Patent Publication Number: US-9836999-B2

Title: LED backlight system for cabinet sign

Description:
This application is a continuation of U.S. patent application Ser. No. 11/784,639, filed on Apr. 9, 2007, which claimed the benefit of U.S. Provisional Patent Application Ser. No. 60/849,653, filed on Oct. 5, 2006. These applications are incorporated herein by reference in their entireties. 
    
    
     BACKGROUND 
     The present exemplary embodiments relate to a backlighting system. It finds particular application in conjunction with the signage industry. One particular application for such a backlighting system is a cabinet sign, and it will be described with particular reference thereto. However, it is to be appreciated that the present exemplary embodiment is also amenable to other like applications. 
     Presently large cabinet signs currently use fluorescent bulbs and ballast as the lighting system. These types of systems are labor intensive and costly to maintain. Often the bulbs need to be replaced within a year or two at most. Given a typical location of the cabinet sign and the size of the bulbs, frequently the use of a bucket truck or other non-readily available equipment is needed to repair the sign. Previously proposed alternatives for a backlighting system for a cabinet sign include a linear light emitting diode array or a perimeter lighting apparatus. However, for various reasons, these options have not obtained any significant commercial success as an alternative to the aforementioned fluorescent backlighting system. 
     BRIEF DESCRIPTION 
     A backlighting system for a cabinet sign is described herein and a method of making the sign. The system may include a plurality of panels. Each panel includes a plurality of light emitting diodes (“LEDs”) attached to the panel. The LED layout spacing pattern has a box sign depth factor of less than about 1.4. An integrated circuit may also be located on the panel. A wire physically connects adjacent panels. Cabinet signs which include the aforementioned back lighting system are also disclosed herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front view of one embodiment of a backlighting system for a cabinet sign described herein; 
         FIG. 2  is a front view of a panel which may be used as part of the backlighting system as described herein; 
         FIG. 3  is a front view of a core plate which may be included as part of a panel; 
         FIGS. 4 and 5  are side views of a panel which include an over mold; 
         FIG. 6  is a front view of another embodiment of the backlighting system; 
         FIG. 7  is an embodiment of a backlighting system described herein along with the frame of the cabinet sign; 
         FIG. 8  is a side view of an embodiment of a column of panels which are foldable; 
         FIG. 9  is a partial view of a backlighting system which includes the foldable column of panels from  FIG. 8 ; 
         FIG. 10  is another embodiment of the backlighting system which includes a rectangular embodiment of the panels; 
         FIG. 11  is a front view of another embodiment of a panel which may be used in the backlighting system disclosed herein; 
         FIG. 12  is a column of the panels disclosed herein; 
         FIG. 13  is an embodiment of a column of panels as shown in  FIG. 12  which are rolled into an easily packagable shape; 
         FIG. 13A  is an embodiment of a column of panels as shown in  FIG. 12  which are folded one on top of another; 
         FIG. 14  is an embodiment of two columns of panels which are stacked one column on top of another column; 
         FIG. 15  is an additional embodiment of a panel; 
         FIGS. 16-19  depict alternatives how power may be supplied to a panel as well as between panels in the same column and between different columns of panels; 
         FIGS. 20 and 21  illustrate alternatives how the backlighting system disclosed herein may be used in double sided signs; 
         FIGS. 22A-F  depict various brackets that may be used with the panels of the backlighting system; 
         FIG. 23  is an embodiment of a cabinet sign which includes a backlighting system as disclosed herein; 
         FIG. 24  is an embodiment of a cabinet sign which includes a double array backlighting system as described herein; 
         FIG. 25  is a rectangular panel which includes an over mold; 
         FIG. 26A  illustrates a three LED module that is coupled to a bridge, in accordance with an exemplary embodiment; 
         FIG. 26B  illustrates a modular electrical connection of the lighting system, in accordance with an exemplary embodiment; 
         FIG. 26C  illustrates a connecting element to allow a second light module to be attached to the lighting system, in accordance with an exemplary embodiment; 
         FIG. 26D  illustrates a single array lighting system, in accordance with an exemplary embodiment; 
         FIG. 26E  illustrates a double array lighting system, in accordance with an exemplary embodiment; 
         FIG. 27A  illustrates a six LED module, in accordance with an exemplary embodiment; 
         FIG. 27B  illustrates a single array utilizing the six LED module, in accordance with an exemplary embodiment; 
         FIG. 27C  illustrates a double array utilizing the six LED module, in accordance with an exemplary embodiment; 
         FIG. 28A  illustrates an alternate six LED module lighting system, in accordance with an exemplary embodiment; 
