, the coefficient is preferably less than about 1.4. In another specific embodiment, the coefficient can be in the range of about 1.25 to about 0.5. In further embodiments, the LEDs can be randomly or uniformly spaced from each other. In a particular embodiment, each LED is substantially equally spaced from its neighboring LEDs.

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

There is no specific wattage requirement for LED 106 except for the appropriate types of LEDs. In a specific application, the wattage of LED 106 can be 1 W or 0.5 W. For panel 104, in a specific embodiment, preferably, the light emitted by LED 106 on panel 104 has a brightness of up to 1500 nits measured at the outer surface of the sign face of the sign.

The panel 104 may also include one or more integrated circuits 108. The integrated circuits 108 may be used to drive the LEDs 106 on the panel 104. In addition to the panel 104 including the circuits 108, the panel 104 may also include one or more LED protection elements. This is an element that can prevent the diode of the LED from physically contacting another tangible item. In one example, the protection element may include an annular cone on the surface of the panel 104, wherein the LED 106 is centered in the recessed portion of the cone. In a second embodiment, the protection element may be a transparent plastic cover over the top of the diode of each LED.

As also shown in FIG. 2 , the panel 104 can be connected to one or more rails 110. The rails can be made of any material known to be suitable for use as a heat sink; non-limiting examples include aluminum and natural graphite. The panel 104 can be connected by any known connection technique. The panel 104 shown is connected using screws 112. Optionally, as shown, the panel 104 can be fixed to or adjustably connected to the rail 110. The rail 110 can be connected to the frame 102 by any known connection technique. In another embodiment, the panel 104 may include one or more integrated or connectable rails that mate closely with a portion of the rail 110 to enable the panel 104 to be easily moved along the rail 110.

As shown, the track 110 can be adjustably connected to the frame 102 using a clamping element 114. Alternatively, other adjustable connecting elements can be used in place of the clamping element 114 or a fixed connecting element can be used in place of the clamping element 114. The panels 104 can be uniformly spaced or randomly spaced. In a specific embodiment, the spacing between any two adjustably connected adjacent panels 104 on the same track 110 can be adjusted to a desired distance. The panel 104 can also include one or more terminals 116. The terminals can be used to connect two (2) adjacent panels 104 together.

FIG. 3 illustrates a front view of one embodiment of an optional assembly of the panel 104. As shown, the panel 104 may include a core plate 105. Optionally, the core plate 105 includes one or more openings 118. Preferably, the openings 118 are sized and spaced so as not to reduce the structural integrity of the panel 104, but at least improve the ability of the panel 104 to transfer heat away from the LEDs, and optionally also improve the strength of the core plate 105. The openings 118 may be uniformly or randomly arranged on the panel 104. Examples of preferred materials for the structure of the core plate 105 include steel, steel alloys, aluminum, aluminum alloys, natural graphite, extruded plastics, any other material that can be used as a heat sink and has sufficient structural integrity, and combinations thereof.

As shown in FIG. 4 , the panel 104 may include a thin ceramic coating 120 that encapsulates the core board 105. The panel 104 may also include an overmold 122. Preferably, the overmold 122 is made of a weather resilient material and has a transparent top surface. Examples of materials that can be used to make the overmold 122 include silicone, epoxy, or plastic extrusions. The plastic extrusions can be formed of thermoplastic elastomers (thermally conductive or non-thermally conductive), polyvinyl chloride, acrylic, polyethylene (high density or low density), polypropylene, polystyrene, and ABS. As shown in FIG. 5 , the overmold 122 can be connected to the top surface of the panel 104, or alternatively, can be connected to the side surface or bottom surface of the panel 104. In addition, the panel 104 may include one or more optional feet 125. Preferably, the feet 125 extend out of the bottom plate 104 from the underside of the bottom plate 104. Preferably, the overmold 122 does not cover the top surface of the LED 106 .

