SIGN UTILIZING FLEXIBLE LED TUBE SECURED BY UNIQUE ELEMENTS AND METHOD OF CREATION/USE

Abstract

This disclosure describes an LED sign that has the exterior appearance of a neon sign, but is much easier and less expensive to mass produce, and has none of the environmentally challenging elements of a neon sign. The sign has a frame that mounts to a background element, through which one or more channels are routed or molded. Flexible LED light tubes are laid into the channels and then closed off with heat shrink tubes. Because the LED light tubes are restrained in the channel, the sign takes on the desired shape that has been formed into the background, allowing the sign to be mass-produced economically for even small quantities, as there is no need for an expensive mold. The background can be 1-piece, or made from multiple pieces connected to each other in a removable fashion.

Claims

1. A lighted sign assembly configured to mimic the look of a classic neon sign and operable to display a message, comprising: a background structure having a front front-facing surface, a rear-facing surface, and at least one elongated recess having a width dimension and a height dimension formed in the front-facing surface in the shape of a pattern, the pattern comprising the message to be displayed by the sign; at least one flexible light tube having a width dimension complimentary to the width dimension of the elongated recess such that at least a portion of the flexible light tube is sized and configured to nest within the elongated recess, the flexible light tube being maneuverable so as to conform to the shape of the pattern, the flexible light tube being operable to illuminate the message displayed by the sign; and a frame assembly including a first component configured to secure the background structure to the frame assembly and a second component configured to secure the frame assembly to a display structure.

2. The lighted sign assembly of claim 1, wherein the at least one recess is formed through at least one of a molding process and a routing process.

3. The lighted sign assembly of claim 1, wherein the background comprises at least one of metal and plastic material.

4. The lighted sign of claim 3, wherein the plastic material comprises polyvinyl chloride sheets.

5. The lighted sign of claim 1, wherein the flexible light tube comprises a light-emitting diode tube.

6. The lighted sign of claim 5, wherein the flexible light tube comprises a first end having a first end cap positioned thereon to seal the first end, and a second end having a second end cap positioned thereon to seal the second end.

7. The lighted sign of claim 6, wherein at least one of the first and second end caps comprises a heat shrink tube end.

8. The lighted sign of claim 1, wherein the elongated recess has a dovetail shaped cross-section.

9. The lighted sign of claim 1, wherein the elongated recess has a plurality of protrusions extending laterally into the recess to enact friction on the flexible light tube.

10. The lighted sign of claim 1, wherein the elongated recess comprises a floor and opposing sidewalls, and the floor further comprises a secondary recess formed therein, the secondary recess sized and configured to receive electrical wires therein, the electrical wires functioning to connect the at least one flexible light tube to a power source.

11. A modular lighted sign assembly configured to mimic the look of a classic neon sign and operable to display a message, comprising: a modular background structure comprising at least two distinct background units that are joinable to form a single contiguous background structure, each background unit having a front-facing surface, a rear-facing surface, and at least one elongated recess having a width dimension and a height dimension formed in the front-facing surface in the shape of a pattern, the pattern comprising a portion of the message to be displayed by the sign; at least one flexible light tube having a width dimension complimentary to the width dimension of the elongated recess such that at least a portion of the flexible light tube is sized and configured to nest within the elongated recess, the flexible light tube being maneuverable so as to conform to the shape of the pattern, the flexible light tube being operable to illuminate the message displayed by the sign; and a frame assembly including a first component configured to secure the background structure to the frame assembly and a second component configured to secure the frame assembly to a display structure; wherein upon joining the at least two distinct background units to form a single continuous background structure, the at least one recess of each distinct unit aligns with one another to form the complete message to be displayed by the sign.

12. The modular lighted sign assembly of claim 11, wherein the at least one recess is formed through at least one of a molding process and a routing process.

13. The modular lighted sign assembly of claim 11, wherein the background comprises at least one of metal and plastic material.

