Patent Publication Number: US-7582000-B2

Title: Method of making an electroluminescent light

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a method of making an electroluminescent light, and methods of using such lights. 
     2. Description of the Related Art 
     Lighted signs are of course well known. Typically, these signs use incandescent light bulbs, fluorescent light bulbs or neon light bulbs. One problem with such lighted signs is that they typically require a fairly thick overall structure when considering the thickness of their outer panel, inner lamp mechanism and mounting box. For applications such as channel lights where a light is positioned within a channel that can be mounted to a surface, the overall thickness makes them aesthetically unappealing. Such channel lights, which are typically used to display words, numbers and or symbols, are also subject to inadvertent physical contact as they protrude quite a distance from the building or other structure to which they are mounted. 
     In addition, such lighted signs are formed from glass that is susceptible to breakage, and/or gases which my be environmentally unfriendly. These signs have limited if any flexibility and generate heat when operated. 
     Furthermore, to create lighted signs with complicated shapes, such as a design of an animal or the like, requires intricate manufacturing and installation procedures with existing incandescent, fluorescent or neon type lighting structures. 
     It would be desirable to provide a method of making lighted signs and the like that do not suffer from the above disadvantages. 
     SUMMARY OF THE INVENTION 
     In accordance with this invention, there is provided a method of making an electroluminescent light comprising at least one design, the method comprising:
     a) providing a flexible electroluminescent lamp, the lamp comprising a front electrode layer, a phosphor layer, a dielectric layer and a rear electrode layer;   b) cutting out a pattern forming the design from the flexible electroluminescent lamp;   c) determining on the rear electrode at least one line which divides the design into at least two desired geometric areas based on the desired performance of the light;   d) scribing the rear electrode layer along such line through the thickness of the rear electrode, but not substantially into the dielectric layer, to thereby form split electrode areas in the rear electrode layer; and   e) attaching a connecting device to each split electrode area of the rear electrode.   

     Also in accordance with this invention, there is provided a method of making an electroluminescent light that is adaptable to be inserted into a channel, the light comprising a least one indicia in the form of a letter, number, symbol, and/or design, the method comprising:
     a) providing a plastic backing sheet;   b) cutting out a first form in the shape of the desired indicia from the backing sheet;   c) providing a flexible electroluminescent lamp, the lamp comprising a front electrode layer, a phosphor layer, a dielectric layer and a rear electrode layer;   d) cutting out a second form in the shape of the desired indicia from the flexible electroluminescent lamp;   e) determining on the rear electrode of the electroluminescent lamp at least one line which divides the second form into at least desired two geometric areas based on the desired performance of the light;   f) scribing the rear electrode layer of the second form along the line through the thickness of the rear electrode, but not substantially into the dielectric layer, to thereby form split electrode areas in the rear electrode layer;   g) sealing the scribed second form between at least two barrier films, the barrier films protecting the electroluminescent lamp against water and ultraviolet light penetration;   h) attaching a connecting device to each split electrode area of the rear electrode, the connecting devices being adapted to be connected to a power source;   i) optionally providing an outer overlay sheet formed from a colored, transparent, or translucent material;   j) optionally cutting out a third form in the shape of the desired indicia from the overlay sheet;   k) stacking the first and second forms, and optionally the third form with the second form between the first and third forms, to form a multilayer light structure; and   l) sealing the periphery of the multilayer sign structure with a sealing material to form a protective seal around its periphery.   

     In further accordance with this invention, there is provided a method of forming a large surface area electroluminescent lamp, the method comprising:
     a) providing a relatively large flexible electroluminescent lamp panel, the lamp panel comprising a front electrode layer, a phospor layer, a dielectric layer and a rear electrode layer;   b) determining on the rear electrode layer of the lamp panel a plurality of lines that divide the panel into a plurality of smaller panel areas;   c) scribing the rear electrode layer along said plurality of lines through the thickness of the rear electrode but not substantially into the dielectric layer to thereby form a plurality of smaller split electrode areas in the rear electrode layer; and   d) attaching a connecting device to each split electrode layer of the rear electrode; whereby a large surface area electroluminescent lamp is provided that can be illuminated as one large area.   