Specific preferred combinations of panel 104 and overmold 122 include printed circuit board panel and plastic or silicone overmold, metal composite circuit board and plastic or silicone overmold, and flexible circuit and plastic or silicone overmold on aluminum or plastic backing. The plastic can be a thermoplastic elastomer or other type of suitable polymer that can be made into plastic.

In one method of applying the overmold material to the panel 104, the panel 104 may include openings and pins may be used to maintain the panel 104 in a fixed position during the overmolding process. If desired in a second embodiment, the openings used may be filled in a separate overmolding step or the holes may be filled with fillers.

As an option, a clip plastic housing can be used to enclose the panel 104. The housing can include a connection front and a connection back that can be used as a shell to protect the board. Preferably, the housing front includes an opening aligned with the LED 106 for emitting the light generated by the LED 106.

The overmolding 122 or housing can be used to connect multiple panels 104 with one-dimensional arrays to form a panel with a two-dimensional array. For example, as shown in Figure 10, two or more panels 104R can be overmolded at the same time to form a composite panel with LEDs arranged in two dimensions. The composite panel will have an orientation similar to the orientation of the panel 104L shown in Figure 12. Alternatively, a housing can be used to make multiple panels 104R with one-dimensional arrays into a two-dimensional array. Such a housing will enclose two or more panels to align the LEDs 106 in the width and length directions of the housing.

6-9 illustrate an arrangement 130 of panels 104. As shown, a plurality of panels 104 are arranged in columns. Adjacent panels 104 in each column are connected by one or more flexible strips 126. Preferably, the flexible strips 126 mechanically connect adjacent panels 104. Optionally, the flexible strips 126 may also electrically connect adjacent panels 104. Preferably, as shown in FIG8, the flexible strips 126 are sufficiently flexible so that the strips 126 may be used to fold one panel 104 of the system 100 over another. In a specific embodiment, the shipping panel 104 may be positioned in a fold as shown in FIG13A. In the embodiment shown in FIG6, a fold may be created between row 104A of panel 104 and row 104B of panel 104 and another fold may be created between row 104B of panel 104 and row 104C of panel 104. As shown, connectors 128 are used to connect the end panels 104 of each column to the support 124. Two non-limiting examples of suitable materials for the flexible strip 126 are ribbon cable and Mylar flexible connection. These typical materials can also be used to provide power between adjacent panels. In the case where the strip 126 includes wires, the wires can optionally be two conductors or three conductors.

The support 124 can be connected to the frame 102 of the cabinet sign. One or more arrangements 130 can be used to form the system 100 for the cabinet sign. Alternatively, as shown in FIG. 9 , a flexible strip 126 can be used to connect the panel 104 to the support 124. In another alternative embodiment, the flexible strip 126 can be used to connect the panel 104 to the frame 102 instead of the support 124.

Figure 10 depicts an alternative embodiment of a panel 104R. In Figure 10, the panel 104R has a rectangular shape and the LEDs 106 are arranged in a single longitudinal line along the length of the panel 104R. This may also be referred to as arranging the LEDs 106 in a one-dimensional pattern, whereas in Figure 2, the LEDs 106 are arranged in a 2-dimensional pattern.

As shown in FIG10 , the panel 104R can be moved along the track 110 in the direction of the double arrow A to any desired point along the track 110. In the illustrated embodiment, each track 110 includes a recessed portion that engages a locking element 129. As shown, the locking element 129 includes a screw sized to fit within the recessed portion 127. In an alternative embodiment, the recessed portion 127 can be sized to engage a foot of the panel 104R, similar to (but not limited to) the foot 125 described with reference to FIG5 .