14. The modular lighted sign of claim 13, wherein the plastic material comprises polyvinyl chloride sheets.

15. The modular lighted sign of claim 11, wherein the flexible light tube comprises a light-emitting diode tube.

16. The modular lighted sign of claim 15, wherein the flexible light tube comprises a first end having a first end cap positioned thereon to seal the first end, and a second end having a second end cap positioned thereon to seal the second end.

17. The modular lighted sign of claim 16, wherein at least one of the first and second end caps comprises a heat shrink tube end.

18. The modular lighted sign of claim 11, wherein the elongated recess has a dovetail shaped cross-section.

19. The modular lighted sign of claim 11, wherein the elongated recess has a plurality of protrusions extending laterally into the recess to enact friction on the flexible light tube.

20. The modular lighted sign of claim 11, wherein the elongated recess comprises a floor and opposing sidewalls, and the floor further comprises a secondary recess formed therein, the secondary recess sized and configured to receive electrical wires therein, the electrical wires functioning to connect the at least one flexible light tube to a power source.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Many advantages of the present disclosure will be apparent to those skilled in the art with a reading of this specification in conjunction with the attached drawings, wherein like reference numerals are applied to like elements and wherein:

[0024] FIG. 1 is a front plan view of an example of a lighted sign according to one embodiment of the present disclosure;

[0025] FIG. 2 is a side plan view of the lighted sign of FIG. 1;

[0026] FIG. 3 is an exploded perspective view of the lighted sign of FIG. 1; and

[0027] FIGS. 4-8 are perspective, sectional views of a portion of the lighted sign of FIG. 1, illustrating an example of a terminal section according to several embodiments.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0028] Illustrative embodiments of the disclosure are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. The lighted sign and related methods disclosed herein boast a variety of inventive features and components that warrant patent protection, both individually and in combination.

[0029] FIGS. 1-3 illustrate an example of a lighted sign 10 according to one embodiment of the present disclosure. By way of example only, the lighted sign 10 described herein includes a frame 12, background 14, and at least one flexible LED light tube 16. Generally, the frame 12 attaches to a wall or other structure, and holds the background in place. The background 14 is essentially a container that has two high sides and a central recess (also valley or channel) into which one ore more LED light tubes 16 are placed. The LED light tube(s) may be optionally covered to further secure it in place. When powered on, the LED light tube 16 creates a bright, attractive display that is very similar to a neon light display, but with easier creation of the work of art, less power consumption, and without the use of toxic chemicals and dangerous materials.

[0030] The frame 12 is configured to enable attachment of the background 14 to a structure upon which the lighted sign 10 is displayed, for example a wall, signpost, rooftop, shelf/ledge, and the like. As such, the frame 12 comprises a background support component, a background engagement component, and a structure engagement component. The frame 12 (and each of its components) is preferably constructed using one or more strong, resilient, rigid or semi-rigid material(s) capable that can either be molded or bent into a desired final shape, for example such as a metal, plastic, and/or wood. A particularly preferred embodiment calls for a frame made from a black, powdered coated metal.

[0031] By way of example only, the background support component of the frame 12 comprises a combination of vertical supports 18 and horizontal supports 20. The combination includes at least one vertical support 18 and at least one horizontal support 20, however the number and arrangement of each may vary depending upon the size and shape of the background to be supported. For instance, the frame 12 of the lighted sign 10 shown by way of example in FIGS. 1-3 includes a pair or vertical supports 18 and a pair of horizontal supports 20 arranged in a crosshatch orientation.

[0032] The background engagement component of the frame 12 comprises any means or mechanism capable of securing the background to the frame, including but not limited to screws, bolts, nails, adhesives, clips, and the like. By way of example, the background 14 of the instant embodiment is secured to the frame 12 by a plurality of fasteners 22 (e.g. screws) each having an enlarged head element 24 and a threaded shank 26. The head element 24 remains on the back side of the frame 12 while the threaded shank 26 passes through one of a plurality of fastener holes 28 formed in the vertical and horizontal supports 18, 20, and into the back face 42 of the background 14. Although not shown, a plurality of complimentary receiving holes may be formed in the back face 42 of the background 14 to receive the shank 26 as it is driven into the background 14. In this fashion, once the fasteners 22 are fully seated within the background 14, the background 14 is securely attached to the frame 12.