     This invention also provides a method of splicing electroluminescent lamp structures to provide a seamless structure, the method comprising:
     a) providing first and second flexible electroluminescent lamp structures, each of the lamp structures comprising a front electrode layer, a phospor layer, a dielectric layer and a rear electrode layer; each of the lamp structures having a terminal end; and each of the lamp structures having at least one scribe line which penetrates through the thickness of the rear electrode of each of the lamp structures so as to form split electrode areas in the rear electrode layer of each of said lamp structures;   b) abutting the terminal end of the first lamp structure with the terminal end of the second lamp structure, with the scribe line in the first lamp structure being aligned with the scribe line in the second lamp structure;   c) attaching a first conductive tape to the rear electrode layer of the first lamp structure and to the rear electrode layer of the second lamp structure, such that the first conductive tape is superimposed over the terminal ends of the first and second lamp structures to thereby attach the first and second lamp structures together, the first conductive tape being located on a first side of the aligned scribe lines of the first and second lamp structures; and   d) attaching a second conductive tape to the rear electrode layer of the first lamp structure and to said rear electrode layer of the second lamp structure, such that the second conductive tape is superimposed over the terminal ends of the first and second lamp structures to thereby attach the first and second lamp structures together, the second conductive tape being located on a second side of the aligned scribe lines of the first and second lamp structures, which second side is on the opposite side of the aligned scribe lines from the first conductive tape;
 
whereby the first and second lamp structures are mechanically and electrically connected to each other.
   

     The invention thus provides improved methods of making lighted structures, such as signs and the like, by utilizing electroluminescent lamp devices. These materials are flexible and can be formed into a desired shape. The thinness of the electroluminescent lamps makes them particularly useful in channel lighting applications. Such lights are relatively easy to manufacture, do not generate heat, do not contain breakable or possibly hazardous materials, use small amounts of power, are thin when installed and have other desirable features as described hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete understanding of the invention can be obtained by considering the following detailed description in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a pictorial view of an electroluminescent lamp employed in the present invention. 
         FIG. 2  is a cross-sectional view (not to scale) of the electroluminescent lamp of  FIG. 1 . 
         FIG. 3A  is a view of a design on the electroluminescent lamp of  FIG. 1 . 
         FIG. 3B  is view of the design after it has been cut out from the lamp of  FIG. 3A . 
         FIG. 4  is a cross-sectional view (not to scale) of the design of  FIG. 3B  along line  4 - 4 . 
         FIG. 5A  is a plan view of an indicia (name) formed on a backing layer. 
         FIG. 5B  is a plan view of the form of the indicia cut out of the backing layer of  FIG. 5A . 
         FIG. 6A  is a plan view of the same indicia formed on an electroluminescent lamp. 
         FIG. 6B  is a plan view of the form of the indicia cut out of the electroluminescent lamp of  FIG. 6A . 
         FIG. 6C  is a plan view of one part of the form of the indicia of  FIG. 6B  with a scribe line indicated and electrical connection leads attached. 
         FIG. 6D  is cross-sectional view (not to scale) taken along line  6 D of  FIG. 6C . 
         FIG. 7  is a cross-sectional view (not to scale) of a lamination of the indicia of  FIG. 6C  sandwiched between two barrier films. 
         FIG. 8A  is a plan view of the same indicia formed on an overlay layer. 
         FIG. 8B  is a plan view of the form of the indicia cut out of the overlay layer of  FIG. 8A . 
         FIG. 9  is a view depicting the overlaying of three forms of indicia. 
         FIG. 10  is a plan view of a large format light panel that has been divided into two panels. 
         FIG. 11  is a plan view of a spliced lamp structure. 