Each pair of panels 104R may include a bracket between adjacent panels 104R. The bracket may be a single element connecting two adjacent panels 104R. Each panel 104R may include a receiving element for the bracket. In addition, the bracket may have a recessed portion so that it will be able to accommodate another panel 104R to align multiple panels in a manner similar to Figure 14. Alternatively, a portion of the bracket can be connected to each panel 104R and closely cooperate with a complementary portion of the bracket on the adjacent panel 104R. In addition, the bracket may include a hinge so that a fold can be formed relative to two adjacent panels. Finally, the bracket can be detachable; so that the bracket can be separated from the panel or the bracket can be divided into two (2) parts.

Optionally, one end of the panel 104R may include a port for connecting a power source to the panel 104R. A second end of the panel 104R may include an electrical connector that abuts an adjacent panel 104R in the horizontal direction of the backlight system.

Another embodiment of a panel 104L in a grid format is shown in FIG12 . The panel 104L may be any desired size, such as, but not limited to, a width (described as “W”) of about twelve inches (12”) and a height (described as “H”) of about four inches (4”) to about six inches (6”). Preferably, the LEDs 106 are spaced at least about two inches (2”) but no more than six inches (6”) apart from adjacent LEDs 106. Preferably, adjacent panels 104L are connected by flexible strips 126. Optionally, the panels 104L may be connected to a bus not shown. Also preferably, as shown in FIG13A , a plurality 134 of the panels 104L may be folded one on top of another, or rolled into a convenient shape for packaging and transport to a desired location. As shown, a convenient shape is substantially a plurality 134 of cylindrical shaped rollers as shown in FIG13 .

In a particular embodiment of the system 100 including panels 104L, the LEDs 106 are preferably spaced equidistant from one another. For example, each LED can be approximately four inches (4") from an adjacent LED. Optionally, a 4" spacing can also be applied to adjacent LEDs 106 on adjacent panels 104L. Adjacent panels 104L can be arranged horizontally or vertically with respect to one another. Panel sizes that are long on one side (e.g., 9 inches) and short on the other side (e.g., less than 5 inches) can provide for easier installation in a rectangular box sign and, by adjusting the positioning of the layout, can accommodate a greater number of box signs of varying heights and widths.

In another embodiment of the system 100 including the panels 104L, as shown in FIG. 14 , the panels 104L may be stacked one on top of the other. In a specific embodiment, the panels 104L are preferably stacked in an offset relationship with each other so that the upper panel 104L does not obstruct the light emitted from the LEDs 106 on the lower panel 104L. This technology can be used to increase the density of LEDs in specific areas of the box sign or in all illuminated areas of the box sign. The panels 104L may be arranged in a stacked structure by various technologies such as tracks, wiring supports, or snap-on features. The bottom surface of the top one of the panels 104L may have snap-on elements and the top surface of the lower panel 104L may have complementary snap-on elements. Optionally, one or more panels 104L may include stand-offs. The stand-offs may be integrated or connected to the panels 104L. In an embodiment of stacking the panels 104L, preferably, the panels 104L do not contact each other. In this embodiment, the standoff insulators may include small pieces of plastic used to maintain the preferred distance between the upper and bottom panels 104L.

31A and 31B show a top view 500 and a bottom view 502 of a PCB assembly 508 utilized in a grid LED panel 104L. FIG. 32 shows a top view of a plurality of grid LED panels 104L as shown in FIG. 12 above. FIG. 33A shows a top view of the overmold 122 and FIG. 33B shows a bottom view of the overmold. FIG. 33C shows an exploded view of the overmold 122 with the PCB assembly 508 and the flexible strip 126. FIG. 34A and 34B show a top view 520 and a bottom view 530 of the PCB assembly 508 shown in FIG. 31A and 31B above.