         FIG. 28B  illustrates an optional wire pass through embodiment of the six LED module lighting system, in accordance with an exemplary embodiment; 
         FIG. 28C  illustrates a single array utilizing the alternate six LED module, in accordance with an exemplary embodiment; 
         FIG. 28D  illustrates a double array utilizing the alternate six LED module, in accordance with an exemplary embodiment; 
         FIG. 29A  illustrates an alternate six LED module lighting system, in accordance with an exemplary embodiment; 
         FIG. 29B  illustrates electrical connectivity of the six LED module in  FIG. 29A , in accordance with an exemplary embodiment; 
         FIG. 29C  illustrates a single array utilizing the six LED module in  FIG. 29A , in accordance with an exemplary embodiment; 
         FIG. 29D  illustrates a double array utilizing the six LED module in  FIG. 29A , in accordance with an exemplary embodiment; 
         FIG. 30A  illustrates a three LED module with a snap together hinge, in accordance with an exemplary embodiment; 
         FIG. 30B  illustrates an embodiment of the three LED module for shipping, in accordance with an exemplary embodiment; 
         FIG. 30C  illustrates a single array utilizing the three LED module, in accordance with an exemplary embodiment; 
         FIG. 30D  illustrates a double array utilizing the three LED module, in accordance with an exemplary embodiment; 
         FIG. 31A  illustrates a top view of the LED panel in the form of a lattice, in accordance with an exemplary embodiment; 
         FIG. 31B  illustrates a bottom view of an LED panel in the form of a lattice, in accordance with an exemplary embodiment; 
         FIG. 32  illustrates a top view of an over mold LED module in the form of a lattice, in accordance with an exemplary embodiment; 
         FIG. 33A  illustrates a top view of an LED module in the form of a lattice, in accordance with an exemplary embodiment; 
         FIG. 33B  illustrates a bottom view of an LED module in the form of a lattice, in accordance with an exemplary embodiment; 
         FIG. 33C  illustrates an exploded view of an LED module in the form of a lattice, in accordance with an exemplary embodiment; 
         FIG. 34A  illustrates a top view of a PCB assembly utilized with an LED panel, in accordance with an exemplary embodiment; 
         FIG. 34B  illustrates a bottom view of the PCB assembly utilized with an LED panel, in accordance with an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     In describing the various embodiments of the backlighting system, like elements of each embodiment are described through the use of the same or similar reference numbers. 
     An embodiment disclosed here includes a plurality of panels which comprise the backlighting system. Each panel includes a plurality of LEDs. Preferably, the LEDs are spaced away from each other on the same panel and likewise relative to LEDs on adjacent panels such that the backlighting system will exhibit lighting qualities similar to those of a fluorescent backlit system. The LED backlit system will exhibit uniformity, brightness, and color rendering consistent with that of a fluorescent backlit system. 
     With reference to  FIG. 1 , illustrated is a front view of a backlighting system,  100 , for a cabinet sign. The depicted system  100  includes a frame  102  and a plurality of panels  104 . Panels  104  are attached to frame  102  in a plurality of rows as shown. Alternatively, panels  104  may be attached to frame  102  in plurality of columns instead of rows. Individual panels  104  are not limited to any particular size. Given that typically a box sign is square or rectangular, a particular useful panel size is 1′×1′. Manufacturers of cabinet signs may find this size panel desirable in that it may be used to make the lighting system for cabinet signs of various sizes. Typically, the cabinet sign has a sign surface having an area of the sign less than about 200 square feet (ft 2 ). In various embodiments of the sign, the surface area of the sign may range from about 4 up to about 200 square feet (ft 2 ). Alternatively, if a flexible material (e.g., a vinyl based material, etc.) is employed for the face of the cabinet, the surface area of the sign can be much greater than 200 square feet. Such an approach can be employed to allow the cabinet face to withstand excessive wind loading. 
     Alternatively, as shown in  FIG. 11 , panels  104  may be rectangular in shape. Panels  104  are not limited to any particular shape or size. Panels  104  are depicted in rectangular and square shapes due to the reason that these are believed to be desirable shapes for sign manufacturers. Panels having other shapes may be manufactured, if desired by an end user. Also, panels of different shapes and/or sizes may be used in the same cabinet sign. 
     In one embodiment, panel  104  may be a printed wiring board. The printed wiring board may be one selected from the group of a printed circuit board, a metal clad printed circuit board, and a flexible circuit. The flexible circuit may include a backing plate. Two examples of preferred materials for the backing plate include aluminum or plastic. Flex circuits are available at least from the following sources: Minco of Minneapolis, Minn., Allflex Inc. of Northfield, Minn., and Uniflex Circuits of San Jose, Calif. In another embodiment, the printed wiring board may include LEDs connected together with a wire in the form of a strip and then the strip is attached to a backing. Typically, the backing may be made of aluminum or plastic. 