         FIG. 12 . is a plan view of a light panel that has been divided into a number of lamps. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The electroluminescent lights manufactured in accordance with this invention incorporate electroluminescent (or EL) lamps. These EL lamps are flexible and generally include a transparent front electrode layer, a phosphor layer, a dielectric layer and a rear electrode. Preferably, the EL lamps used in the present invention and their manufacture are those described in U.S. Pat. No. 5,491,377 to Janusauskas and U.S. Pat. No. 5,976,613 to Janusauskas, the disclosures of which are expressly incorporated herein by reference. 
     In one embodiment of an EL lamp that is shown in  FIG. 1 , the lamp may be in the form of a flexible panel  10  which may comprise a multilayer inner cell sealed within an outer moisture resistant envelope  12 . 
     Within the active cell are shown four layers, i.e., a front electrode layer  14 , a phosphor layer  16 , a dielectric layer  18  and a rear electrode layer  20 . The electrodes  14  and  20  may be provided with external silver or other leads  22  and  24  respectively during the manufacturing process, or alternatively with ribbon connectors each being adapted for connection to a suitable source of power (preferably AC, although DC with an inverter is also applicable). As is known in the art, the application of an electrical potential across the two electrode layers  14  and  20  results in the excitation of the phosphor layer  16 . 
     As shown more clearly in the elevational view of a cross-section of  FIG. 1  illustrated in  FIG. 2 , the phosphor layer  16  is immediately contiguous to the front electrode layer  14  but spaced from and electrically isolated from the rear electrode layer  20  by a dielectric layer  18 . This phosphor sandwich is protected from the rear by an overcoat  26 . 
     Additional exterior layers or interior layers may also be employed in the invention. Preferably, the various layers are formed by extrusion through a slot die, or they may alternatively be formed by a screen printing manufacturing process. Front conductor layer  14  may be formed on any suitable material, such as a polyester layer  28 . The polyester layer may be heat stabilized. The front conductor layer comprises conventional indium tin oxide (ITO) compounds in a binder. Preferably, the binder is a fluoropolymer, such as polyvinylidene fluoride. A typical composition from which the front conductor layer  14  is formed comprises, in weight percents based on the total weight of the composition, of from about 50 to about 85 percent indium tin oxide compounds, from about 5 to about 25 percent of 2-(2-ethoxyethoxy)-ethyl acetate, from about 5 to about 25 percent of 2-butoxyethyl acetate, and from about 2 to about 30 percent of polyvinylidene fluoride. Typical thicknesses of the front electrode layer  14  range from about 15 to about 40 microns, more preferably from about 20 to about 25 microns. 
     The phosphor layer  16  may include any suitable conventional phosphor such as copper activated zinc sulfide in a suitable binder, preferably a fluoropolymer binder such as polyvinylidene fluoride. In one preferred embodiment, the binder is substantially the same as employed for the front electrode layer  14 . For example, the phosphor layer  16  may comprise, in weight percents based on the total weight of the composition, from about 50 to about 60 percent of copper activated zinc sulfide, about 5 to about 25 percent of 2-(2-ethoxyethoxy)-ethyl acetate, about 5 to about 25 percent of 2-butoxyethyl acetate, and about 2 to about 30 percent of polyvinylidene fluoride. Typically, the thickness of the phosphor layer  16  ranges from about 30 to about 60 microns, more preferably from 45 to about 50 microns. 
     The dielectric layer  18  may include any suitable conventional dielectric powder, such as white dielectric powder, in a suitable binder. Preferably, the binder comprises a fluoropolymer binder such as polyvinylidene fluoride. More preferably, the binder is substantially the same as employed in the front electrode layer  14  and the dielectric layer  16 . In one embodiment, the white dielectric powder may be an admixture of titanium dioxide (20-60 wt. %), silicon dioxide (3-10 wt. %), and aluminum silicate (3-10 wt. %). The dielectric layer is preferably formed from a composition which comprises, in weight percents based on the total weight of the composition, from about 50 to about 60 percent of the dielectric powder, about 5 to about 25 percent of 2-(2-ethoxyethoxy)-ethyl acetate, about 5 to about 25 percent of 2-butoxyethyl acetate, and about 2 to about 30 percent of polyvinylidene fluoride. Typically, the thickness of the phosphor layer  16  ranges from about 5 to about 20 microns, more preferably from about 10 to about 15 microns. 