As shown in FIG. 17 , a power source 144 can be used to provide power to one (1) or more columns of panels using a splice connector 146. Alternatively, as described in FIG. 18 , an IDC 136 and a quick connect line 148 can be used between columns to carry power from one column of panels 104L to the next column of panels 104L. As shown in FIG. 16 and FIG. 17 , current is transmitted on both sides of the panel 104L. Alternatively, current can be transmitted only on one side of the panel 104L and the IDC 136 can be located on the side of the panel 104 transmitting current for transmitting power to another column of panels 104L. As shown in FIG. 19 , if necessary, a flexible strip 162 can be connected to the other side of the panel 104L for support. Alternatively, wiring between adjacent panels can be welded to each panel. For a specific system, a combination of IDC and welding can be used. In another embodiment, as shown in FIG. 15 , power can be provided to both sides of the panel 104L. The panel 104L of Figure 15 may include one or more IDCs 136. A further optional feature is mounting points 138 if mounting of the panel 104L is desired for a particular application.

In a certain embodiment, a single power supply can be used to provide power to a sufficient number of rows or columns of panels 104 to illuminate a surface area of up to about twenty (20) square feet ( ^ft2 ) of the sign face. Further preferably, the power supply is used to provide power to a surface area of at least about fourteen (14) square feet ( ^ft2 ) of the sign face. The embodiments for the backlight system described herein are applicable to both 12V and 24V systems. In addition, the system 100 can be operated with a constant voltage applied to each panel, a constant current applied to each panel, or a constant voltage power supply.

In a specific embodiment, the LEDs 106 on the panel 104L can be electrically connected together and mounted to the panel 104L using a flexible circuit or wiring. The entire panel 104L can be mounted with a cover molded part 122. In one method, when the packaging is removed and when the sign back is fixed, the use of wiring as part of the mechanical support of the system 100 can participate in the layout. In addition, the wiring can provide a trouble-free component by providing a redundant electrical connection to the power supply. For example, one of the two wirings can be cut without cutting the electrical connection (eletrical tie), thereby providing additional flexibility in panel placement or rotation of the starting point of a new row. The module can be constructed to allow the overlap of the panels to provide gaps in the material, which allow the LEDs to illuminate the cabinet sign surface from the bottom panel.

The system 100 can be used in a double-sided cabinet sign as described in Figures 20 and 21. In Figure 20, two (2) columns of panels 104L are mounted back to back. Snap connectors can be used to mount the opposing panels 104L back to back. Alternatively, as shown in Figure 21, the opposing panels 104L can be separated by a desired distance D.

When the panel 104L is mounted to the backplane, if the concern is to keep the LED 106 on the panel 104L perpendicular to the front surface of the cabinet sign, the guide rail 150 can be used to maintain the position of the panel 104L. Various guide rails 150 are shown in Figures 22A-22F. In Figure 22A, the guide rail 150 can be described as a flat bar that spans all panels 104L in the panel column. In a second embodiment, the guide rail 150 can be composed of two flat bars; one is mounted to each end of the panel 104L in a specific column of the panel 104L. A third embodiment is shown in Figure 22C. The guide rail 105 can be composed of two flat bars applied to two adjacent panels 104L in the panel column. In the last embodiment, shown in Figures 22D-22F, the guide rail 150 can include a bracket. Preferably, the bracket includes a bottom edge 152 and two vertical arms 154. In the embodiment shown in Figure 22E, the panel 104L can be mounted in the sliding track of each arm 154. 22F , two adjacent panels 104L may be connected together, with the first panel connected along the top of each arm 154 of the rail 150 and the second panel 104L connected along the bottom edge 152 of the rail 150 .

The guide rail 150 for aligning the panel 104L can be made of any suitable material. In one embodiment, the guide rail 150 can be made of plastic. However, other materials of structure can also be suitable. In addition, if necessary, the guide rail 150 can be fixed to the back plate.

In an alternative embodiment, the panel 104L can be formed by a connector between vertically adjacent panels 104R. The connector can be an integrated block of one of the two vertically adjacent panels 104R. In addition, each panel can include a channel for passing wiring from one vertically adjacent panel 104R to another vertically adjacent panel 104R. In addition, the connector can be a single element or a multi-piece unit. Finally, the connector can include a hinge so that the first panel can be moved to the second panel in a non-parallel arrangement between two adjacent panels 104R.