     As shown in  FIG. 2 , each panel  104  includes a plurality of light emitting diodes (“LEDs”)  106 . LEDs  106  may be arranged in any particular pattern on panel  104 . Also, the number of LEDs  106  on each panel may vary or may be uniform. In one particular embodiment, each LED  106  is no more than 4″ away from one or more adjacent LEDs. In another embodiment, LED spacing may be determined by the box sign depth factor. This is the ratio of the distance the LED is from the sign face of the cabinet sign (“depth”) divided by the distance between the closest adjacent LED and the subject LED. For example, if the subject LED is 4″ away from the closest adjacent LED and the depth of the LED below the sign is 4″, the factor is 1. In another example if the distance between adjacent LEDs remains the same, but, the depth changes to 5″, the factor is 1.25. In a further example, adjacent LEDs are spaced about 6″ away from each other and the depth is about 8″, the sign box depth factor is about 1.33. 
     In a particular embodiment, a preferred factor is less than about 1.4. In another particular embodiment, the factor may range from about 1.25 to about 0.5. In a further embodiment, the LEDs may be randomly or uniformly spaced apart from one another. In one certain embodiment, each LED is substantially equally spaced apart from its adjacent LEDs. 
     Any suitable type of LED may be used in conjunction with the panel  104 . Examples of typical types of LEDs which may be used include surface mount LEDs and hole through LEDs. Panel  104  is not limited to a particular number of LEDs  106 . Any desired number of LEDs may be used. A typical panel  104  may have anywhere from four (4) to twelve (12) LEDs associated with it. 
     In addition to various types of LEDs being suitable, LEDs  106  do not have to have any specific wattage requirement. In one particular application LED  106  wattage may be 1 W or 0.5 W. As for panel  104 , in one particular embodiment it is preferred that the light emitted by LEDs  106  on panel  104  has a brightness of up to about 1500 nits, measured at the outside surface of the sign face of the sign. 
     Panel  104  may also include one or more integrated circuits  108 . Integrated circuits  108  may be used to drive LEDs  106  on panel  104 . In addition to panel  104  including circuit  108 , panel  104  may include one or more LED protective elements. This is an element which may protect the diode of the LED from coming in physical contact with another tangible item. In one example, the protective element may comprise a ring shaped cone on the surface of panel  104  in which LED  106  is in the center of the recessed portion of the cone. In a second embodiment, the protective element may be a clear plastic cap over the top of the diode of each LED. 
     Also illustrated in  FIG. 2 , panels  104  may be attached to one or more rails  110 . The rails may be constructed from any material which is known to be suitable for use as a heat sink; non-limiting examples include aluminum and natural graphite. Panels  104  may be attached by any know attachment technique. As illustrated panels  104  are attached by the use of screws  112 . Optionally, panels  104  may be fixed to rails  110  or adjustably attached to rails  110 , as shown. Rails  110  may be attached to frame  102  by any known attachment technique. In another embodiment, panels  104  may include one or more integral or attachable guides that mate with a portion of rails  110  and enable panels  104  to easily move along rails  110 . 
     As illustrated, rails  110  may be adjustably attached to frame  102  by the use of a clamping element,  114 . Alternatively, other adjustable attachment elements may be used instead of clamping element  114  or fixed attachment elements may be used in place of clamping element  114 . Panels  104  may be uniformly spaced apart or randomly spaced apart. In one particular embodiment, the spacing between any two adjustably attached adjacent panels  104  on the same rail  110  may be adjusted to a desired distance. Panel  104  may also include one or more terminals  116 . The terminals may be used to connect two (2) adjacent panels  104  together. 
     Depicted in  FIG. 3  is a front view of one embodiment of an optional component of panel  104 . As illustrated panel  104  may include a core plate  105 . Optionally, core plate  105  includes one or more openings  118 . Preferably, openings  118  are sized and spaced so not to detract from the structural integrity of panel  104  but to improve at least the ability of panel  104  to transfer heat away from the LEDs and optionally also the strength of core plate  105 . Openings  118  may be uniformly or randomly oriented on panel  104 . Examples of preferable materials of construction of core plate  105  include steel, steel alloys, aluminum, aluminum alloys, natural graphite, extruded plastic, any other material which may be used as a heat sink and have sufficient structural integrity, and combinations thereof. 
     As shown in  FIG. 4 , panel  104  may include a thin ceramic coat  120  encapsulating core plate  105 . Panel  104  may also include an over mold  122 . Preferably, over mold  122  is made from weather resilient material and has a transparent top surface. Examples of materials which may be used to make over mold  122  include silicone, epoxy, or a plastic extrusion. The plastic extrusion may be formed from thermoplastic elastomers (thermo-conductive or non thermo-conductive), polyvinyl chloride, acrylic, polyethylene (high density or low density), polypropylene, polystryrene, and ABS. Over mold  122  may attach to a top surface of panel  104  or alternatively may attach to a side or bottom surface of panel  104 , as shown in  FIG. 5 . Additionally, panel  104  may include one or more optional feet  125 . Preferably feet  125  extend away from panel  104  from an underside of panel  104 . Preferably, over mold  122  does not cover a top surface of LEDs  106 . 
