Method and apparatus for simulating the appearance of a neon sign

A plurality of light emitting diodes (LEDs) disposed in a customized housing produce bright colored light simulating the appearance of a neon sign. The housing includes an opaque portion that reflects light from the LEDs and a translucent portion shaped in the form of an image or lettering that diffuses light from the LEDs. The inside surface of the opaque portion has a polished reflective surface while the outside surface has a dull textured surface. Light emanating from the LEDs propagates through the translucent portion of the housing appearing to a viewer as a bright uniform and colorful light similar in appearance to the light emitted from a neon sign.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to signage devices, and more particularly, to lighting devices that simulate the appearance of a neon gas light sign with solid state light emitters.

2. Description of Related Art

Advertisers and business establishments make extensive use of neon lights to convey a message and their appearances have become acceptable to customers. The bright, uniform, and colorful light distribution emitted from a neon light attracts attention making neon signs a good advertising medium. Neon signs have been used extensively for close to one hundred years.

To construct a segment of a neon sign, an artisan can heat lead glass tubing using a small blow torch and can shape the lead glass tube into a desired shape. During the shaping process, the artisan attaches an electrode to each end of the tube. The artisan then attaches the tube to a manifold with a high quality vacuum pump. The pump evacuates air from the tube. During evacuation a high voltage pulse is applied to the electrodes resulting in arcing from one electrode the other creating a high temperature inside the tube. Dirt and other impurities gasify and are pumped out of the tube resulting in a very clean interior vacuum. The artisan then introduces into the tube one or more noble gasses such as Neon, Krypton, Xenon, Argon or Helium.

The gasses introduced into the tube effect the neon light color. Neon produces an orange red glow. Argon with a droplet of mercury produces an ultraviolet light. The interior can also be coated with a variety of phosphors that react to ultraviolet light and emit colored light in the visible spectrum. These components can provide polluting material that should be removed upon disposal of the signs.

After all the segments of the neon sign have been formed the artisan assembles the segments into a single structure. The artisan wires each segment of the neon sign by electrically coupling the electrodes to a transformer that steps the voltage up from 120 volts to somewhere between 3,000 and 15,000 volts.

Light Emitting Diodes (LEDs) convert electrical energy into distinct colors of light. Tradition gallium arsenide LEDs emit red light when electrically stimulated. Advances in LED technology and material science have enabled semiconductor manufacturers to create very bright LEDs in a variety of colors. LED lighting offers numerous advantages over neon lighting. LEDs do not require transformers that step up voltages to dangerous levels instead LED's operate at low potentials of 3 to 24 volts. LED's can easily be packaged in a variety of safe materials and do not require large breakable tubular lead crystal structures. LED brightness can easily be controlled with very quick response allowing for visual effects not possible with neon lights. LED's may also be mass produced at low cost.

Those concerned with the use of neon signs have long recognized the need for more controllable, safer, less fragile and less expensive neon signs. The present invention significantly advances the prior art by simulating the bright uniform colorful appearance of a neon sign while using more efficient LED technology in unique housing configurations.

SUMMARY OF THE INVENTION

The present invention simulates the appearance of a neon sign. The invention comprises multiple housing portions composed of opaque and translucent materials and a plurality of LEDs arranged to produce light that propagates through the translucent portion of the housing. The housing portions mate to form a single rigid structure that surrounds the plurality of LEDs. The translucent portion has a shape that conveys a message via image, icon, lettering or other indicia.

The opaque portion of the housing has a shiny interior surface that reflects light emitted from the LEDs. The outer portion of the housing has a dark textured appearance making the surface appear flat and dull in stark contrast with the illuminated translucent portion. This contrast minimizes the visibility of the opaque portion of the housing creating a realistic neon like illumination particularly at night or in a dark setting.

The housing has a form that profiles the contours of the message to be conveyed. This contoured shape creates a more authentic neon sign like appearance. The housing is compartmentalized to focus the LED energy and prevent unwanted mixing of light from different colored LEDs.

One embodiment of the invention has an open structure wherein the desired message is cantilevered to permit a viewer to see through openings in the supporting housing adjacent the openings to further emphasize a neon sign effect.