System 100 as described above has particular advantageous application as a lighting system for cabinet signs having a surface area of less than 200 square feet ( ^ft2 ). In another embodiment, use of system 100 in cabinet signs will maximize uniformity and not require the same depth between signs and cabinet signs using fluorescent sources.

Furthermore, system 100 will reduce sign construction costs by reducing the time to install the backlight system into the cabinet. In addition, LEDs generally have a longer life expectancy than fluorescent bulbs, which reduces maintenance costs. In addition, system 100 is simple to install and flexible to adapt to different cabinet sign sizes. In addition to the system 100 being adaptable to cabinets of different sizes, system 100 can be arranged at various distances from the sign face of the cabinet sign. In addition, system 100 is applicable to those types of cabinet signs that have a back plate for mounting system 100, and to those signs that do not include a back plate. Therefore, system 100 is applicable to single-sided cabinet signs and double-sided cabinet signs.

In addition, the panels 104 of the system 100 can use a series/parallel configuration. Moreover, adjacent columns of panels 104 can have the advantage of plug-and-play connections between columns. The plug-and-play connections between columns can include panels 104 that include one or two insulation displacement connectors or one or more butt joints.

As for the individual panels, in one embodiment, each panel may include two (2) separate series LED chains. Alternatively, each panel may include at least two (2) separate drivers/per panel for separate series LED chains (mixed on the panel). Since the LEDs of each chain are spatially mixed, this will have the advantage that the failure of one LED will not be noticed on the sign face, thereby not significantly affecting an area of the sign face.

Shown in FIGS. 23 and 24 are cabinet signs including partial views of the sign face, showing the backlighting system for each sign. In FIG. 23 , the sign 200 includes a single array of panels 104L that illuminate the sign face 202. The panels 104L are arranged in vertical columns as shown in FIG. 12 . FIG. 24 includes a dual array backlighting system, in which the panels 104L are configured as shown in FIG. 14 . If desired, a dual array may be used if it is desired to increase the light density used to illuminate the sign face 202.

25 is an illustration of a panel 104L including an overmold 122 and a plurality of LEDs 106. The panel 104L also includes a housing 160 and the overmold 122 surrounding the outer edges of the panel 104L.

The backlight system 100 may be substantially free of optics. Optionally, the system 100 may not include any of the following: (1) a phosphor panel, (2) a brightness enhancement film, (3) a diffuser, and (4) a light pipe. Furthermore, the system 100 may not include a fluorescent bulb and/or a ballast.

The system 100 also provides unique advantages in packaging and storage, in that the system 100 can be foldable or rollable at the end user's choice. This makes the system 100 easy to package and transport to the end user, and likewise, after delivery, the system 100 is convenient for the end user to store.

Additionally, specific embodiments of system 100 may have a cut resolution of no greater than 3, more preferably no greater than 2, and even more preferably no greater than 1.

FIG. 26A shows an alternative embodiment in which two modules 202 are connected to a bridge 204 in order to provide a flexible lighting system with specific required size and light output. The bridge 204 can actually be made of any suitable material such as plastic or other similar materials. Each module 202 can be connected to the bridge 204 via a recessed portion that can receive a mechanical joint connector or similar structure on the bridge. In one approach, the bridge can include an electrical connector to facilitate the delivery of electrical energy and/or electrical control signals to the modules 202. In addition, the bridge can include a connector 212 to accommodate additional modules.

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

Power may be delivered to the LEDs 203 on the module 202 using the end cap power input plug-in 206. The end cap power input plug-in 206 may be a male component and connects to the module via a female power input connector 208. The power input plug-in 206 includes electrical contacts that connect to the female connector 208 to deliver power when the power input plug-in 206 is inserted. In this manner, power may be delivered via the connection between the power input plug-in 206 and the female connector 208 when the module 202 is installed in a particular location.