[0033] The structure engagement component of the frame 12 includes any means or mechanism capable of securing the frame 12 to a display structure (e.g. wall, signpost, rooftop, shelf/ledge, etc.), including but not limited to superior flanges 30, inferior flanges 32, lateral flanges 34, and/or engagement apertures 36. By way of example, the superior flanges 30 extend generally perpendicularly in a forward direction from the superior ends of the vertical supports 18 and are configured to engage one or more hanging elements (e.g. hooks, chains, ropes, etc.) to enable hanging of the sign 10 from an overhead structure (e.g. ceiling, signpost, etc.). The superior flanges 30 extend in a forward direction to ensure that the sign 10 hangs in a straight vertical orientation.

[0034] The inferior flanges 32 extend generally perpendicularly in both the forward and backward directions from the inferior ends of the vertical supports 18, and are configured to provide a stable support for the sign 10 when positioned on a horizontally oriented structure such as a shelf, ledge, tabletop, etc. The inferior flanges 32 may be molded or adjusted to extend at non-perpendicular angles in the forward and/or backward directions, for example to enable positioning on an angled surface such as a slanted rooftop.

[0035] The lateral flanges 34 extend generally perpendicularly in a forward direction from the lateral ends of the horizontal supports 20 and may be configured to engage one or more hanging elements (e.g. hooks, chains, ropes, etc.) to enable hanging of the sign 10 from an overhead structure (e.g. ceiling, signpost, etc.) and/or one or more vertical support elements (e.g. sign posts) to enable secure positioning of the sign 10 between multiple vertical support elements. Although not shown in the Figures, any of the flanges 30, 32, 34 may be further equipped with additional structure to enable attachments to the various display structures, including but not limited to loops, through-holes, etc.

[0036] The engagement apertures 36 are formed within a crossbeam 38 extending between at least two vertical supports 18. The engagement apertures 36 are sized and configured to receive fasteners therethrough that fasten the frame 12 to a vertically-oriented structure, for example such as a wall or signpost. The crossbeam 38 may also serve as an attachment point for a back-mounted power supply 39, which may be in the form of a battery unit or a circuit hub with an external A/C plug extending therefrom to be plugged into a wall outlet (for example).

[0037] The background 14 is attached to the front of the frame 12 and includes a front face 40, a back face 42, and at least one elongated recess 44 (or channel) formed in the front face 40. The at least one elongated recess 44 is sized and configured to securely receive at least a portion of an LED light tube 16 therein. The number of elongated recesses 44 formed in the background 14 corresponds to the number of LED light tubes 16 that are needed for the design of the lighted sign 10. In the instant example shown in FIGS. 1-3, the lighted sign 10 is represented as an OPEN sign, in which the background 14 includes four letter-shaped sections (one for each of the O, P, E, and N) and a pair of curved sections that are arranged to form a broken oval shape around the letter-shaped sections. In this example, the background 14 includes seven distinct elongated recesses 44, with one recess 44 forming the O, one forming the P, two recesses 44 forming the E, one recess 44 forming the N, and one recess 44 for each of the peripheral broken oval sections. It should be noted that the path of the recesses 44 determine the positioning of the LED light tubes 16, and thus the recesses 44 are formed with precision into the background 14 to produce the desired lighted sign 10.

[0038] According to preferred embodiment, the background 14 and/or recesses 44 may be formed using laser cutting and/or computer numerical control (CNC) routing. This produces a greater ability for precision, which in turn allows the sign shape to be cut closer to the recesses 44/light tubes 16, as can be see by way of example with the open spaces 45 in the sign shown in FIG. 1. These open spaces 45 minimize the bulk of the background 14 around the light tubes 16, giving the lighted sign 10 a skeletal simulation of a true neon sign. Attaching the skeletal background 14 to the metal frame 12 with the back-mounted power supply 39 completes the overall look and feel of a vintage neon sign.

