Method and system for flexible illuminated devices having edge lighting utilizing light active sheet material with integrated light emitting diode

• US 8,876,352 B2
• Filed: 07/27/2012
• Issued: 11/04/2014
• Est. Priority Date: 07/27/2011
• Status: Expired due to Fees

• Current Assignee: Grote Industries LLC (Grote Industries Incorporated)
• Original Assignee: Grote Industries LLC (Grote Industries Incorporated)
• Inventors: Robbins, Stanley D., Bozich, Richard C., Marx, Martin J., Roberts, James E., Ehlers, Jennifer M., Bolander, Al
• Primary Examiner(s): BRUCE, DAVID VERNON
• Application Number:
  US13/560,535
• Publication Number:
  US 20130027976A1
• Time in Patent Office: 830 Days
• Field of Search: 362/612, 362/605, 362/488, 362/501, 438/27
• US Class Current: 362/612
• CPC Class Codes: B60Q 1/0041 of several lamps in relation to each other
• CPC Class Codes: B60Q 1/26 the devices being primarily intended to indicate the vehicle, or parts thereof, or to give signals, to other traffic
• CPC Class Codes: B60Q 1/2607 comprising at least two indicating lamps
• CPC Class Codes: B60Q 1/302 mounted in the vicinity, e.g. in the middle, of a rear window
• CPC Class Codes: B60Q 1/323 on or for doors illuminated exterior door handles B60Q1/2669; illuminated door locks E05B17/10
• CPC Class Codes: B60Q 2400/10 Electro- or photo- luminescent surfaces, e.g. signalling by way of electroluminescent strips or panels
• CPC Class Codes: B60Q 3/20 for lighting specific fittings of passenger or driving compartments; mounted on specific fittings of passenger or driving compartments lighting for dashboards B60Q3/10
• CPC Class Codes: B60Q 3/217 Doors, e.g. door sills; Steps
• CPC Class Codes: B60Q 3/229 Cup holders
• CPC Class Codes: B60Q 3/233 Seats; Arm rests; Head rests
• CPC Class Codes: B60Q 3/54 Lighting devices embedded in interior trim, e.g. in roof liners
• CPC Class Codes: B60Q 3/76 for spotlighting, e.g. reading lamps spotlighting on or for specific fittings B60Q3/20; spotlighting in mass transit vehicles B60Q3/44
• CPC Class Codes: B60Q 3/78 for generating luminous strips, e.g. for marking trim component edges
• CPC Class Codes: F21K 9/00 Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
• CPC Class Codes: F21K 9/65 specially adapted for changing the characteristics or the distribution of the light, e.g. by adjustment of parts
• CPC Class Codes: F21S 4/24 of ribbon or tape form, e.g. LED tapes
• CPC Class Codes: F21S 41/151 arranged in one or more lines
• CPC Class Codes: F21S 41/19 Attachment of light sources or lamp holders achieving variable light distribution by movable light sources F21S41/657
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/19 Attachment of light sources or lamp holders
• CPC Class Codes: F21S 43/255 : Filters
• CPC Class Codes: F21V 33/0008 : Clothing or clothing accessories, e.g. scarfs, gloves or belts
• CPC Class Codes: F21W 2106/00 : Interior vehicle lighting devices
• CPC Class Codes: F21Y 2105/10 : comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2107/90 : on two opposite sides of supports or substrates
• CPC Class Codes: F21Y 2115/10 : Light-emitting diodes [LED]
• CPC Class Codes: H01L 25/0753 : the devices being arranged next to each other
• CPC Class Codes: H01L 25/0756 : Stacked arrangements of devices
• CPC Class Codes: H01L 2924/00 : Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 : Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: Y10T 29/49002 : Electrical device making

Abstract

An edge lighting device, and a method of providing edge lighting, including providing a lighting device with at least one light emitting diode (LED) chip embedded therein, wherein the LED chip(s) generates light photons. A path of the light photons within the lighting device that are emitted by the LED chip(s) from a top surface of the LED chip(s), are redirected from a first edge of the lighting device back through the lighting device to a second edge of the lighting device opposite to the first edge. The first edge and the second edge of the lighting device are perpendicular to the top surface of the LED chip(s). The photons which were redirected from the first edge of the lighting device then follow a path through the second edge of the device and are then output from the edge lighting device at the second edge of the device.

