Configurations and methods for embedding electronics or light emitters in manufactured materials
DCFirst Claim
1. A system, comprising:
- a plurality of embedded units, each embedded unit comprising at least one LED-based light source;
at least two conductive elements conductively connected to the plurality of embedded units;
a matrix of surface material surrounding the plurality of embedded units and the conductive elements such that the plurality of embedded units are embedded within the surface material;
the matrix comprisinga first module serving as a frame for supporting the plurality of embedded units and the conductive elements in a fixed position during fabrication of the matrix and having features thereon for supporting the plurality of embedded units and the conductive elements; and
a second module bonded to the first module and configured to surround the plurality of embedded units and the conductive elements; and
at least one connection mechanism configured to couple to the conductive elements at least one of power and at least one control signal for the plurality of embedded units.
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Litigations
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Accused Products
Abstract
Methods and means for embedding electronic components, such as LED-based light sources and associated control circuitry, into molded or continuously cast surface materials (e.g., material manufactured under the trademark CORIAN®). During the manufacture of the surface material, the components can be held in position using a scaffold or frame constructed of a sacrificial material, the same material as the finished surface material and/or another material used in the manufacture of the finished product. The embedded components can include control circuitry, e.g., printed circuit boards, for separately controlling each component, power conductors and data busses. Conductors and/or busses can be in the form of conductive rails, wire mesh or sheets. Access to the conductors in the finished product can be made by a number of methods, including but not limited to sanding, grinding, drilling into, screwing into, and/or inserting pins into the finished material.
220 Citations
44 Claims
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1. A system, comprising:
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a plurality of embedded units, each embedded unit comprising at least one LED-based light source; at least two conductive elements conductively connected to the plurality of embedded units; a matrix of surface material surrounding the plurality of embedded units and the conductive elements such that the plurality of embedded units are embedded within the surface material;
the matrix comprisinga first module serving as a frame for supporting the plurality of embedded units and the conductive elements in a fixed position during fabrication of the matrix and having features thereon for supporting the plurality of embedded units and the conductive elements; and a second module bonded to the first module and configured to surround the plurality of embedded units and the conductive elements; and at least one connection mechanism configured to couple to the conductive elements at least one of power and at least one control signal for the plurality of embedded units. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A system, comprising:
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a plurality of embedded units, each embedded unit comprising at least one LED-based light source; at least two conductive elements conductively connected to the plurality of embedded units; a matrix of surface material surrounding the plurality of embedded units and the conductive elements such that the plurality of embedded units are embedded within the surface material; at least one connection mechanism configured to couple to the conductive elements at least one of power and at least one control signal for the plurality of embedded units; and a frame for supporting the plurality of embedded units and the conductive elements in a fixed position during fabrication of the matrix, the frame comprising a sacrificial material absorbed into the matrix during fabrication thereof. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44)
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Specification