     Specific preferred combinations of panel  104  and over mold  122  include a printed circuit board panel and a plastic or silicone over mold, a metal clad circuit board and a plastic or silicone over mold, and a flex circuit on an aluminum or plastic backing and a plastic or silicone over mold. The plastic may be a thermoplastic elastomer or other type of suitable polymer which may be formed into plastic. 
     In one method of applying over mold material to panel  104 , panel  104  may include openings and pins may be used to maintain panel  104  in a fixed position during the over molding process. If desired in a second embodiment, the openings used may be filled in a separate over molding step or the holes may be filled with a filler. 
     Alternatively, panels  104  may be encased in a snap together plastic housing. The housing may include connecting front and back sections which may be used as an enclosure to protect the board. It is preferred that the front section of housing includes openings aligned with LEDs  106  for the emission of the light generated by LEDs  106 . 
     Over mold  122  or the housing may be used to connect a plurality of panels  104  having a one-dimensional array to form a panel having a two-dimensional array. For example, two or more panels, such as shown in  FIG. 10, 104R  may be over molded at the same time to form a composite panel having the LEDs arranged in two dimensions. The resulting panel would have an orientation similar to that of the panel  104 L, shown in  FIG. 12 . Alternatively, a housing may be used to form a plurality of panels  104 R having a one-dimensional array into a two-dimensional array. Such a housing would encase two or more panels to align LEDs  106  in the width and length direction of the housing. 
     An arrangement  130  of panels  104  is illustrated in  FIGS. 6 to 9 . As shown, a plurality of panels  104  is arranged in columns. Adjacent panels  104  in each column are attached by one or more flexible strips  126 . Preferably flexible strips  126  mechanically connect adjacent panels  104 . Optionally, flexible strips  126  may also electrically connect adjacent panels  104 . Preferably flexible strips  126  have sufficient flexibility that strips  126  may be used to fold panels  104  of system  100  one on top of another, as illustrated in  FIG. 8 . In one particular embodiment, panels  104  may be shipped in the folded orientation as shown in  FIG. 13A . In the embodiment shown in  FIG. 6 , one fold may occur between row  104 A of panels  104  and row  1046  of panels  104  and another fold may occur between row  104 B of panels  104  and row  104 C of panels  104 . As shown, a connector  128  is used to attach the end panel  104  of each column to a support  124 . Two non-limiting examples of suitable materials for flexible strip  126  are a ribbon cable and a Mylar flex connection. These exemplary materials may also be used to supply power between adjacent panels. In the case that strip  126  includes a wire, the wire may optionally be either a two conductor wire or a three conductor wire. 
     Supports  124  may be attached to frame  102  of a cabinet sign. One or more of the arrangements  130  may be used to form the system  100  for a cabinet sign. Alternatively, as shown in  FIG. 9 , flexible strips  126  may be used to attach panels  104  to support  124 . In another alternate embodiment, flexible strips  126  may be used to attach panels  104  to frame  102  instead of support  124 . 
     An alternate embodiment of panels  104 R is depicted in  FIG. 10 . In  FIG. 10 , panel  104 R has a rectangular shape and LEDs  106  are arranged in a single file line along the length of panel  104 R. This may also be referred to as arranging LEDs  106  in a one dimensional pattern, whereas in  FIG. 2 , LEDs  106  are arranged in a 2-dimensional pattern. 
     As shown in  FIG. 10 , panels  104 R may be moved in the direction of double arrow A along rails  110  to any desired point along rails  110 . In the illustrated embodiment, each rail  110  includes a recess to engage a locking element  129 . As shown locking element  129  includes a bolt sized to fit into recess  127 . In an alternate embodiment, recess  127  may be sized to engage the feet of panel  104 R similar, but not limited, to feet  125  depicted in  FIG. 5 . 
     Each pair of panels  104 R may include a bracket in between adjacent panels  104 R. The bracket may be a unitary element which connects two adjacent panels  104 R. Each panel  104 R may include a receiving element for the bracket. Additionally, the bracket may have a recess such that it will be able to receive another panel  104 R to align a plurality of panels in a manner similar to as shown in  FIG. 14 . Alternatively, a portion of the bracket may be attached to each of the panels  104 R and mate with a complimentary portion of the bracket on the adjacent panel  104 R. Also, the bracket may include a hinge such that a fold may be formed relative to the two adjacent panels. Lastly, the brackets may be detachable; such that the bracket may be detached from a panel or that the bracket may be separated into two (2) sections. 
     Optionally, one end of panels  104 R may include a port for connecting a power source to panel  104 R. A second end of the panel  104 R may include an electrical connector to adjoin adjacent panels  104 R in the horizontal direction of the backlighting system. 