     The rear electrode layer  20  may include suitable conventional conductive ink or silver, carbon, or ceramic, or blends of carbon silver or nickel silver, in a suitable binder. Again, preferably the binder is a fluoropolymer binder, such as polyvinylidene fluoride. Also, the binder may be substantially the same binder as employed in the other layers mentioned above. Preferably, the rear electrode is formed from a composition which comprises, in weight percents based on the total weight of the composition, from about 50 to 85 percent metallic silver, from about 5 to about 25 percent of 2-(2-ethoxyethoxy)-ethyl acetate, from about 5 to about 25 percent 2-butoxyethyl acetate and from about 2 to about 30 percent of polyvinylidene fluoride. 
     The protective overcoat  26  may comprise any suitable conventional material such as a fluoropolymer powder (e.g., Teflon® PFA powder). The overcoat composition preferably includes a fluoropolymer binder, such as polyvinylidene fluoride, and may be substantially the same as the binders of the other layers. In a preferred embodiment, the protective overcoat  26  is formed from a composition comprising, with about 5 to about 25 percent fluoropolymer powder (e.g., Teflon® #532-5011), and a binder comprising in weight percent of the binder, from about 15 to about 45 percent of 2-(2-ethoxyethoxy)-ethyl acetate, from about 10 to about 45 percent 2-butoxyethyl acetate, and from about 20 to about 80 percent polyvinylidene fluoride. Typically, the thickness of the overcoat layer is from about 5 to about 30 microns, more preferably from about 15 to about 20 microns. 
     In each of the aforesaid layers, conventional additives may be added in conventional amounts, such as, for example, 2 to 10 weight percent based on the total weight of the respective composition. 
     By use of a fluoropolymer binder such as polyvinylidene fluoride for all of the layers of the lamp, a thick film lamp may be produced which has high resistance to many chemical solvents, to ultraviolet and nuclear radiation, weathering, fungi and a low water transmission rate 
     The use of a common binder results in a lamp in which the various layers have a similar coefficient of temperature expansion, thus significantly reducing failures from exposure to elevated temperatures, and the inclusion of an ultraviolet absorbing component in the binder for at least the phosphor, and preferably all layers, obviates the need for and expense of an additional UV resistant coating. 
     The use of a common binder for both phosphor and adjacent dielectric layers also reduces lamp failure due to localized heating, thus increasing light output for a given voltage and excitation frequency, and increasing the ability of the lamp to withstand overvoltage conditions without failure. 
     EL lamps of the above structure are available from Electro-LuminiX of the USA under the trademark Light Tape®. 
     The EL lamp structure is formed as a continuous flexible sheet which may be rolled up. In accordance with the method of this invention, a desired pattern is cut out from a section of the EL lamp sheet material, which section may be any desired size. The pattern may be printed on the EL lamp by any conventional means, for example a digital printer can print the desired shape or pattern as a template or overlay to aid in cutting in the field. Alternatively, the desired image can be loaded into a computer which is integrated with the cutter to cut the desired pattern. As shown in  FIGS. 3A and 3B , the chosen design may be any desired design.  FIG. 3A  depicts a sheet  15  of EL lamp  10  having a pattern  30  formed thereon. Pattern  30  is preferably cut out from sheet  15  using a non-metal laser cutting machine in order to provide an accurate pattern. More expensive metal laser cutting machines are not required, but of course may be used. Likewise, any suitable cutting device can be employed. The pattern shown in  FIG. 3B  depicts the design with the rear electrode layer  20  facing outwardly. 
