Illumination panel
10673378 ยท 2020-06-02
Assignee
Inventors
Cpc classification
B32B37/1292
PERFORMING OPERATIONS; TRANSPORTING
Y02E10/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
G09F13/04
PHYSICS
B32B2307/422
PERFORMING OPERATIONS; TRANSPORTING
B32B2457/20
PERFORMING OPERATIONS; TRANSPORTING
B32B37/04
PERFORMING OPERATIONS; TRANSPORTING
B32B38/0008
PERFORMING OPERATIONS; TRANSPORTING
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02S40/38
ELECTRICITY
B32B2307/40
PERFORMING OPERATIONS; TRANSPORTING
F21V33/0012
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
A47B2220/0077
HUMAN NECESSITIES
B32B2310/0887
PERFORMING OPERATIONS; TRANSPORTING
B32B37/18
PERFORMING OPERATIONS; TRANSPORTING
Y02E70/30
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
G09F27/007
PHYSICS
International classification
B32B37/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An illumination panel includes a transparent structural core having two opposing surfaces, a matrix of light releasing dots substantially covering both the opposing surfaces, and a protective panel in abutting contact with each of the opposing surfaces whereby the dots are an adhesive for bonding the core to the protective panels and wherein the density or size of the dots increases across the illumination panel in a direction away from an illumination panel edge adjacent a light emitting element.
Claims
1. An illumination panel comprising a transparent structural core having two opposing surfaces, a matrix of light releasing dots substantially covering both said opposing surfaces, and a protective panel in abutting contact with each of said opposing surfaces whereby each of the dots acts as a light transmitting, refracting and reflecting medium as well as an adhesive for bonding the core to the protective panels so that the illumination panel operates as a structural element without a supporting edge frame, and wherein the density or size of the dots increases across the illumination panel in a direction away from an illumination panel edge adjacent a light emitting element.
2. The illumination panel according to claim 1, wherein a transparent or translucent protective panel is bonded to both sides of the core.
3. The illumination panel according to claim 1 wherein an outer layer is bonded to each protective panel.
4. The illumination panel according to claim 3, wherein the outer layer is paint, ink, a transfer, metal, glass, plastics, wood or wood veneer.
5. The illumination panel according to claim 1, wherein the core is acrylic.
6. The illumination panel according to claim 1, wherein the matrix of releasing dots comprise a pressure sensitive adhesive.
7. The illumination panel according to claim 1, wherein the protective panel is metal, timber, plastics or glass and can be translucent.
8. The illumination panel according to claim 1, wherein the matrix of dots is applied to the transparent core by etching, painting, screen printing, printing or spraying, or transferred from or as part of a film.
9. The illumination panel according to claim 1, wherein the matrix of dots is provided by induction, dielectric or microwave activation of a distributed receptor that bonds the surface of the core to the protective panel.
10. A method of manufacturing the illumination panel according to claim 1, including the step of curing the matrix of dots by UV light or infra-red heating or laser activation to bond the surface of the core to the protective panel.
11. The illumination panel according to claim 1, wherein a light is positioned adjacent or on one or more edges of the panel.
12. The illumination panel according to claim 11, wherein the light releasing dots increase along the panel in density, size or combinations thereof across the panel in a direction away from the light source.
13. The illumination panel according to claim 11 wherein the lights comprise a plurality of LEDs secured to or embedded in one or more edges of the panel.
14. A cabinet having walls and shelves, some of the walls or shelves comprising illumination panels according to claim 1 with a light source adjacent or in one or more edges of each panel.
15. A shelf comprising an illumination panel according to claim 1 with a light source adjacent or in one or more edges of the panel.
16. The illumination panel according to claim 1, wherein each dot includes a pigment comprises a titanium dioxide based pigment.
17. The illumination panel according to claim 16, wherein the pigment comprises a white pigment.
Description
DESCRIPTION OF THE DRAWINGS
(1) Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings in which:
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DESCRIPTION OF THE PREFERRED EMBODIMENTS
(12) An illumination panel essentially comprises a transparent sheet of clear acrylic plastics with at least one surface covered with a matrix of spaced light refracting and reflecting dots. When light is introduced to the appropriate edges of the panel it is refracted and reflected by the dots and released to illuminate the whole surface of the panel. Patent Application No. W0 92/05535 is an example of this kind of illumination panel. However, it has not hitherto been known to use the dots to adhere adjacent elements of the panel to make them integral.