[0039] Preferred embodiments for the width and height of the recesses 44 depend upon with diameter of the light tubes 16 to be used. For lighted signs 10 intended for indoor use, the light tubes 16 tend to be smaller in diameter than those used in outdoor signs. With respect to indoor signs, for light tubes 16 that are 4 mm in diameter, the preferred dimensions of recesses 44 range from 2 mm to 6 mm in width, and 4 mm to 8 mm in height, with a particularly preferred embodiment calling for widths around 4 mm and heights around 6 mm. For light tubes 16 that are 6 mm in diameter, the preferred dimensions of recesses 44 range from 4 mm to 8 mm in width, and 6 mm to 10 mm in height, with a particularly preferred embodiment calling for widths around 6 mm and heights around 8 mm. For light tubes 16 that are 8 mm in diameter, the preferred dimensions of recesses 44 range from 6 mm to 10 mm in width, and 8 mm to 11 mm in height, with a particularly preferred embodiment calling for widths around 8 mm and heights around 11 mm. For light tubes 16 that are 10 mm in diameter, the preferred dimensions of recesses 44 range from 8 mm to 12 mm in width, and 10 mm to 14 mm in height, with a particularly preferred embodiment calling for widths around 10 mm and heights around 12 mm.

[0040] With respect to lighted signs 10 intended for outdoor use, most manufacturers use light tubes 16 that are larger in diameter (and better protected against the elements), and thus the size dimensions of the recesses 44 would be adjusted accordingly. For example, for light tubes 16 that are 15 mm in diameter, a preferred embodiment calls for recesses 44 that are approximately 14 mm to 18 mm in width and 16 mm-20 mm in height.

[0041] The background 14 may have any shape desired, however in most cases the shape of the background 14 will be roughly the shape of the desired end product. The background 12 may be created through molding, routing, or any other process that includes formation of one or more recesses 44 therein. The background 14 can be manufactured from any moldable or routable substance, including but not limited to metal, plastic, polyvinyl chloride (PVC) and/or wood. According to a preferred embodiment, a lighted sign 10 intended for indoor use may have a background 14 made from PVC sheets (e.g. Sintra), while a lighted sign 10 intended for outdoor use may have a background 14 made from a more durable substance such as metal or plastic.

[0042] Each flexible LED light tube 16 is sized and configured for insertion into a specific recess 44, and then attached to a power source (not shown). Because the LED light tubes 16 are flexible, it is only necessary to provide them with the correct length dimensions to fit into each recess 44. At each end of the flexible LED light tubes 16 is an end cap 46, which serves to physically and electronically insulate the light tube 16 as well as provide a cosmetically attractive end to the light tube 16.

[0043] FIGS. 4-8 are perspective, cross-sectional views of several examples of the terminal ends of the LED light tubes 16, each illustrating one or more features that may be included independently or in combination with other features disclosed herein (even if not described within the context of the same embodiment).

[0044] FIG. 4 illustrates a portion of an example of the lighted sign 10 according to one embodiment, illustrating in particular the relative positioning of the LED light tube 16, background 14, and frame 12. By way of example, the LED light tube 16 includes a generally bulbous head portion 48 and a neck portion 50 extending from the bulbous head portion 48. The neck portion 50 is sized and configured to nest within the recess 44 of the background 14. The bulbous head portion 48 protrudes away from the front face 40 of the background 14 and provides a rounded exterior that mimics a neon light tube. An end cap 46 is positioned at the end of the LED light tube 16, and in this embodiment comprises (by way of example) a heat shrink closure that seals the end of the LED light tube 16 and provides an exit for wires 52, which are connected to a timer or power source (not shown). In this embodiment, the wires 52 may pass through holes 54 formed within the recess 44 to exit on the back side of the background 14.

[0045] FIG. 5 illustrates a portion of an example of the lighted sign 10 according to another embodiment, illustrating in particular the relative positioning of the LED light tube 16, background 14, and frame 12. By way of example, the LED light tube 16 includes a generally bulbous head portion 48 and a neck portion 50 extending from the bulbous head portion 48. The neck portion 50 is sized and configured to nest within the recess 44 of the background 14. The bulbous head portion 48 protrudes away from the front face 40 of the background 14 and provides a rounded exterior that mimics a neon light tube. A formed end cap 46 is positioned at the end of the LED light tube 16 that seals the end of the LED light tube 16 and provides an exit for wires 52, which are connected to a timer or power source (not shown). The formed end cap 46 provides the same seal as the heat shrunk end cap previously described but without the need for heat-shrinking.

