Abstract:
A lighted architectural panel system includes an architectural panel; a light source panel; and a diffusion panel disposed between the architectural panel and the light source panel.

Description:
TECHNICAL FIELD 
       [0001]    The disclosure herein relates to an architectural panel, and more particularly, to an architectural panel system having a light element therein, and a method of making the same. 
       BACKGROUND 
       [0002]    Architectural panels such as those made from a rigid mesh are generally used in commercial and business environments to provide elegant wall panels, doors and other surfaces whenever an aesthetic appearance of polish and prestige are of primary importance. Architectural mesh is also an excellent choice for high contact areas, such as the interior walls of elevator cabs, escalator walls, and sales and reception areas, because it is generally scratch, dent and corrosion resistant. As such, architectural mesh maintains a stunning appearance with minimal maintenance. Architectural mesh panels can also be used to provide protection from the wind and other elements such as, for example, in a parking garage where the exterior walls are only several feet high on each level, thus leaving a several foot open area through which rain and sleet can enter the garage. 
         [0003]    Woven into panels from brass, stainless steel, copper, and/or other desired metals or alloys, or combinations thereof, architectural metallic mesh offers a richness of texture, pattern and color that cannot be duplicated by any other material. Depending upon the chosen weave, the interstices or apertures between the weft or fill wires and the warp wires may allow light to pass through the architectural mesh. There is difficulty in achieving a consistent light pattern, however, if the weave pattern is tight or the interstices are not spaced in a consistent pattern. 
         [0004]    U.S. Pat. No. 6,793,360 assigned to Cambridge International Inc., the contents of which are hereby incorporated herein, discloses an example of an architectural mesh panel wherein a light element is interwoven with the plurality of wires in the mesh. The result is an attractive and decorative mesh panel with accent light effects therethrough. The type of mesh panel disclosed in this patent includes woven weft and fill wires and the light element is substituted for one of the weft wires during the manufacture of the mesh. While this type of interweaving securely holds the light element in place, repair or replacement of the light element may be quite difficult and labor intensive and the pattern of light provided is fixed so that it cannot be changed or altered. 
         [0005]    Accordingly, it would be desirable to provide an architectural panel having a light element therein, so as to create a greater aesthetic appeal in environments benefitted by the presence of accent lighting, wherein the light element is more readily accessible, replaceable, and/or interchangeable as desired. 
       SUMMARY OF THE INVENTION 
       [0006]    The disclosure herein provides a lighted architectural panel system comprising an architectural panel, a light source panel, and a diffusion panel disposed between the architectural panel and the light source panel. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0007]    These, and other objects, features, and advantages of the disclosure will become more readily apparent to those skilled in the art upon reading the following detailed description, in conjunction with the appended drawings in which: 
           [0008]      FIG. 1  is an exploded perspective view of a lighted architectural panel system in accordance with an exemplary embodiment of the disclosure herein. 
           [0009]      FIG. 2  is a front view of an exemplary embodiment of an architectural mesh panel. 
           [0010]      FIG. 3  is a front view of an exemplary embodiment of an interchangeable backer plate with LED lighting. 
           [0011]      FIG. 4  is a cross section taken generally along line A-A shown in  FIG. 3 . 
           [0012]      FIG. 5  is an enlarged view of Detail C shown in  FIG. 3 . 
           [0013]      FIG. 6  is an enlarged view of Detail B shown in  FIG. 4 . 
           [0014]      FIG. 7  is an exploded perspective view of an architectural panel system in accordance with a further exemplary embodiment of the disclosure. 
           [0015]      FIG. 8  is an exploded perspective view of an architectural panel system in accordance with a still further exemplary embodiment of the disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    A lighted architectural mesh panel system in accordance with an exemplary embodiment of the disclosure is shown generally in  FIG. 1  by reference numeral  10 . The architectural mesh panel system  10  preferably includes an architectural mesh panel  12 , a diffusion panel  14 , an outer backer board frame  16 , and an interchangeable backer board  18  including a lighting system  20 . The various components of the architectural panel system  10  are secured together by known attachment hardware  26 . 
         [0017]    The mesh panel  12  is woven from a combination of wires of two or more different metals, for example, brass and stainless steel, or the mesh may be woven using wires  22  and  24  that are made from the same metal or other substantially rigid material. All of the wires  22 ,  24  may be the same size or shape, or they may have different characteristics. The materials most commonly used in rigid metallic mesh are stainless steel, aluminum, brass, bronze and copper. The combination of the different size wires and materials creates a unique texture appearance for architectural metallic mesh. 
         [0018]    In the architectural mesh panel  12 , the members  22  are strands of wire in the fill or weft direction of weaving and the members  24  are strands of wire in the warp direction. In the illustrated embodiment, the warp members  24  cross under and over the wires  22  in a plain weave. However, it should be apparent to one skilled in the art that other weaves, such as a twill weave or hollander (Dutch) weave, for example, could also be used. The wires  22  and  24  are illustrated in an evenly spaced relation for ease of understanding, and although mesh panel  12  could be so manufactured, the wires could be directly closely adjacent one another, or unevenly spaced, in practice. Thus, the architectural mesh panel  12  is a typical example of a continuously woven metallic mesh having wires  22  in the fill direction and wires  24  in the warp direction. 