Claims

1. A method of providing edge lighting, comprising:

providing a lighting device with at least one light emitting diode (LED) chip embedded therein, wherein the at least one LED chip generates light photons; and

redirecting a path of the light photons within the lighting device that are emitted by the at least one LED chip from a top surface of said at least one LED chip, from a first edge of the lighting device back through the lighting device to a second edge of the lighting device opposite to the first edge, the first edge and the second edge being perpendicular to the top surface of said at least one LED chip, the photons which were redirected from the first edge of the lighting device being transmitted in a path through the second edge of the device and then being output from the lighting device at the second edge of the device.

2. The method of claim 1, wherein the lighting device comprises a unitary structure of at least two substrates sandwiching the at least one LED chip.

3. The method of claim 1, further comprising

providing a metalized film on the first edge of the lighting device, wherein the metalized film redirects the path of the light photons back emitted from the at least one LED chip back through the lighting device toward the second edge.

4. The method of claim 1, further comprising

providing a laser cut finish on the first edge of the lighting device, wherein the laser cut finish redirects the path of the light photons emitted from the at least one LED chip back through the lighting device toward the second edge.

5. The method of claim 1, further comprising

providing a laser etch mark on a surface of a substrate forming the lighting device, the laser etch mark being positioned to intercept the light photons emitted from the at least one LED chip toward the surface of the substrate and to couple the intercepted light photons to the second edge of the lighting device.

6. The method of claim 1, further comprising

providing a metalized film on a surface of a substrate forming the lighting device, the metalized film being positioned to intercept the light photons emitted from the at least one LED chip toward the surface of the substrate and to couple the intercepted light photons to the second edge of the lighting device.

7. The method of claim 1, further comprising

providing a plurality of the lighting devices in one assembly in a sandwich structure, at least one of the lighting device emitting light in a color different from light emitted by others of the plurality of the lighting devices, each of the lighting devices being individually selectable to provide selectable colored lighting.

8. The method of claim 1, wherein the second edge of the lighting device has a width of 5 mm or less, wherein light which is output at the second edge and which includes the light photons which were redirected from the first edge of the lighting device provides an appearance of a substantially continuous ribbon of light having a width of 5 mm or less along the second edge.

9. The method of claim 1, wherein the lighting device comprises at least one optically transparent electrically conductive substrate that sandwiches the at least one LED chip, the first and second edges being formed on the transparent electrically conductive substrate, the light photons being emitted from the at least one LED chip through the optically transparent electrically conductive substrate.

10. The method of claim 1, wherein

the lighting device is a transparent light active sheet material,

the transparent light active sheet material comprises top and bottom electrically conductive transparent substrates, a pattern of LED chips sandwiched between the electrically conductive transparent substrates, and a non-conductive transparent adhesive material disposed between the top and bottom electrically conductive transparent substrates and the LED chips,

the LED chips are preformed before being patterned in the light active sheet material as an unpackaged discrete semiconductor device having an anode p-junction side and a cathode n-junction side,

wherein either of the anode and the cathode side is in electrical communication with one of the electrically conductive transparent substrates and the other of the anode and the cathode side is in electrical communication with the other of the electrically conductive transparent substrates.

11. The method of claim 1,

further comprising disposing the at least one LED chip in the lighting device and the second edge to be separated by a predetermined distance, to provide a predetermined brightness and diffused appearance on the second edge.

12. The method of claim 1, wherein

the at least one LED chip is a plurality of LED chips that generate the light photons, the plurality of LED chips being linearly disposed in the lighting device parallel to at least one of the first and second edges.

13. A method of providing a conveyance with edge lighting, comprising:

providing edge lighting as recited in claim 1;

mounting the edge lighting on the conveyance; and

electrically connecting the edge lighting to an electrical wiring harness of the conveyance.

14. The method of claim 12, wherein the edge lighting is arranged within a designed gap between trim pieces of the conveyance.