A control circuit inside the housing controls the voltage applied to the LEDs. A control panel mounted on the outside of the housing provides user input to the control circuit. The control panel allows a user to select and control visual effects such as flashing and flash rate. A direct current (DC) port on the control panel receives electrical power for the control circuit and the LEDs. An alternating current (AC) adapter cable converts 120 volt AC power into DC power for powering the control circuit and the LEDs through the DC port.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1 and 2show a first embodiment of the neon sign simulator. The neon sign simulator includes a housing2formed approximately in the shape of indicia of a message to be conveyed. In this case, the indicia include the lettering “OPEN” with an underlining and an oval motif. The housing2defines a plurality of openings4that complement the lettering and design of the message and permits a viewer to see through the adjacent opening. This reinforces the concept of a neon sign with subjectively bent tubes at a fraction of the cost.

The housing has a base6with a textured outer surface to create a dull opaque appearance. The base6is composed of a lightweight rigid plastic such as Acrylonitrile-Butadiene Styrene (ABS) with black pigment. A cover member8mates with the base6to complete the housing2. The cover member8is composed of a lightweight sheet of plastic such as sanded or frosted acrylic with filler providing the cover member8with a textured translucent appearance. The cover member8is cut to complement the opening4and base6.

A silk screened inked portion10of the cover member8is not light transmissive, and forms an opaque template of the indicia of the message to be conveyed. First un-inked portions12shaped in the form of the indicia of the message to be conveyed provide surface areas for illumination (explained hereinafter). Second un-inked portions14complementary to the first un-inked portions12and located on the sides of the cover member8provide surface areas for illumination that cooperate to create a three dimensional visual effect emulating a bright glow having a halo characteristic of neon lights. Two ring posts15mounted on the base6provide convenient attaching structures for hanging chain fasteners.

In this embodiment the cover member8is composed of a frosted or sanded acrylic. The un-inked portions12and14of the cover member8act as diffusive lenses for light. Any suitable material that propagates and diffuses light may be substituted for the frosted or sanded acrylic, including plastic with filler particles.

The textured outer surface of the base6with its dull opaque appearance minimizes the visibility signature of the base6when the first and second un-inked portions12and14of the cover member8are illuminated. The bright colored light emitted is contrasted against the hard to see base6and makes each of the first un-inked portions12appear like an independent bright neon lamp segment. The plurality of openings4creates an illusion of transparency allowing a viewer to see objects on the other side of the housing2. This see through characteristic simulates the look of the federated lamp segments of a neon sign. The second un-inked portion14emits diffused light perpendicular to the diffused light emitted from the first un-inked portions12emulating the bright glow with halo characteristic of a neon signs.

The message to be conveyed by the sign through the “OPEN” lettering, underlining and oval motif is exemplary. The housing2may be constructed, and the cover member8inked, to convey any message through any indicia including lettering, images and icons.

The inked portion10of the cover member may be inked using a silk screening process. The inked portion10of the cover member8may also be rendered opaque through the use of dark paint bonding an opaque material to the cover member8or a masking template sandwiching the cover member8.

FIG. 2shows an exploded view of the neon sign simulator. The neon sign includes the cover member8, a printed circuit board (PCB)17, and the base6. The cover member8has a large flat surface area with a plurality of openings4that complement the lettering and design. The cover member8is partially inked with a dark opaque ink forming a template of indicia of a message to be displayed. The first un-inked portions12with frosted or sanded acrylic surfaces define discrete simulated neon light segments. The first un-inked portions12include an “O”19, a “P”21, an upper “E”23, a lower “E”25, “N”27, an underline24and an oval motif26. The second un-inked portions14radiate light perpendicular to the first unlinked portions12providing a neon like visual effects.

The PCB17has the same shape as the housing2with a plurality of LED's16mounted on the surface. The LEDs16provide illumination for the neon sign. The LED's16may be of one or more colors. For example, the LEDs16that form the lettering “OPEN” may be red and the LEDs16forming the underline and oval motif may be blue. InFIG. 8, a power and control circuit (not shown) accepts DC power at an input port90and control inputs92,94, and96from a control panel98, which is shown schematically without defining a location on the housing2, to provide electrical signals to the PCB17and the LEDs16.