     The shape of the pattern may be symmetrical or asymmetrical and may be of any desired or custom shape. The pattern may readily be cut from the EL lamp in the field with basic tools. 
     A scribe line  32  is determined on the rear electrode  20  of EL lamp  10 . Such line can be determined manually or through the use of a laser. A scribe is then made along line  32  through the entire thickness of rear electrode layer  20 , but not substantially into dielectric layer  18 . The location of the scribe line depends on the desired performance of the light. For example, if it is desired that the light be seen without flashing and as a continuous light source, then scribe line  32  is made along a line which divides the pattern into two approximately geometrically equal areas  34  and  36 . If the areas  34  and  36  are not approximately equal, then the EL lamp structure will flash imbalanced illumination as one hemisphere receives more current that the other(s). By having uneven areas of the split electrode results in the ability to make varying brightness lamps. For some applications such flashing may be desirable, but for a constant on light such flashing would not normally be desirable. The line  32  may be scribed with any suitable implement, such as a scribe tool with a metal cutting bit. Although scribe line  32  is shown as a vertical line, it may alternatively be a horizontal line, a diagonal line, a curve, etc. 
     It should be noted that more than one scribe line  32  may be cut into the rear electrode layer  20  of pattern  30 , and that the resultant cut areas may or not be of equal area, again depending upon the desired performance characteristics of the light. Multiple scribe lines will allow the conductive layers to carry current more efficiently, thus enabling large format lights. Regardless of the number of scribe lines made, rear electrode layer  20  is split into at least two areas which form split electrode areas shown by numerals  34  and  36 . 
       FIG. 4  depicts in a cross-sectional view the pattern  30  cut from EL lamp  10 , with the rear electrode layer  20  facing upwards. To utilize the EL lamp as the desired light structure, electrical connectors  38 ,  40  (shown schematically) each having penetrating teeth  42 ,  44  are connected to the split electrode areas  34 ,  36  and are connected to an AC power supply (or DC power with inverter) in a conventional manner by connecting the two leads (no polarity) to the two output connections coming from the power supply (not shown). 
     In use, the light formed from pattern  30  of material  15  is preferably attached to other layers, including an overlay sheet and a backing sheet (not shown). Thus a backlit structure is created which can be used indoors or outdoors and may be of any suitable design. The indicia may be in the form of individual letters, numbers, symbols and/or designs, as well as a plurality of such indicia which are interconnected with one another. 
     Thus it can be seen that EL lights of custom shapes (both regular and irregular) can be easily made using the EL lamps and method of this invention. 
     In another aspect of this invention, there is provided a method of making an EL light that is adapted to be inserted into a channel. The method includes the cutting out of a desired indicia from at least two layers—a plastic backing sheet and an EL lamp layer. Turning now to  FIGS. 5A and 5B , an indicia, in this case several letters forming a name, indicated by reference numeral  52 , is cut from a backing sheet layer  50 . The indicia may be any suitable one or more letters, numbers, symbols and/or designs, and more than one type of them may be used. For example, indicia  52  may be in the form of multiple letters which are interconnected with one another, such as in the form of script letters, or may otherwise be connected. Alternatively, the individual letters may be separately connected to the power source with leads connected to each letter.  FIG. 5B  depicts indicia  52  after being cut out from backing sheet  50 . 
     Backing sheet layer  50  may be formed from any suitable material that provides the desired structural support to the light. Backing sheet layer  50  preferably is formed from a sheet of suitable plastic material, such as acrylics, polycarbonates, polyvinyl chloride (PVC), fiberglass and other non-conductive materials. The thickness of backing sheet layer  50  may range, for example, from about 0.1 to about 3 inches (0.25 to 7.6 cm). 
     Any suitable device or equipment may be used to provide the cutting out of indicia  52 , although a non-metal laser cutting machine is preferred. The backing sheet indicia  52  is preferably cut somewhat larger than the EL lamp indicia mentioned below, so as to provide edges that extend outwards to accommodate a barrier lamination edge seal. The layers of the light may be cut in one or more steps. 