(13) In the following paragraphs an embodiment of the present invention as depicted in
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(15) Each illumination panel 10 comprises a core 11 of transparent acrylic acting as a light guide panel which is usually 6 mm, 8 mm or 10 mm in thickness. The core may include an optical brightener. The core 11 can have any surface sectional area and, although shown planar in
(16) If required, a layer 30, 31 can optionally be added to the outer side of the protective panels 25, 26. It is understood that the layer 30, 31 may be any material such as glass, timber, metal, paint, ink, photographic film or veneer which could be attached to the protective panel 25, 26 for various purposes, for example painting or veneering a surface to match the surroundings, or printing signs and images. The surfaces of the protective panels 25, 26 may also be left untreated, simply allowing the light to release for general illumination.
(17) The important feature of this embodiment is that the matrix of adhesive dots 20 acts as a light transmitting, refracting and reflecting medium as well as an adhesive, firmly securing the protective panel 25 to the core 11 and protecting the core and dot matrix from damage, for example, by scratching or moisture while also providing a light transmitting surface that can be used without affecting light distribution from the core. The glue is of a light reflecting, refracting or transmitting material and it is understood that there are a large variety of different glues which are suitable.
(18) The matrix of adhesive dots may be applied in many different ways including by etching, painting, printing, screen printing or spraying or transferred from a film or even as part of a film or layer that is then fixed to the core by the adhesive dots.
(19) Alternatively, the matrix of dots may be provided by localized spot applications of energy, such as laser energy from a laser, or high frequency ultrasonic acoustic vibration from a sonotrode.
(20) For example, a laser can be used to etch the surface of the core 11 through the protective panel 25 to define the array of dots whilst, at the same time, bonding the protective panel to the core. Laser etching by focusing a laser beam on the surface of a material is a method that is well known to those skilled in the art for marking a surface. When the laser energy and the speed of laser movement across a target material is correctly adjusted for the type and thickness of the material, the surface of the material at the focal point of the laser beam will be changed or etched.
(21) Where used herein the term laser etching is intended to mean the application of sufficient laser energy to etch the surface of the core, that is, melt and mark to create a matrix of light diffusing dots and at the same time bond a protective panel or film to the core.
(22) The laser energy is adjusted by controlling the overall energy delivered from the laser (0-100%) and the speed at which the beam is passed over the material. Typically, for example, when using an 80 micron laminating polyester film, a 400 watt laser is adjusted to 8% power, and moving at 1 metre per second can effectively etch and bond the film to the core.
(23) Alternatively the matrix of dots may be provided by providing high frequency ultrasonic acoustic vibrations to create dots while ultrasonically welding the surface of the core to the protective panel.
(24) The process might also be achieved by laying an appropriate film between the core and protective panel and under laser activation, have the film bond to both surfaces in an array of light transmitting dots.
(25) The invention of the present application can be contrasted with the inventions of US 2008/0037272 by Song et al (
(26) As illustrated in
(27) In use, all the elements of the panel of Song et al are held together in the upper 110 and lower casing 160, that is, within a frame. If the frame were to be removed, only the diffuser 120, light collecting layer 130 and light guide plate 131 would remain and the panel would not function because light would be lost through the light reflection surface 113 which would also be exposed and thus vulnerable to damage.
(28) The panel of Song et al (
(29) Thus Song et al constructs an optical plate from a light guide plate, a base film and a light collecting layer. The light collecting layer is not a light reflecting and refracting layer. This action is carried out by the reflection surface 113 of the light guide plate. Various patterns may be formed on reflection surface 113 including a dot pattern, a V-cut groove, a prism pattern or the like. The light collecting layer is made using clear resin, and the resin is laid down on the base film at an increasing density away from the light source in the light guide plate. So also are the dot pattern, V-cut groove pattern, prism pattern or the like that are reflecting the light in the light guide plate. That is, the further away from the light source, the denser the light reflecting elements on the rear surface of the light guide 131. Therefore, more light collecting patterns are required to collect the light on the light emission surface 112. However, any dots are not an adhesive for bonding to the reflector.
(30) In another example of the prior art, the panel of Higashiyama is depicted in
(31) Higashiyama (
(32) The panel of Higashiyama has an air layer interposed between the diffusion layer 214 and a front facing surface of the light guide plate 212 and the embossed surface 213 and the semi-transparent reflector 215. The panel is designed to selectively deliver more light to the front facing surface so that the main LCD screen of the phone receives the most light, while a secondary smaller screen on the rear surface of the phone can be illuminated by a lower transmission of light from the light guide plate 212. There is no teaching or use of adhesive dots in the Higashiyama panel.
(33) In another example of the prior art, the panel of Wu is depicted in
(34) Unlike the panel of the present invention, the prior art panel of Wu uses mechanical means (screws and brackets) to hold components adjacent or in contact with the core. If the screws were to be removed, only the light guide panel 321 and light deflection parts 322 would remain attached to the core, but light would not be diffused and the light deflection parts and both surfaces of the wave guide would be exposed and vulnerable to damage.