Similarly, the module 202 can be connected to the additional module 209 via the module power pass-through port 210. FIG. 26B shows the connection between the module 202 and the module 209 via the module power pass-through port 210 and the corresponding female power input connector 208 located on the module 209. In this embodiment, the module power pass-through port 210 is located on the opposite side of the module 202 as the external power input terminal. However, it can be found that the module power pass-through port 210 can be set in any position on the module 202. The location of the module power pass-through port 210 can be related to the desired configuration of the modules 202 relative to each other. Flexible connection between modules is allowed by providing the associated power connectors at convenient locations, thereby facilitating flexible design and manufacture of various desired lighting elements.

FIG26C shows how the second array 214 is connected to the bridge 204 via the connector 212. In one embodiment, FIG26D shows a single array lighting system 220 made using multiple modules 202 and bridge 204 as shown in FIG26A. FIG26E shows a dual array lighting system 224. In one method, the lighting system 224 is made by connecting multiple second arrays 214 to multiple corresponding connectors 212.

Figure 27A shows an interlocking LED panel 230 that is conducive to a single array or a dual array module. The interlocking panel 230 includes multiple recessed portions 232, 234, 236, 238, 240, 242, and 244 that can accommodate completely different interlocking modules to provide additional light output for the system. Each recessed portion 232-244 can include one or more connectors that protrude from the surface of each recessed portion of the LED panel 230 and are installed in the back side of the LED panel stacked on the top. An LED is provided on each raised structure 246, 248, 250, 252, 254, and 256. As shown in Figure 12 above, power lines 260 and 262 located on either side of the panel 230 provide electrical energy to the interlocking panel 230. It can be found that in fact, the LEDs can be spaced apart at any distance from each other and this spacing can be uneven on the entire panel.

27B shows a single array lighting system 270 utilizing multiple interlocking LED panels 230. The lighting system 270 includes five columns, each of which includes four interlocking panels 230. Power from each column is distributed via power connectors 272, 274, 276, and 278. In this manner, multiple panels may be connected in virtually any configuration.

FIG. 27C shows a lighting system 280 including a dual array of interlocking LED panels 230. A second group of LED panels is stacked on top of the first group, connecting the back of the top LED panel to the bottom group LED panel via a connector located on the surface of each recessed portion 232-244. The dual array system 280 is very similar to the single array system 270 in terms of connectivity. However, the system 280 also includes a second group of LED panels 230 located in the recessed portions 232-244 of the single array system 270. Power for the second group of LED panels can be provided via two power cords 260 and 262. In one approach, power is provided via a connector from the bottom group LED panel to the top group LED panel, so that the top group panel does not require a power cord connected to it.

28A shows an I-shaped LED panel 290 including a first arm 310 and a second arm 312 disposed parallel to each other and connected by a bridging member 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 via a bridge 314 including a connector 300. Connectors can be utilized to allow stacking of I-shaped LED panels 290 to provide a dual array LED panel for a desired lighting system configuration. In one approach, the connectors are protrusions from the surface of the I-shaped LED panel that fit into corresponding recesses on the back of the LED panel stacked on top of it.

Power is delivered to the I-shaped LED panel 290 via power lines 302 and 304. FIG28B shows an alternative embodiment of delivering power to the I-shaped LED panel 290 via power lines 306 and 308. In this embodiment, the first arm 310 and the second arm 312 are connected via power lines 306 and 308, respectively. In an entirely different embodiment, power can be delivered to the top LED panel in a dual array configuration via connectors 292-300.

