Electroluminescent lamp devices and their manufacture

• US 6,465,951 B1
• Filed: 05/01/2000
• Issued: 10/15/2002
• Est. Priority Date: 12/16/1992
• Status: Expired due to Fees

• Current Assignee: Durel Corporation (Rogers Communications Inc.)
• Original Assignee: Durel Corporation (Rogers Communications Inc.)
• Inventors: Paciorek, Walter J., Eckersley, Rodney T., McGuigan, Ralph, Krafcik, Robert J., Munson, Harold T., Wheeler, Douglas T., Johnson, Dee Lynn
• Primary Examiner(s): Patel, Ashok
• Assistant Examiner(s): Santiago, Mariceli
• Application Number:
  US09/563,546
• Time in Patent Office: 897 Days
• Field of Search: 313/506, 313/510, 313/511, 313/512, 313/513, 313/515, 445/22, 445/23, 445/24, 445/52, 427/66, 405/41, 405/42, 405/44
• US Class Current: 313/512
• CPC Class Codes: B29C 2043/3647 Membranes, diaphragms
• CPC Class Codes: B29C 43/10 Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
• CPC Class Codes: B29C 43/203 Making multilayered articles
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: G09F 13/12 using a transparent mirror or other light reflecting surface transparent to transmitted light whereby a sign, symbol, picture or other is visible only when illuminated
• CPC Class Codes: G09F 13/22 electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: G09F 2013/227 Electroluminescent displays for vehicles
• CPC Class Codes: H01H 2009/186 using an electroluminiscent panel
• CPC Class Codes: H01H 2219/018 Electroluminescent panel
• CPC Class Codes: H01H 2219/066 Lens
• CPC Class Codes: H01H 2229/036 ultrasonic
• CPC Class Codes: H01H 2231/022 Telephone handset
• CPC Class Codes: H01H 2231/032 Remote control
• CPC Class Codes: H01H 9/0235 specially adapted for remote control, e.g. of audio or video apparatus
• CPC Class Codes: H01J 61/305 Flat vessels or containers
• CPC Class Codes: H04M 1/22 Illumination; Arrangements for improving the visibility of characters on dials
• CPC Class Codes: H05B 33/02 Details
• CPC Class Codes: H05B 33/10 Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
• CPC Class Codes: H05B 33/12 Light sources with substantially two-dimensional radiating surfaces
• CPC Class Codes: H05K 3/328 : by welding

Abstract

A method for forming an electroluminescent lamp unit. A multi-layer sheet form electroluminescent lamp, the multi-layer sheet form lamp includes a pair of sheet-form conductive layers, one of which is transparent for transmitting light emitted from the particles, an electroluminescent sheet-form layer disposed between the pair of sheet-form conductive layers and having electroluminescent particles, and a carrier substrate for supporting the pair of sheet-form conductive layers and electroluminescent sheet-form layer. The multi-layer sheet form lamp is heated at a temperature sufficient for maintaining the operational integrity of said carrier substrate and said thermoplastic layers. The multi-layer sheet form lamp is them formed into a desired three-dimensional shape.

Claims

1. A method of forming an electroluminescent lamp, comprising:

providing a multi-layer, sheet form electroluminescent lamp including;

a pair of sheet-form conductive layers, one of which is transparent for transmitting light,

an electroluminescent sheet-form layer disposed between the pair of sheet-form conductive layers and having electroluminescent particles,

a carrier substrate for supporting the pair of sheet-form conductive layers and electroluminescent sheet-form layer, the multi-layer, sheet-form having a first three-dimensional shape;

heating the multi-layer, sheet-form electroluminescent lamp at a temperature sufficient for maintaining the operational integrity of said carrier substrate, said pair of sheet-form conductive layers, and said electroluminescent layers; and

deforming the multi-layer, sheet-form electroluminescent lamp into a desired second three-dimensional shape, different than the first three-dimensional shape.

2. The method of claim 1 wherein the heating step includes heating the multi-layer, sheet-form electroluminescent lamp in a temperature range below the softening point temperature of the carrier substrate.

3. The method of claim 2 wherein the heating step includes heating the multi-layer, sheet-form electroluminescent lamp in a temperature range between 190°

F. and 270°

F.

4. The method of claim 2 wherein the heating step includes heating the multi-layer, sheet-form electroluminescent lamp in a temperature range between 230°

F. and 260°

F.

5. The method of claim 1 wherein the multi-layer, sheet-form electroluminescent lamp includes contact conductors.

6. The method of claim 5 further comprising deforming the contact conductors to provide spring detents.

7. The method of claim 6 wherein a first one of the conductors is deformed in a direction opposite to that of another of the conductors.

8. The method of claim 1 wherein the first three-dimensional shape is planar and the desired second three-dimensional shape is substantially non-planar.

9. A method of forming an electroluminescent lamp, comprising:

providing a multi-layer, sheet form electroluminescent lamp including;

a pair of sheet-form conductive layers, one of which is transparent for transmitting light,

an electroluminescent sheet-form layer disposed between the pair of sheet-form conductive layers and having electroluminescent particles,

a carrier substrate for supporting the pair of sheet-form conductive layers and electroluminescent sheet-form layer;

heating the multi-layer, sheet-form electroluminescent lamp at a temperature sufficient for maintaining the operational integrity of said carrier substrate, said pair of sheet-form conductive layers, and said electroluminescent layers;

deforming the multi-layer, sheet-form electroluminescent lamp into a desired three-dimensional shape, and wherein at least one of the conductive layers includes a fluoropolymer resin.