         [0019]    A further element of lighted architectural mesh system  10  is the interchangeable backer board or plate  18  shown in  FIG. 3 . A backer board frame  16  may optionally be provided for additional support and rigidity, with the interchangeable backer plate  18  being mounted thereon in any known manner. The backer plate  18  contains fluted grooves  28  with clearance to hold the lighting system  20 , such as a LED rope light. The grooves  28  may be machined to comprise letters, graphics, or patterns for commercial offerings. A matrix of grooves  28  can also be inlaid to provide a grid of LED elements to allow for more elaborate graphics and media presentations. The grooves  28  allow for the insertion of flexible LED elements  20 , thus making the system self-contained. The backer plate  18  is typically painted a dark color with the LED receiving grooves  28  being a lighter color to provide greater contrast and light dispersion. As shown best in  FIGS. 4-6 , grooves  28  may be formed as a V-shaped groove with a fluted edge  30 . The V-shape of the groove  28  as illustrated in the exemplary embodiment includes a flat groove bottom  32  and angled side walls  34  shown at forty degrees, although this angle can be varied. It has been found that this shape of the grooves  28  also assists with light dispersion, but any shape groove capable of securing light element  20  therewithin could of course also be used. The backer plate  18  and backer board frame  16  are typically made from a material such as medium density fiberboard (MDF) for interior use or a polycarbonate material for exterior use. The LED backer plate  18  is designed to be interchangeable, to thus allow for removal and maintenance of the LED lighting  20  or for changing the LED lighting elements to provide different logos or patterns. As such, lighted architectural mesh system  10  can be maintained or changed for different applications without the need to disassemble the entire panel. 
         [0020]    An example of such a light element  20  is a flexible light rope or any similarly know elements. The light-emitting diode (LED) can be of any desired color to create the desired light effect. The LEDs may be wired to a power grid or powered by one or more batteries, or otherwise powered as known in the art, and may be configured for either continuous power or flashing on and off for longer life. Still further, the LEDs may be used to create a picture, logos, wording, or even a continuously moving light display. The disclosure here is not limited to the size or shape of the light element  20  shown in the figures, it being clear to one skilled in the art that various sizes and shapes can be used depending upon the size of the recess  28  formed in the backer board  18 . 
         [0021]    Depending on the chosen weaving pattern, the interstices between the warp and weft wires will allow light to pass through the architectural mesh. There may be difficulty in achieving a consistent light pattern, however, if the weave pattern is tight or the interstices are not spaced in a consistent pattern. 
         [0022]    This lighting limitation is overcome by providing diffusion panel  14  between the backer board  18  and the mesh panel  12 . The diffusion panel  14  is a translucent panel that may be made of frosted glass, Plexiglas, or any type of plastic which is sandwiched between the outer rigid mesh panel  12  and the LED lighting  20  contained in the interchangeable backer plate  18 . The translucent panel  14  distributes the lighting across the back face of the rigid mesh  12 . Thus the LED lighting  20  does not have to align or be sized exactly with the mesh openings or pattern. The LED lighting  20  can be triggered by touch, motion sensors, manual controls, or otherwise as dictated by the application. 
         [0023]    A lighted architectural panel system in accordance with a further exemplary embodiment of the disclosure is shown generally in  FIG. 7  by reference numeral  100 . The architectural panel system  100  preferably includes an architectural panel  120 , a translucent panel  14 , an outer backer board frame  16  (optional), and an interchangeable backer board  18  including an LED lighting system  20 . Like reference numerals are being used to denote like elements described above relative to the embodiment of  FIG. 1 . Architectural panel  120  replaces the woven mesh panel  12  and is formed from a perforated metal sheet. The perforations  122  may be provided in any type of symmetrical or random pattern as desired. 
         [0024]    A lighted architectural panel system in accordance with a still further exemplary embodiment of the disclosure is shown generally in  FIG. 8  by reference numeral  200 . The architectural panel system  200  preferably includes an architectural panel  12 ,  120 , a translucent panel  14 , and a printed circuit board (PCB)  210  that can be spot welded to the metal of architectural panel  12 ,  120 , thus eliminating a need for the backer plate or backer plate frame therebetween. The printed circuit board  20  has conductive copper tracks that may be laminated into a non-conductive surface. Electronic components can thus be surface mounted or through-hole mounted, such as LED light elements  220 , and the components are connected by the copper tracks to form a circuit. 
         [0025]    While the disclosure herein has been described with respect to particular exemplary embodiments of the invention, this is by way of illustration for purposes of disclosure rather than to confine the invention to any specific arrangement as there are various alterations, changes, deviations, eliminations, substitutions, omissions and departures which may be made in the particular embodiment shown and described without departing from the scope of the present invention as defined only by a proper interpretation of the appended claims.