FIG. 28C shows a single array lighting system 340 including a plurality of I-shaped LED panels 290. The single array lighting system 340 includes five columns of I-shaped LED panels, wherein each column includes four I-shaped LED panels. It can be found that substantially any number of LED panels can be configured in substantially any manner. Each column of I-shaped LED panels is connected via connecting wires 342, 344, 346, and 348. Connecting wires 342-348 can be used to provide power and/or control signals from one group of I-shaped LED panels to another group. FIG. 28D shows a dual array lighting system 350 including a single array lighting system 340 having an additional array of I-shaped light-emitting elements stacked on top thereof. As discussed above, a second top array can be connected to a bottom array via connectors 292-300.

FIG. 29A shows an H-shaped LED panel 360. The LED panel 360 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 connected via a third arm 366 oriented perpendicularly to the first arm 362 and the second arm 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 power cords located within the arm body. The bottom of the third arm 366 may include a male power connector 376. The top of the third arm 366 may include a female power socket 378. In this way, an H-shaped LED panel may be connected to one or more completely different H-shaped LED panels via male and female power connectors that deliver power to all LED panels. Figure 29B shows this power delivery. It can be found that although power is delivered via the third arm 366, any signal can actually be conveyed. An example may be a control signal utilizing a specific communication protocol.

FIG. 29C shows a single array lighting system 380 including a plurality of H-shaped LED panels 360. The single array lighting system 380 includes five columns of H-shaped LED panels, wherein each column includes four H-shaped LED panels. It can be found that substantially any number of LED panels can be configured in substantially any manner. Each column of H-shaped LED panels is connected via connecting wires 382, 384, 386, and 388. Connecting wires 382-388 can be utilized to provide power and/or control signals from one group of H-shaped LED panels to another group. FIG. 29D shows a double array lighting system 390 including a single array lighting system 380 having an additional array of H-shaped light-emitting elements stacked on top thereof. The second top array can be connected to the bottom array via connectors 366-374. The lighting systems 380 and 390 can be decomposed into a plurality of single LED panels to facilitate compact transportation from one location to another.

Figure 30A shows two modules 400 and 402 each including three LEDs. Each module is composed of three sockets (pod) (one socket for each LED) on a single axis, wherein an arm connects each socket to an adjacent socket. Module 400 includes an outer hinge assembly 404 on a first side of the module and an inner hinge assembly 406 on a second side. The middle socket accommodates a power cord 408. Module 400 is connected to module 402 via the outer hinge assembly 404 and the inner hinge assembly 406 of module 400 to the corresponding inner hinge assembly and outer hinge assembly of module 402. Connectors 410 and 412 are utilized to facilitate stacking the second group of LED modules on the top of the first group and mechanically connected to the dual array lighting system of the first group. Figure 30B shows that two groups of multiple modules are folded together to provide a more compact footprint for transmission. This folding is facilitated via a hinge connecting two or more modules together.

FIG. 30C shows a single array lighting system 420 including a plurality of LED modules 400. The single array lighting system 420 includes five columns of LED modules, wherein each column includes four LED modules. It can be found that virtually any number of LED modules can be configured in substantially any manner. FIG. 30D shows a dual array lighting system 440 including a single array lighting system 420 having an additional array of LED modules stacked on top thereof. The second top array can be connected to the bottom array via connectors 410 and 412. The lighting systems 420 and 440 can be broken down into a plurality of individual LED modules to facilitate compact transportation from one location to another.

The exemplary embodiments have been described with reference to the preferred embodiments. Obviously, there will be various modifications and changes based on others reading and understanding the previous detailed description. It is intended that the exemplary embodiments be interpreted as including all such changes and substitutions within the scope of the appended claims or equivalents thereof.

Claims (28)

1. A backlighting system for cabinet signs, comprising:

A plurality of panels, each panel comprising:

A plurality of light emitting diodes ("LEDs") attached to the panel, each LED having a box sign depth factor of less than about 1.4, and

An integrated circuit in which one or more thermally conductive tracks physically connect adjacent panels and the plurality of panels are attached to the one or more tracks, and one or more wires facilitate electrical connection between the panels and the tracks are composed of aluminum.