10. A method of forming an electroluminescent lamp, comprising:

providing a multi-layer, sheet form electroluminescent lamp including;

a pair of sheet-form conductive layers, one of which is transparent for transmitting light,

an electroluminescent sheet-form layer disposed between the pair of sheet-form conductive layers and having electroluminescent particles,

a carrier substrate for supporting the pair of sheet-form conductive layers and electroluminescent sheet-form layer;

heating the multi-layer, sheet-form electroluminescent lamp at a temperature sufficient for maintaining the operational integrity of said carrier substrate, said pair of sheet-form conductive layers, and said electroluminescent layers;

deforming the multi-layer, sheet-form electroluminescent lamp into a desired three-dimensional shape, and wherein the deforming step comprises applying pressure after heating of the multi-layer, sheet-form electroluminescent lamp.

11. A method of forming an electroluminescent lamp, comprising:

providing a multi-layer, sheet form electroluminescent lamp including;

a pair of sheet-form conductive layers, one of which is transparent for transmitting light,

an electroluminescent sheet-form layer disposed between the pair of sheetform conductive layers and having electroluminescent particles,

a carrier substrate for supporting the pair of sheet-form conductive layers and electroluminescent sheet-form layer;

heating the multi-layer, sheet-form electroluminescent lamp at a temperature sufficient for maintaining the operational integrity of said carrier substrate, said pair of sheet-form conductive layers, and said electroluminescent layers;

deforming the multi-layer, sheet-form electroluminescent lamp into a desired three-dimensional shape, and further comprising;

providing a die having a male member and a mating female member, which together define the desired three-dimensional shape;

heating at least one of the male member and female member of the die;

positioning the multi-layer, sheet-form electroluminescent lamp between the male member and female member of the die; and

applying pressure to the male member and female member of the die.

12. The method of claim 11 further comprising providing a clamp for applying pressure to the male member and female member of the die.

13. A method of constructing a three dimensional illuminating object comprising,

forming a multi-layer, sheet-form lamp member having a first three-dimensional shape by providing upon a generally sheet-form, light-transmitting thermoplastic carrier substrate an electroluminescent lamp comprised of a thin film transparent electrode deposited on said carrier substrate and, thereon, a plurality of intimately bonded superposed thermoplastic layers including a layer containing phosphor particles that forms a phosphor layer, an insulative layer and a back conductive electrode layer,

placing said multi-layer, sheet-form lamp member over a die, and

pressure forming said multi-layer, sheet-form lamp member by pressing said lamp member against said die to form said lamp member to a desired second three dimensional shape, different than the first three-dimensional shape, under conditions maintaining the operational integrity of said carrier substrate and said thermoplastic layers to produce a formed shape capable of emitting light.

14. The method of claim 13 wherein the first three-dimensional shape is planar and the desired second three-dimensional shape is substantially non-planar.

15. The method of claim 13 wherein said superposed thermoplastic layers are of coated or printed form.

16. The method of claim 15 wherein said carrier substrate is a biaxially oriented sheet.

17. The method of claim 15 wherein said carrier substrate is a polyester.

18. The method of claim 15 wherein said carrier substrate is a polycarbonate.

19. The method of claim 15 wherein said superposed thermoplastic layers are comprised of a fluoropolymer polymer resin.

20. The method of claim 15 wherein prior to pressure forming said lamp member, said lamp member is heated to a molding temperature below the softening point temperatures of the thermoplastic of the carrier substrate and of the thermoplastic of said superposed layers and thereafter said lamp member is cooled in said molded three-dimensional form.

21. The method of claim 20 wherein said molding temperature is below a temperature at which substantial shrinking of said carrier substrate occurs.

22. The method of claim 21 wherein said molding temperature is in the range between 190°

F. and 270°

F.

23. The method of claim 21 wherein said molding temperature is in the range between 230°

F. and 260°

F.

24. A three dimensional illuminating object provided by the method of claim 15.

25. The illuminating object of claim 24 in the form of a decorative embossed, self-illuminating figure.

26. The illuminating object of claim 24 in the form of an embossed, self-illuminating alphanumeric symbol.

27. The illuminating object of claim 24 in the form of a shaped pendant self-illuminating ornament.

28. The illuminating object of claim 24 in the forn of a shaped, self-illuminating identifying logo.

32. A three dimensional illuminating object provided by the method of claim 24.

29. A method of constructing a three dimensional illuminating object comprising, forming a lamp member by

providing upon a generally sheet-form biaxially oriented light-transmitting polyester carrier substrate an electroluminescent lamp comprised of

a thin film transparent electrode deposited on said carrier substrate and a plurality of intimately bonded superposed polyvinylidene fluoride layers including a layer containing phosphor particles, a layer containing insulative particles and a layer containing conductive particles forming a back conductive electrode,

heating said lamp member to a molding temperature in the range between 190°

F. and 270°

F. and molding said heated lamp member at said temperature to a desired three dimensional shape whereby shrinkage of said carrier substrate is avoided and the operational integrity of said polyester carrier substrate and said polyvinylidene layers is maintained, and

cooling said lamp member in said three-dimensional molded form.

30. The method of claim 29 wherein said molding temperature is in the range between 230°

F. and 260°

F.

31. A method of producing an article comprising a three-dimensionally shaped, extended structural member having at least one illuminated area at a selected region smaller than said structural member, comprising fabricating said structural member with a three-dimensional receptor surface at said selected region, providing a three-dimensionally shaped lamp member cooperatively sized and shaped to match with said receptor surface, said lamp member being produced by the method according to claim 29, and joining said matching three dimensionally shaped lamp member to its respective receptor surface on said structural member.