(35) In another example of the prior art, the panel of JP 100 21720 is depicted in
(36) Specifically, prior art edge illuminated light guide panels have principally been used for illuminating signs and LCD display panels for calculators, cameras, portable computers, television sets and mobile phones. Much refinement of edge light panels has taken place over the last 15 years, particularly relating to LCD television sets and portable computers.
(37) There are three basic elements that commonly make up a single sided edge light panel systems of the prior art for the abovementioned devicesa wave guide panel that distributes and releases light, a reflector to send light released from the panel in one direction, and a diffuser to provide a usable spread of diffused light.
(38) The wave guide is the key component and operates by releasing light evenly across either one or both planer surfaces. This is normally achieved by applying a matrix of dots or laser etched lines that increase in area or number in a direction away from the light source, and when done correctly, light is released evenly.
(39) Waveguides are typically made from acrylic. For example the acrylic used typically has a refractive index of approximately 1.45 which is higher than air, so light introduced into the edge of a clear, untouched acrylic panel will pass through the panel and out the other side, as the light is internally reflected at the acrylic-air interface. Any marks, scratches, moisture or finger prints change the reflective and refractive nature of the wave guide surface and this results in light being released, so both surfaces of the wave guide need to be protected from any contact or surface contamination once the correct light distribution has been established.
(40) The surfaces of the wave guides used within the above devices remain protected because they are sandwiched between the reflector and diffuser and all the elements are held together in a frame or case to allow the system to work.
(41) While the various wave guides will function outside the cases or frames they are held within, that is, will act to distribute light from their surfaces, the panels are vulnerable to any contact on either surface and therefore are very limited in application. In essence, embodiments of the present invention stem from the realisation that it is possible to remove the frame while providing permanent protection of both the wave guide surfaces by bonding the diffuser and reflector to the wave guide by the matrix of light releasing and reflecting adhesive dots. This releases the edge light panel elements from the need for a frame and allows the panel to be used for a multitude of applications. Because the elements are bonded together, the panel becomes structural as well as illuminating, and this is a very practical and highly innovative development.
(42) One embodiment of the method of producing the illumination panel of the present invention, comprises the step of placing a protective panel in abutting parallel contact with each surface of a transparent structural core and laser etching or activating a matrix of light releasing dots through the protective panel onto the surface of the core to adhere the layer to the core and providing light distribution across the transparent structural core.
(43) Another embodiment of the method of producing the panel shown in
(44) An adhesive dispenser 101 is arranged to complete a reciprocal movement along a rod 102 transversely across the conveyor 100. The rod 102 is held by fixed rectangular supports 103, 104. The dispenser 101 places a line of spaced dots of adhesive transversely across one surface of the core, the adhesive preferably containing a small percentage of pigment, typically from 0.5 to 2.0 wt %, depending on the size of the finished panels and the material used for the protective panels. As the core moves forward, the rows of dots are spaced as shown in
(45) Typically the adhesive comprises acrylates. Typically the pigment is a white pigment, such as a titanium dioxide based pigment. Prior to printing, a special hardening formulation is added at 3-5% of adhesive volume and this material assists in cross-linking the adhesive bond to the material used for the protective panel.
(46) Downstream of the dispenser 101 is a UV light 105 which fully or partially cures the adhesive depending on type or process. A commercially available UV curing machine such as those sold under the ADCO trade mark may be suitable. The UV energy source is typically adjusted to deliver from 600 to 900 milijoules/cm2 depending on the level of pigment mixed in the adhesive.
(47) A protective panel 25 is positioned above the first glued surface of the wave guide core in a squaring frame and aligned with the core. The core and protective panel are then pressed together and consolidated by passing through a pressing roller 110 that rotates to exert downward pressure on the panel 25 to bring the cover panel 25 into abutting contact with the dots on the core 11 or the panel can be manually pressed to the dots on the core. The adhered elements are then sent back to have the adhesive applied to the second surface of the wave guide core. The adhesive is again cured under UV light as described above and the panel again placed in the squaring frame where the second protective panel is aligned and pressed into position as described above.
(48) The three elements making up the finished panel are then pressed under a vacuum press at 0.8 to 0.9 Atm, preferably about 0.85 Atm (approximately 8 ton/m2) for 2 to 5 minutes, preferably about 3 minutes.
(49) A significant amount of pressure may be applied, for example, around 30,000 kg on a 2500 mm1300 mm panel according to the present invention.