2. The backlighting system as recited in claim 1, wherein each panel comprises a printed wiring board.

3. The backlighting system as recited in claim 2, wherein the printed wiring board comprises at least one of a printed circuit board, a metal composite printed circuit board, and a flexible circuit.

4. The system of claim 1, wherein the LEDs are equally spaced apart on the panel.

5. The system of claim 1, further comprising a cover film attached to the panel, the cover film to be located between the LED and the front surface of the sign.

6. The system of claim 5, wherein the top surface of the wrapsheet is made of a transparent weatherproof material.

7. The system of claim 1, wherein the LEDs are arranged in a two-dimensional orientation.

8. The system of claim 1, further comprising each LED having a protection element aligned to protect the diode of each LED from physical contact.

9. The system of claim 1, wherein each panel comprises a plug and play connector.

10. The system of claim 1, wherein each rail includes a recess for engagement with locking elements of the plurality of panels.

11. The system of claim 1, wherein each of the plurality of panels comprises one or more integrated or connectable rails that mate with a portion of the one or more tracks to enable the plurality of panels to move along the tracks.

12. A cabinet sign comprising a backlight system, the system comprising:

a plurality of spaced apart panels, each panel comprising:

A plurality of light emitting diodes ("LEDs") attached to the panel, each LED having a box sign depth factor of less than about 1.4, and

An integrated circuit in which tracks physically connect vertically adjacent panels arranged in columns and rows, and the adjacent panels are attached to one or more tracks, and one or more insulated wires facilitate electrical connection between the panels.

13. The cabinet sign of claim 12 wherein the columns provide electrical connections in series or parallel between adjacent panels of each column.

14. The cabinet sign of claim 12, each portion of the surface area of the sign face having a source connection, the portion comprising a sign face from at least about fourteen (14) square feet (ft ²) of the sign face to no more than about twenty (20) square feet (ft ²) of the sign face.

15. The cabinet sign of claim 12 wherein the panel is supported on the rail.

16. The cabinet sign of claim 15 wherein the rail is made of a material suitable for use as a heat sink.

17. The cabinet sign of claim 12 wherein each column is interconnected with a second column.

18. The cabinet sign of claim 12 wherein each panel includes at least one insulation displacement connector.

19. The cabinet sign of claim 12 wherein the mounting spacing between adjacent panels is adjustable.

20. The cabinet sign of claim 12 further comprising a cover film covering all of the panels.

21. The cabinet sign of claim 12 wherein the panels are stacked on top of one another.

22. The cabinet sign of claim 21 wherein the panels are stacked in offset relation to one another such that light emitted by the LEDs on the lower panel is not blocked by the upper panel.

23. The cabinet sign of claim 22 wherein the bottom surface of the upper panel includes a snap element and the top surface of the lower panel includes a complementary snap element.

24. The cabinet sign of claim 12 wherein the panels are stacked back-to-back.

25. The cabinet sign of claim 24 wherein the panels include snap connectors for mounting back-to-back to opposing panels.

26. A module for use in backlighting a cabinet sign, comprising:

A printed wiring board;

A plurality of LEDs mounted to the first surface of the circuit board, wherein the LEDs are equally spaced apart;

an overmold attached to the printed wiring board on the first surface;

a protection element on top of each LED for protecting the diode of each LED from physical contact;

a support structure configured to support the module and one or more spaced apart distinct modules, the support structure being one or more rails and the one or more modules being adjustably attached to the one or more rails; and

An interconnectivity assembly that facilitates electrical connection between the module and the one or more different modules, wherein the support structure includes one or more glide tracks that enable a panel to move along the one or more tracks.

27. The module of claim 26, wherein the interconnectivity element is one of a male connector and a female connector connected to the module by wiring or insulation displacement connectors.

28. The module of claim 26, wherein each of the modules comprises one or more integrated or connectable rails that mate with a portion of the one or more tracks that enable the plurality of panels to move along the tracks.