     Illustrated in  FIG. 12  is another embodiment of panel in the form of a lattice  104 L. Panel  104 L may be any desired dimension, such as but not limited to about twelve inches (12″) wide (depicted as “W”) and a height of about four inches (4″) to about six inches (6″) (depicted as “H”). Preferably the LEDs  106  are spaced at least about two inches (2″), but no more than six inches (6″), apart from an adjacent LED  106 . Preferably, adjacent panels  104 L are connected by flexible strips  126 . Optionally, panels  104 L may be connected to a bus, not shown. It is also preferred that the plurality  134  of panels  104 L may be folded one on top of the other as shown in  FIG. 13A , or rolled into a convenient shape of packaging and transporting to a desired location. As shown, one convenient shape is the substantially cylindrical type shaped roll of the plurality  134  illustrated in  FIG. 13 . 
     In one particular embodiment of system  100  that includes panels  104 L, it is preferred that the LEDs  106  are equally spaced apart from one another, For example, each LED may be about four inches (4″) apart for an adjacent LED. Optionally, the 4″ spacing may also apply to adjacent LEDs  106  on adjacent panels  104 L. Adjacent panels  104 L may be arranged either horizontally or vertically to one another. Dimensions of a panel, long on one side (e.g., nine inches), short on the other (e.g., less than five inches) can provide easier fit within rectangular cabinet sign and, by adjusting orientation of layout, may accommodate a greater number of box signs of varying heights and widths. 
     In another embodiment of system  100  which includes panels  104 L, panels  104 L may be stacked one on top of another as shown in  FIG. 14 . In one particular embodiment, it is preferred that the panels  104 L are stacked in an offset relationship to one another such that the light emitting from those LEDs  106  on a lower panel  104 L is not blocked by the upper panel  104 L. This technique may be used to increase the density of the LEDs in a particular area of the cabinet sign or over all of the illumination areas of the cabinet sign. Panels  104 L may be arranged in a stacked configuration by various techniques, such as rails, wire supports, or snap-on features. A bottom surface of a top one of panels  104 L may have a snap-on element and the top surface of the lower panel  104 L may have a complimentary snap-on element. Optionally, one or more of panels  104 L may include a stand-off. The stand-off may be integral or attached to panel  104 L. In one embodiment of stacked panels  104 L, it is preferred that panels  104 L do not contact one another. In this embodiment, the stand-off may include a small piece of plastic which is used to maintain a preferred distance between the upper and bottom panels  104 L. 
       FIGS. 31A and 31B  show a top view  500  and bottom view  502  of a PCB assembly  508  utilized in the lattice LED panel  104 L.  FIG. 32  shows a top view of a plurality of lattice LED panels  104 L as illustrated in  FIG. 12  above.  FIG. 33A  illustrates a top view and  FIG. 33B  illustrates a bottom of view of the over mold  122 .  FIG. 33C  illustrates an exploded view of the over mold  122  with the PCB assembly  508  and the flexible strips  126 .  FIGS. 34A and 34B  illustrate top and bottom views  520  and  530  of the PCB assembly  508  shown in  FIGS. 31A and 31B  above. 
     Illustrated in  FIG. 17 , one power supply  144  may be used to supply the power to one (1) or more columns of panels through the use of splice connectors  146 . Alternatively, IDCs  136  and quick connect wires  148  may be used between the columns to deliver power from one column of panels  104 L to the next panel  104 L, as depicted in  FIG. 18 . As shown in  FIGS. 16 and 17 , current is carried on both sides of panel  104 L. Alternatively, current may be carried on only one side of panel  104 L and IDC  136  may be located on the side of panel  104 L which carries the current for delivering power to another column of panels  104 L. If desired a flexible strip  162  may be attached to the other side of panel  104 L for support as shown in  FIG. 19 . Alternatively, the wire between adjacent panels may be soldered to each panel. For a particular system, combinations of IDCs and soldering may be used. In another embodiment, power may be supplied to both sides of panel  104 L as shown in  FIG. 15 . Panel  104 L in  FIG. 15  may include one or more IDCs  136 . A further optional feature is mounting points  138 , if mounting of panel  104 L is desired for the particular application. 
     In one certain embodiment, a single power supply may be used to supply power to a sufficient amount of columns or rows of panels  104  to illuminate up to about twenty (20) square feet (ft 2 ) of surface area of a sign face. It is further preferred that the power source is used to provide power to at least about fourteen (14) square feet (ft 2 ) of surface area of a sign face. The embodiments for a backlight system described herein are applicable to both of 12V and 24V systems. Also, system  100  may operate as a constant voltage applied to each board, constant current applied to each panel, or a constant voltage power source. 
     In one particular embodiment, LEDs  106  on panel  104 L may be electrically connected together and mounted to panel  104 L using a flex circuit or wires. The entire panel  104 L may be fitted with an over mold  122 . In one approach, use of the wires as part of the mechanical support for the system  100  can assist in layout when removing from packaging and when securing to a sign back plate. In addition, wires can provide trouble-free assembly, by providing a redundant electrical connection to power. For example, one of the two wires can be cut without severing electrical ties, thereby providing additional flexibility in panel placement or rotation for start of a new row. Modules can be structured to allow overlapping of panels to provide gaps in material for LEDs from bottom panel to shine through to the face of the cabinet sign. 