[0046] FIG. 6 illustrates a portion of an example of the lighted sign 10 according to another embodiment, illustrating in particular the relative positioning of the LED light tube 16, background 14, and frame 12. By way of example, the LED light tube 16 includes a generally bulbous head portion 48 and a neck portion 50 extending from the bulbous head portion 48. The neck portion 50 is sized and configured to nest within the recess 44 of the background 14. The bulbous head portion 48 protrudes away from the front face 40 of the background 14 and provides a rounded exterior that mimics a neon light tube. A formed end cap 46 is positioned at the end of the LED light tube 16 that seals the end of the LED light tube 16 and provides an exit for wires 52, which are connected to a timer or power source (not shown). In this embodiment, a secondary recess 56 is formed in the background 14, and more specifically within the floor of the recess 44. The secondary recess 56 has a narrower width than the width of the recess 44, and is sized and configured to receive the wires 52 therein. This allows the wires 52 to be directed to a gathering point in a more visually appealing manner (e.g. unseen), where they will then extend from the background 14 to a timer and/or power source.

[0047] FIG. 7 illustrates a portion of an example of the lighted sign 10 according to another embodiment, illustrating in particular the relative positioning of the LED light tube 16, background 14, and frame 12. By way of example, the LED light tube 16 includes a generally bulbous head portion 48 and a neck portion 50 extending from the bulbous head portion 48. The neck portion 50 is sized and configured to nest within the recess 44 of the background 14. The bulbous head portion 48 protrudes away from the front face 40 of the background 14 and provides a rounded exterior that mimics a neon light tube. A formed end cap 46 is positioned at the end of the LED light tube 16 that seals the end of the LED light tube 16 and provides an exit for wires 52, which are connected to a timer or power source (not shown). In this embodiment, the recess includes a continuous dovetail cut 58 which allows the recess 44 to more securely grip the neck 50 of the LED light tubes 16.

[0048] FIG. 8 illustrates a portion of an example of the lighted sign 10 according to another embodiment, illustrating in particular the relative positioning of the LED light tube 16, background 14, and frame 12. By way of example, the LED light tube 16 includes a generally bulbous head portion 48 and a neck portion 50 extending from the bulbous head portion 48. The neck portion 50 is sized and configured to nest within the recess 44 of the background 14. The bulbous head portion 48 protrudes away from the front face 40 of the background 14 and provides a rounded exterior that mimics a neon light tube. A formed end cap 46 is positioned at the end of the LED light tube 16 that seals the end of the LED light tube 16 and provides an exit for wires 52, which are connected to a timer or power source (not shown). In this embodiment, the recess includes a dovetail cut/protrusion 60 positioned intermittently along the recess 44 (e.g. at intervals of 3-5 inches) which allow the recess 44 to more securely grip the neck 50 of the LED light tubes 16. This intermittent protrusion embodiment achieves the same result of increased security of the LED light tube 16 without having to machine the dovetail groove along the entire length of each recess 44.

[0049] Although shown and described herein as having a background 14 that is a single piece of uniform construction, it should be understood that the background 14 may be provided in several portions that are then attached to one another (e.g. after transit to an install location) such that the recesses 44 align and one light tube 16 (or a combination of several light tubes 16) can be nested within the recesses 44 across different portions of the background 14. The different sections are attachable to one another by way of any suitable attachment mechanism, for example including but not limited to screws, nuts and bolts, magnets, hook and loop fasteners, snap fit, or have male and female parts of a jigsaw puzzle that could be used to attach them together. Making the sign 10 in smaller individual components that are later assembled may be advantageous in that it would be easier to ship and stand less chance of a background breaking during transit because of the smaller size.

[0050] It should be understood that while preferred embodiments are described in some detail herein, the present disclosure is made by way of example only and that variations and changes thereto are possible without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof.

[0051] All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.