15. The method of claim 12, wherein the edge lighting is arranged to bend the second edge of the lighting device to have a radius.

16. An edge lighting apparatus, comprising:

a lighting device with at least one light emitting diode (LED) chip embedded therein, wherein the at least one LED chip generates light photons; and

a path of the light photons within the lighting device that are emitted by the at least one LED chip from a top surface of said at least one LED chip, being redirected from a first edge of the lighting device back through the lighting device to a second edge of the lighting device opposite to the first edge, the first edge and the second edge being perpendicular to the top surface of said at least one LED chip, the photons which were redirected from the first edge of the lighting device being transmitted in a path through the second edge of the device and then being output from the lighting device at the second edge of the device.

17. The edge lighting apparatus of claim 16, wherein the lighting device comprises a unitary structure of at least two substrates sandwiching the at least one LED chip.

18. The edge lighting apparatus of claim 16, further comprising

a metalized film arranged on the first edge of the lighting device, wherein the metalized film redirects the path of the light photons back emitted from the at least one LED chip back through the lighting device toward the second edge.

19. The edge lighting apparatus of claim 16, further comprising

a laser cut finish provided on the first edge of the lighting device, wherein the laser cut finish redirects the path of the light photons emitted from the at least one LED chip back through the lighting device toward the second edge.

20. The edge lighting apparatus of claim 16, further comprising

a laser etch mark on a surface of a substrate forming the lighting device, the laser etch mark being positioned to intercept the light photons emitted from the at least one LED chip toward the surface of the substrate and to couple the intercepted light photons to the second edge of the lighting device.

21. The edge lighting apparatus of claim 16, further comprising

a metalized film on a surface of a substrate forming the lighting device, the metalized film being positioned to intercept the light photons emitted from the at least one LED chip toward the surface of the substrate and to couple the intercepted light photons to the second edge of the lighting device.

22. The edge lighting apparatus of claim 16, further comprising

a plurality of the lighting devices in one assembly in a sandwich structure, at least one of the lighting device emitting light in a color different from light emitted by others of the plurality of the lighting devices, each of the lighting devices being individually selectable to provide selectable colored lighting.

23. The edge lighting apparatus of claim 16, wherein the second edge of the lighting device has a width of 5 mm or less, wherein light which is output at the second edge and which includes the light photons which were redirected from the first edge of the lighting device provides an appearance of a substantially continuous ribbon of light having a width of 5 mm or less along the second edge.

24. The edge lighting apparatus of claim 16, wherein the lighting device comprises at least one optically transparent electrically conductive substrate that sandwiches the at least one LED chip, the first and second edges being formed on the transparent electrically conductive substrate, the light photons being emitted from the at least one LED chip through the optically transparent electrically conductive substrate.

25. The edge lighting apparatus of claim 16, wherein

the lighting device is a transparent light active sheet material,

the transparent light active sheet material comprises top and bottom electrically conductive transparent substrates, a pattern of LED chips sandwiched between the electrically conductive transparent substrates, and a non-conductive transparent adhesive material disposed between the top and bottom electrically conductive transparent substrates and the LED chips,

the LED chips are preformed before being patterned in the light active sheet material as an unpackaged discrete semiconductor device having an anode p-junction side and a cathode n-junction side,

wherein either of the anode and the cathode side is in electrical communication with one of the electrically conductive transparent substrates and the other of the anode and the cathode side is in electrical communication with the other of the electrically conductive transparent substrates.

26. The edge lighting apparatus of claim 16, wherein

the at least one LED chip in the lighting device and the second edge as disposed to be separated by a predetermined distance, to provide a predetermined brightness and diffused appearance on the second edge.

27. The edge lighting apparatus of claim 16, wherein

the at least one LED chip is a plurality of LED chips that generate the light photons, the plurality of LED chips being linearly disposed in the lighting device parallel to at least one of the first and second edges.

28. A conveyance with edge lighting, comprising:

the edge lighting apparatus as recited in claim 16 mounted on the conveyance, the edge lighting apparatus being electrically connected to an electrical wiring harness of the conveyance.