     System  100  may be used in a double sided cabinet signs as depicted in  FIG. 20  and  FIG. 21 . In  FIG. 20 , two (2) columns of panels  104 L are mounted back to back. Snap-on connectors may be used to mount the opposing panels  104 L back to back. Alternatively, as illustrated in  FIG. 21 , opposing panels  104 L may be separated by a desired distance D. 
     When mounting panel  104 L to a back plate, if maintaining LEDs  106  on panel  104 L perpendicular to the front surface of the cabinet sign is a concern, a guide  150  may be used to maintain the location of panels  104 L. Variations of guide  150  are illustrated in  FIGS. 22A-F . In  FIG. 22A , guide  150  is depicted as a flat bar applied across all panels  104 L in a column of panels. In a second embodiment, guide  150  may consist of two flat bars; one mounted to each end of panels  104 L in a particular column of panels  104 L. A third embodiment is shown in  FIG. 22C . Guide  150  may consist of two flat bars which are applied to two adjacent panels  104 L in a column of panels. In the final embodiment, depicted in  FIG. 22  D-F, guide  150  may comprise a bracket. Preferably, the bracket includes a base  152  and two vertical arms  154 . In the embodiment shown in  FIG. 22E , panel  104 L is mounted in a sliding track in each one of arms  154 . As for  FIG. 22F , two adjacent panels  104 L may be connected together. A first panel is attached along a top section of each of arms  154  of guide  150  and a second panel  104 L is attached along base  152  of guide  150 . 
     Guides  150  may be made out of any suitable material for aligning panels  104 L. In one embodiment, guides  150  are constructed from plastic. However, other materials of construction may be suitable also. Additionally, guides  150  may be secured to a back plate if desired. 
     In an alternate embodiment, panel  104 L may be formed by connector in between vertically adjacent panels  104 R. The connector may be an integral piece of one of either of the vertically adjacent panels  104 R. Additionally, each panel may include one or more pass throughs to pass a wire from one vertically adjacent panel  104 R to another vertically adjacent panel  104 R. Also, the connector may be a unitary element or a multi-piece unit. Lastly, the connector may include a hinge such that between two adjacent panels  104 R, a first panel may be moved located in a non-parallel manner to the second panel. 
     The system  100  as described above has a particular advantageous application as the lighting system of cabinet sign with a surface area of less than 200 square feet (ft 2 ). In another embodiment, the use of system  100  in the cabinet sign will maximize uniformity and not require the same depth between the sign and the light source as a cabinet sign which uses a fluorescent light source. 
     Furthermore, system  100  will decrease sign building costs by reducing installation time of the backlighting system into the cabinet. Also LEDs typically have a much longer life expectancy than fluorescent bulbs which will reduce maintenance costs. Additionally, system  100  is simple to install and it is flexible to accommodate different cabinet sign sizes. In addition to system  100  being adaptable to different sized cabinets, system  100  may be arranged various distances from the sign face of the cabinet sign. Also, system  100  is suitable for those types of cabinet signs having a backing plate for mounting system  100  and for those signs which do not include a backing plate. Accordingly, system  100  is suitable for single sided and double sided cabinet signs. 
     Also, panels  104  of system  100  may use series/parallel architecture. Furthermore, adjacent columns of panels  104  may have the benefit of plug-n-play connections between the columns. The plug-n-play connections between the columns may comprise panels  104  including one or both of an insulation displacement connector or one or more butt splices. 
     As for the individual panels, in one embodiment, each panel may include two (2) separate series of LED chains. Alternatively, each panel may include at least two (2) separate drivers per panel for separate series LED chains, intermixed on the panel. This will have the benefit of the failure of one LED not being noticed on the face of the sign due to the LEDs from each chain being spatially intermixed so that one area of the face of the sign is not significantly impacted. 
     Depicted in  FIGS. 23 and 24  are cabinet signs which include a partial view of the sign face so that the backlighting system for each sign is shown. In  FIG. 23 , sign  200  includes a single array of panels  104 L to illuminate sign face  202 . The panels  104 L are arranged in vertical columns as shown in  FIG. 12 .  FIG. 24  includes a double array backlighting system in which panels  104 L are arranged as illustrated in  FIG. 14 . If so desired, a double array may be used if it is desired to increase the intensity of the light used to illuminate sign face  202 . 
       FIG. 25  is an illustration of a panel  104 L which includes a plurality of LEDs  106  and an over mold  122 . Panel  104 L also includes a casing  160  around the exterior edges of panel  104 L and over mold  122 . 
     Backlighting system  100  may be substantially devoid of optics. System  100  optionally may not include any of the following items: (1) phosphor panel, (2) a brightness enhancing film, (3) a diffuser, and (4) a light pipe. Furthermore, system  100  may not include a fluorescent bulb and/or ballasts. 