     In a similar manner, with reference to  FIGS. 6A and 6B  a sheet  60  of EL lamp layer  10  is cut to form the desired indicia  62 , preferably in the same shape as indicia  52 . The same or different type of cutting apparatus employed for the backing sheet layer  50  may be used for this purpose.  FIG. 6B  illustrates indicia  62  after it has been cut from sheet  60 . 
     With reference to  FIG. 6C , at least one scribe line  64  is formed in indicia  62 . For ease of view, only one letter of indicia  62  is shown in  FIG. 6C . Although shown as a vertical line, the scribe line may alternatively extend horizontally, diagonally or at any other angle, or may be a curve, etc. As shown in cross-sectional view  FIG. 6D , scribe line  64  extends through rear electrode layer  20  but not substantially into dielectric layer  18 . Scribe line  64  splits the rear electrode layer  20  into at least two geometric areas  66  and  68 . As described above with respect to  FIG. 3 , the location of the scribe line is chosen based on the desired performance of the light. If a constant lit structure is desired, then areas  66  and  68  are of approximate equal area, but if flashing of the light is desired, then areas  66  and  68  may be unequal. 
     Electrical connection tabs  60 ,  70  shown schematically in  FIG. 6C  are attached by suitable means to each of the split electrode areas  66  and  68 . Their connection is similar to that described with respect to  FIG. 4 . In general, there are two metal tabs  76 ,  78  ( FIG. 6D ) for each connection, with one for each side of the electrode. The tabs are conductive with penetrating teeth or spikes protruding generally perpendicular to the main surface of the tabs. The teeth or spikes are forced through the rear electrode forming a connection to carry the current into the lamp. Alternatively, conductive tapes or tabs may be attached by an adhesive to the surface of the rear electrode. The connectors are then connected to the conductive tape which is applied to the lamp for final connection. Conductive tapes or tabs with adhesive are particularly useful for connections in which it is desired not to alter or intrude into the face of the lamp and thus block light. Tabs  60 ,  70  are adapted to be connected to a power source, such as an AC power source or DC with inverter. 
     As shown in  FIG. 7 , to provide additional barrier protection to the EL lamp structure in the form of indicia  62 , the lamp is laminated between two clear barrier film sheets  72 ,  74 . Such barrier film provides additional protection against water vapor, ultraviolet light and other deleterious materials. Preferably, barrier film sheets  72 ,  74  are formed from fluoropolymer materials such as chlorotrifluoroethylene polymers; a preferred material is Clarus® polychlorotrifluoroethylene films available from Honeywell International Inc., Morristown, N.J. USA. Such films may have a thickness of between about 0.2 to about 10 mils (5.1 to 254 μm), more preferably from about 0.5 to about 6 mils (12.7 to about 152.4 μm). 
     The barrier film sheets  72 ,  74  are laminated with the EL lamp structure  62 , with the EL lamp between the barrier film sheets. Any suitable lamination technique may be employed, such as thermal lamination, cold lamination or pressure lamination. Excess barrier film is trimmed around the periphery of indicia  62  so that a lamination seal of about 0.25 inch (0.64 cm) is formed around the edges of EL lamp indicia  62 . 
     Preferably, an overlay layer is employed in the light structure. With reference to  FIGS. 8A and 8B , the desired indicia  82  is cut out from overlay layer  80 , using the same or different equipment employed with the other layers and in the same or separate step.  FIG. 8B  depicts indicia  82  after being cut from layer  80 . Overlay layer  80  may be in the form of a colored, transparent or translucent layer, such as a plastic layer. Materials useful as overlay  80  include thin PVC, acrylic, polyester or other plastic sheets that may be uniform in color or contain a digital image such as a logo. Overlay layer  80  provides additional weathering and/or impact protection for indicia layer  62  that forms the EL lamp. It may also provide a desired color or other appearance to the light. Preferably, the overlay layer indicia  82  is cut as to be slightly wider than the EL lamp indicia  62 . For example, overlay layer indicia  82  may be cut so as to extend a distance of about 0.1 inch (0.25 cm) over the edges of EL lamp indicia  62 . 