29. The conveyance of claim 28, wherein the edge lighting is arranged within a designed gap between trim pieces of the conveyance.

30. The conveyance of claim 28, wherein the edge lighting is arranged to bend the second edge of the lighting device to have a radius.

31. A method of making an edge lighting apparatus, comprising:

providing a lighting device with at least one light emitting diode (LED) chip embedded therein, wherein the at least one LED chip generates light photons when powered, the lighting device having a first edge and a second edge which is opposite to the first edge; and

treating at least one of the first edge and the second edge, so that the second edge is more transmissive of the light photons than the first edge, and the first edge redirects a path of the light photons within the lighting device that are emitted by the at least one LED chip from a top surface of said at least one LED chip, from the first edge of the lighting device back through the lighting device to a second edge of the lighting device opposite to the first edge, the first edge and the second edge being perpendicular to the top surface of said at least one LED chip, the photons which were redirected from the first edge of the lighting device being transmitted in a path through the second edge of the device and then being output from the lighting device at the second edge of the device.

32. The method of claim 31, wherein the lighting device comprises a unitary structure of at least two substrates sandwiching the at least one LED chip.

33. The method of claim 31, further comprising

arranging a metalized film on the first edge of the lighting device, wherein the metalized film redirects the path of the light photons back emitted from the at least one LED chip back through the lighting device toward the second edge.

34. The method of claim 31, wherein

the treating of the at least one of the first edge and the second edge comprises performing a laser cut to form the first edge of the lighting device, wherein the laser cut finish redirects the path of the light photons emitted from the at least one LED chip back through the lighting device toward the second edge.

35. The method of claim 31, further comprising

etching a laser etch mark on a surface of a substrate forming the lighting device, the laser etch mark being positioned to intercept the light photons emitted from the at least one LED chip toward the surface of the substrate and to couple the intercepted light photons to the second edge of the lighting device.

36. The method of claim 31, further comprising

providing a metalized film on a surface of a substrate forming the lighting device, the metalized film being positioned to intercept the light photons emitted from the at least one LED chip toward the surface of the substrate and to couple the intercepted light photons to the second edge of the lighting device.

37. The method of claim 31, further comprising

stacking a plurality of the lighting devices in one assembly in a sandwich structure, at least one of the lighting device emitting light in a color different from light emitted by others of the plurality of the lighting devices, each of the lighting devices being individually selectable to provide selectable colored lighting.

38. The method of claim 31, wherein the second edge of the lighting device has a width of 5 mm or less, wherein light which is output at the second edge and which includes the light photons which were redirected from the first edge of the lighting device provides an appearance of a substantially continuous ribbon of light having a width of 5 mm or less along the second edge.

39. The method of claim 31, wherein the lighting device comprises at least one optically transparent electrically conductive substrate that sandwiches the at least one LED chip, the first and second edges being provided on the transparent electrically conductive substrate, the light photons being emitted from the at least one LED chip through the optically transparent electrically conductive substrate.

40. The method of claim 31, wherein

the lighting device is a transparent light active sheet material,

the transparent light active sheet material comprises top and bottom electrically conductive transparent substrates, a pattern of LED chips sandwiched between the electrically conductive transparent substrates, and a non-conductive transparent adhesive material disposed between the top and bottom electrically conductive transparent substrates and the LED chips,

the LED chips are preformed before being patterned in the light active sheet material as an unpackaged discrete semiconductor device having an anode p-junction side and a cathode n-junction side,

wherein either of the anode and the cathode side is in electrical communication with one of the electrically conductive transparent substrates and the other of the anode and the cathode side is in electrical communication with the other of the electrically conductive transparent substrates.

41. The method of claim 31, further comprising

cutting at least one of the first and second edges of the lighting device so that the at least one LED chip embedded in the lighting device and the second edge are separated at a predetermined distance, to provide a predetermined brightness on the second edge and diffused appearance on the second edge.

42. The method of claim 31, wherein the at least one LED chip is a plurality of LED chips that generate the light photons, further comprising

disposing the plurality of LED chips linearly and parallel to at least one of the first and second edges.