     System  100  also offers a unique advantage with packaging and storage, in that system  100  may be foldable or rollable at an end user&#39;s options. This makes system  100  easy to package and transport to an end user and likewise, system  100  is convenient for the end user to store once it has been delivered. 
     Additionally, a particular embodiment of system  100  may have a cut resolution of no more than about 3, more preferably, no more than about 2, and even more preferably no more than about 1. 
       FIG. 26A  illustrates an alternative embodiment, wherein two modules  202  are coupled to a bridge  204  in order to provide flexible lighting systems that have particular desired size and light output. The bridge  204  can be constructed of substantially any suitable material such as a plastic or other similar material. Each module  202  can be coupled to the bridge  204  via a recessed portion that can accept a mechanical tab connecter or equivalent from the bridge. In one approach, the bridge can include electrical connectors in order to facilitate delivery of power and/or electrical control signals to the modules  202 . In addition, the bridge can include a connector  212  to accommodate an additional module. 
     Each module  202  includes a plurality of LEDs  203 . In one representative embodiment, three LEDs are included for with each module  202 . The LEDs  203  can be spaced apart a predetermined distance such that a fixed number of LEDs  203  are based in part upon the length of the modules  202 . Since each module is detachable from the bridge  204 , the lighting system can easily be deconstructed and packaged for transport. 
     Power can be delivered to the LEDs  203  on the modules  202  utilizing an end cap power input plug  206 . The end cap power input plug  206  can be a male component and coupled to the module via a female power input connector  208 . The power input plug  206  includes electrical contacts that are coupled to the female connector  208  to deliver power when the power input plug  206  is plugged in. In this manner, once the modules  202  have been mounted in a particular location, power can be delivered via the connection between the power input plug  206  and the female connector  208 . 
     Similarly, modules  202  can be coupled to an additional module  209  via a modular power throughput port  210 .  FIG. 26B  illustrates the connection between the module  202  and the module  209  via the modular power throughput port  210  and corresponding female power input connector  208  located on the module  209 . In this embodiment, the modular power throughput port  210  is located on the opposite side of the module  202  as the external power input. It is to be appreciated, however, that the modular power throughput port  210  can be located in substantially any location on the module  202 . The location of the modular power throughput port  210  can be related to a desired configuration of the modules  202  in relation to one another. Allowing flexible connectivity between modules by providing associated power connectors in convenient locations facilitates flexible design and manufacture of various desired illumination elements. 
       FIG. 26C  illustrates how a second array  214  can be coupled to the bridge  204  via the connector  212 . In one embodiment, the  FIG. 26D  illustrates a single array illumination system  220  that is created utilizing a plurality of modules  202  and bridges  204  as shown in  FIG. 26A .  FIG. 26E  illustrates a double array illumination system  224 . In one approach, the illumination system  224  is created by coupling a plurality of second arrays  214  to a plurality of respective connectors  212 . 
       FIG. 27A  illustrates an interlocking LED panel  230  that facilitates a single or a double array of modules. The interlocking panel  230  includes a plurality of recesses  232 ,  234 ,  236 ,  238 ,  240 ,  242 , and  244  that can accommodate a disparate interlocking module to provide additional light output for a system. Each recess  232 - 244  can include one or more connectors that protrude from the surface of each recess of the LED panel  230  and are seated in the back of an LED panel which is stacked on top. One LED is located on each raised form  246 ,  248 ,  250 ,  252 ,  254 , and  256 . Power is provided to the interlocking panel  230  via power lines  260  and  262  located on either side of the panel  230  as described above in  FIG. 12 . It is to be appreciated that the LEDs can be spaced apart substantially any distance from each other and that such spacing may not be uniform throughout the panel. 
       FIG. 27B  shows a single array lighting system  270  that employs a plurality of interlocking LED panels  230 . The lighting system  270  includes five columns wherein each column includes four interlocking panels  230 . Power from each column is distributed via a power connector  272 ,  274 ,  276 , and  278 . In this manner, a plurality of panels can be connected in substantially any configuration. 
       FIG. 27C  illustrates a lighting system  280  that includes a double array of interlocking LED panels  230 . A second set of LED panels is stacked on top of the first set such that the back of the top LED panels is coupled to the bottom set of LED panels via connectors located on the surface of each recess  232 - 244 . The double array system  280  is very similar to the single array system  270  in terms of connectivity. However, the system  280  also includes a second set of LED panels  230  that are placed in the recesses  232 - 244  of the single array system  270 . Power for the second set of LED panels can be provided via two power lines  260  and  262 . In one approach, power is provided via the connectors from the bottom set of LED panels to the top set of LED panels so that the top set of panels does not require power lines to be connected therewith. 