(50) It is understood that this process may also be achieved by the adhesive being applied to the protective panels which are then bonded to the cores.
(51) In another method, the adhesive may be printed to the core or protective panel and the two components then pressed together and the adhesive cured by light.
(52) It may also be necessary to alter the surface characteristics of the protective panels prior to bonding in order to have the adhesive and the protective panels to bond firmly. For example, if the protective panels are made from acrylic, polycarbonate or other plastic material, they may be passed through corona discharge plasma to raise the surface energy to preferably between 50 and 55 Dyne/cm2. It may also be helpful to treat the acrylic core in the same way.
(53) The dot matrix substantially covers the surface of the core 11 and operates to control the release of light introduced along one or more sides of the panel 10. It is usual for the density or size of dots, or both to increase along the panel 10 in a direction away from the edge where the light is introduced for a single light source, and when light is introduced from opposite sides of the core panel, the density or size of dots or both increases to a point equal distance from both light sources. To achieve an even light distribution across the core panel, the density of dots can be increased or alternatively, the gaps between the dots can remain constant and the size of the dots increased, or both the density and size of the dots increased.
(54) The dots may comprise a grid work of lines or even concentric circles of differing diameters. The adhesive dots may be any one of a number of adhesive materials including various formulations of UV curing inks and adhesives, and adhesive of clear or white silicon.
(55) Both panels 10 described above are in themselves structural units and thus can be supported or used as wall panels, shelves or in a wide variety of structural environments. The panels do not have to be enclosed within a supporting frame and can, by themselves, operate as structural elements.
(56) In one embodiment, it is envisaged that at least one edge of the panel would have LEDs embedded therein which would operate on low voltage to define a highly illuminated structural element. The panel may also be finished with a dress edge on one or more sides. The LEDs could also be simply attached to one or more edges of the panel by a metal or plastic extrusion, or clips. The dress edge may be made from translucent acrylic to allow light to be released. The advantage of embedding LED lighting into the panel means that, as a structural unit, it is complete. Since LEDs have a long lifespan the panels could be left illuminated for very lengthy periods operating on a low safe voltage without the need of maintenance. The light delivered could be white or any number of different colours available from LED lighting elements.
(57) In another embodiment, the protective panel 25 could be either a light transmitting diffuser panel or a reflective reflector panel. The protective panel could be a suitable material such as plastic, glass, metal or timber such as the acrylic and polyester surfacing provided under the Laminex trade mark. The surface of the panel 25 that is to be bonded to the core could be painted or treated to define a reflective surface when the panel operates as a reflector.
(58) For example, a white polystyrene or polyethylene panel may be bonded directly to the core 11 with the surface of the plastic reflecting the light released from the core by the glue dots. The opposite side of the core could be bonded to a glass sheet. This arrangement could be used for a kitchen splashback or a glass shelf.
(59) Alternatively, the opposite side of the core could have an opal translucent panel bonded by the matrix of adhesive dots, and used as a single sided sign.
(60) In a further example, a decorative surfacing such as those sold under the trade mark Laminex may be bonded directly to the core 11 with the inside (or bonding) surface of the veneer having been painted white to reflect light. The veneer then provides the finished external surface while the internal face of the veneer acts to reflect light back through the core and out the opposite surface. This front light releasing surface of the core can be protected by a clear or opal translucent material that is attached by another light releasing matrix of glue dots. This could be the case when the illumination panel is used as the walls and/or base of a cupboard, or a retail display, see
(61) A rectangular kitchen cupboard 50 is shown in
(62) In
(63) As shown in
(64) The side panels may transmit light either internally into the cabinet or on both sides and the base panel is designed primarily to transmit light to the underside. A single or dual light source is located along the rear and or front edges and a reflective covering is placed on the top side. Where the light travels in both directions it is understood that translucent panels would be used on both sides.
(65) In
(66) In
(67) In
(68) In the embodiment shown in
(69) In this panel, a translucent diffuser is bonded to the core 11 to define the underside of the panel and the upper side of the panel has a reflective surface that is part of or which supports the solar panels 91.
(70) In another embodiment, the core could comprise a series of thin panels each with appropriate positioning of adhesive dots which are in alignment or offset from the adhesive dots on the adjacent panel. In this way a laminated structure is produced with an added dimension of dot matrix refinement; in the direction horizontally away from the light source the dots may get bigger on each layer and then vertically in the direction of the light being released the dots may get proportionally smaller. Seen from the light releasing face, the dots may appear to cover the surface, but in fact they may be positioned on each layer in different positions.
(71) In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word comprise or variations such as comprises or comprising is used in an inclusive sense, that is, to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.