Using the control panel98inFIG. 8. a user can turn the LEDs16on using control input92, command the LEDs16to flash using control input96, or adjust the flash rate using control input94. The use of the control panel98to control a variety of visual effects such as sequencing, dimming, auto start and auto shutdown is also contemplated.

The base6features multiple concavities18that house segments of the PCB17. The interior surfaces of the concavities18have a smooth texture that reflects light emitted from the LEDs16.

FIG. 3shows an A-A cross section ofFIG. 1. The cover member8has inner edges22that mate with the inner edges20of the base6. The cover member8inner edges22and the base6inner edges20can be bonded together using ultrasound technology for further securing the cover member8to the base6. The PCB17is mounted to the base6with screws24that engage threaded mounting posts27. The LEDs16are mounted on the PCB17. The LEDs are embedded in the concavity18which has a dark polished surface that reflects light from the LEDs16. Light emitted from the LEDs16travels through the first un-inked portions12and the second un-inked portions14of the cover member8while diffusing in the process. The second un-inked portion14substantially perpendicular to the first un-inked portion12provides a three dimensional lighting effect. The inked portion10defining the indicia contours helps create this effect.

Inked portions10provide regions of non-transmissiveness in the cover member8. The inked portions10define the precise contours of the lettering and the design. The diffused light emanating from the first and second un-inked portions12,14of the cover member8appears to an observer as a bright uniform light similar to the light emitted from a light segment of a conventional neon light.

FIG. 4shows a B-B cross section ofFIG. 1. The cover member8inner edges22mate with the base6inner edges20. The cover member8diffuses light emitted from the LEDs16. Inked portions10of the cover member8prevent light from radiating, forming a light mask that defines the contours of letters and images in the cover member8. The mounting posts27support the PCB17on which individual LEDs16are mounted. The concavity18surrounds the series of LEDs16in a channel like structure.

FIG. 5shows a perspective view of an alternate embodiment of the simulated neon sign. The neon sign simulator includes a housing28that approximates the profile of the indicia of a message to be conveyed. Openings37on the top of the housing28further complement the profile. In this case, the indicia include the lettering for the word “OPEN” with an upper and lower design. The housing28includes a bottom32, a top30, and a plurality of translucent segments34that collectively define the message to be conveyed. The top is composed of a transparent plastic material. The bottom32is composed of transparent lightweight rigid plastic. The translucent segments34are acrylic with a diffusive frosting.

FIG. 6shows an exploded view of the simulated neon sign ofFIG. 5. The plurality of translucent segments34include an “O”36, “P”38, “E”40, “N”42, an upper curvilinear design44and a lower curvilinear design46. The translucent segments34collectively convey the message “open”. Each of the translucent segments34has one or more latching members48for engagement with the top30(explained hereinafter). The translucent segments34have a domed shape that simulates the cylindrical glass tubing of a neon light.

The top30has multiple concavities50that accommodate the plurality of translucent segments34. Individual concavities “O”52, “P”54, “E”56, “N”58, upper curvilinear design60and lower curvilinear design62accommodate respective translucent segments3638404244and46. Openings37in the top30further accentuate the lettering. The top30has a textured outer surface with dull opaque appearance. The top30is composed of Acrylonitrile-Butadiene Styrene (ABS).

A plurality of Light Emitting Diodes (LEDs)64are mounted on a plurality of printed circuit boards66that extend into the bottoms of the multiple concavities. Each of the printed circuit boards687072747678correspond to each of the concavities525456586062respectively. The diodes generate light that exits through the plurality of translucent segments34. The diffused light that emanates from the translucent segments has a uniform colored glow similar to the light emitted from a neon light.

The bottom32mates with the top30. A control circuit35mounted to the bottom is wired to each of the printed circuit board66687072747678and controls illumination of the LEDs66.

FIG. 7shows the A-A cross section of the simulated neon sign ofFIG. 5. Translucent segment34engages with the top30through latching member48. Latching member48engages with notch88located in the concavity61. The concavity61has a plurality of apertures88through which the LEDs64extend. The LEDs64are mounted on the PCB76that is affixed to the bottom of the concavity with screws80.

Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the amended claims, the invention may be practiced other than as specifically described herein.