       FIG. 28A  illustrates an I-shaped LED panel  290  that includes a first arm  310  and a second arm  312  positioned in parallel to one another and connected by a cross member  314 . The first arm  310  includes three LEDs and two connectors  292  and  294 . The second arm  312  includes three LEDs and two connectors  292  and  294 . The first arm  310  and the second arm  312  are connected via the bridge  314  which includes a connector  300 . The connectors can be employed to allow stacking of the I-shaped LED panels  290  to provide a double array of LED panels for a desired lighting system configuration. In one approach the connectors are a protrusion from the surface of the I-shaped LED panel which is seated in corresponding dimples in the back of LED panels stacked on top thereof. 
     Power is delivered to the I-shaped LED panel  290  via power lines  302  and  304 .  FIG. 28B  shows an alternated embodiment wherein power is delivered to the I-shaped LED panel  290  via power lines  306  and  308 . In this embodiment, the first arm  310  and the second arm  312  are connected via the power lines  306  and  308  respectively. In a disparate embodiment, power can be delivered to top LED panels in a double array configuration via the connectors  292 - 300 . 
       FIG. 28C  illustrates a single array lighting system  340  that includes a plurality of I-shaped LED panels  290 . The single array lighting system  340  includes five columns of I-shaped LED panels wherein each column includes four I-shaped LED panels. It is to be appreciated that substantially any number of LED panels can be configured in substantially any manner. Each column of I-shaped LED panels is connected via coupling lines  342 ,  344 ,  346 , and  348 . The coupling lines  342 - 348  can be employed to provide power and/or control signals from one group of I-shaped LED panels to another.  FIG. 28D  illustrates a double array lighting system  350  that includes the single array of lighting system  340  with an additional array of I-shaped light elements stacked on top therewith. As discussed above, the second top array can be coupled to the bottom array via connectors  292 - 300 . 
       FIG. 29A  illustrates an H-shaped LED panel  360 . The LED panel  360  includes a first arm  362 , a second arm  364  and a third arm  366 . The first arm  362  and the second arm  364  are parallel to one another and are connected via the third arm  366  which is oriented perpendicular to the first and second arms  362  and  364 . The first arm includes three LEDs and connectors  366  and  368 . The second arm includes three LEDs and connectors  370  and  372 . The third arm  366  includes a connecter  374  that is located between the first arm  362  and the second arm  364 . 
     The third arm  366  can include one or more power lines that are located within the body of the arm. The bottom of the third arm  366  can include a male power connector  376 . The top of the third arm  366  can include a female power receptacle  378 . In this manner, the H-shaped LED panel can be coupled to one or more disparate H-shaped LED panels via the male and female power connectors wherein power is delivered to all the LED panels. Such power delivery is illustrated in  FIG. 29B . It is to be appreciated that although power delivered via the third arm  366 , substantially any signal can be communicated. One example can be a control signal utilizing a particular communication protocol. 
       FIG. 29C  illustrates a single array lighting system  380  that includes a plurality of H-shaped LED panels  360 . The single array lighting system  380  includes five columns of H-shaped LED panels wherein each column includes four H-shaped LED panels. It is to be appreciated that substantially any number of LED panels can be configured in substantially any manner. Each column of H-shaped LED panels is connected via coupling lines  382 ,  384 ,  386 , and  388 . The coupling lines  382 - 388  can be employed to provide power and/or control signals from one group of H-shaped LED panels to another.  FIG. 29D  illustrates a double array lighting system  390  that includes the single array of lighting system  380  with an additional array of H-shaped light elements stacked on top therewith. The second top array can be coupled to the bottom array via connectors  366 - 374 . The lighting systems  380  and  390  can be broken down into single LED panels to facilitate compact transport from one location to another. 
       FIG. 30A  illustrates two modules  400  and  402  which each include three LEDs. Each module is comprised of three pods (one for each LED) on a single axis wherein an arm connects each pod to the one adjacent. Module  400  includes a male hinge component  404  on a first side of the module and a female hinge component  406  on a second side. The middle pod accommodates a power line  408 . Module  400  is coupled to module  402  via the male and female hinge components  404  and  406  of module  400  to the corresponding female and male hinge components of module  402 . Connectors  410  and  412  are employed to facilitate a double array lighting system wherein a second set of LED modules is stacked on top of a first set and coupled mechanically thereto.  FIG. 30B  illustrates folding two a plurality of modules together to provide a more compact footprint for transport. Such folding is facilitated via the hinges to couple two or more modules together. 
       FIG. 30C  illustrates a single array lighting system  420  that includes a plurality of LED modules  400 . The single array lighting system  420  includes five columns of LED modules wherein each column includes four LED modules. It is to be appreciated that substantially any number of LED modules can be configured in substantially any manner.  FIG. 30D  illustrates a double array lighting system  440  that includes the single array of lighting system  420  with an additional array of LED modules stacked on top therewith. The second top array can be coupled to the bottom array via connectors  410  and  412 . The lighting systems  420  and  440  can be broken down into single LED modules to facilitate compact transport from one location to another. 
     The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.