     As shown in  FIG. 9 , indicia  52  and  62  (as well as  82  if utilized) are overlayed one on top of the other, with EL lamp indicia  62  positioned between backing sheet layer indicia  52  and overlay layer indicia  82 . This forms a multilayer light structure designated as numeral  84 . As mentioned above, preferably the edges of indicia  52  and  82  extend outwardly from the edges of indicia  62 . To prevent moisture from penetrating through the edges of the light structure, the edges are preferably sealed with an adhesive bead of a suitable material. Alternatively, the edges of the lamp may be sealed with a barrier film (e.g., a PCTFE film) that has adhesive coated on one side. The barrier film is folded in length in half and applied to the edge of the lamp to provide an effective seal. 
     In use, connection tabs  60 ,  70  of indicia  62  are adapted to be connected to a power source, such as an AC power source, by conventional wiring. Of course, if multiple indicia such as words formed from multiple letters are desired, then the letters are interconnected so that there is electrical continuity with all of the indicia. Alternatively, each letter may be connected to the power source by means of a plurality of connectors. The multilayer light structure  84  may be very thin, such as on the order of from about 0.5 to about 4 inches (1.3 to 10.2 cm), more preferably from about 1 to about 3 inches (2.5 to 7.6 cm) or so. The multilayer light structure  84  is insertable into a channel mounting structure (not shown) or without backing to form an EL light structure on a desired mounting surface. 
     As can be seen from the above description, the method described herein allows the construction of custom signs of various shapes in the field. The flexible EL lamp stock material can be purchased by a sign shop, and using relatively inexpensive equipment a desired custom sign of a desired shape can be readily manufactured. The use of split electrode technology in the EL light structure permits intricate shapes to be cut and connected economically versus bus bar technology. The laminate structures are designed so that a manufacturer can cut and supply a replacement light structure when the originally installed lamp burns out. 
     The individual shapes, images and channel letters can be mounted on a variety of surfaces, such as billboards, industrial and corporate buildings, moving vehicles, machines, and entertainment, office and retail spaces. 
     The invention also facilitates the production of large format panels. For example, as shown in  FIG. 10 , multiple scribe lines  101 ,  102 ,  103  can be provided in large format lamp panel  104  to divide panel  104  into four smaller panels  105 ,  106 ,  107 ,  108 . Preferably smaller panels  105 ,  106 ,  107  and  108  are of the same approximate area. By attaching connectors  109  to the four smaller panels, a lamp structure is provided which enables a large surface area to be illuminated as one piece. 
     In addition, as shown in  FIG. 11  seamless repairs can be achieved to join two lamp structures together by using conductive tapes between the two lamp structures as splices. As shown, lamp sections  110 ,  112 , each having terminal ends  115 ,  117 . Each lamp section has a scribe line  114 ,  116 . The terminal ends  115 ,  117  are abutted together, with scribe lines  114 ,  116  aligned. The lamp sections can be connected via conductive tapes  118 ,  119  that are superimposed over terminal ends  115 ,  117  such that tapes  118 ,  119  are on opposite sides of scribe lines  114 ,  116 . As a result, lamp sections  110 ,  112  are both mechanically and electrically attached. The conductive tapes pass current from one section of the lamp structure to the other section, thereby electrically joining the two lamp structures together. 
     A multiple of lamp structures can be formed by scribing one panel multiple times. For example, as shown in  FIG. 12 , panel  120  of an EL lamp are provided with four scribe lines, namely diagonal scribe lines  122  and  124 , horizontal scribe line  126  and vertical scribe line  128 . These lines are shown as intersecting at the center of panel  120 . A total of eight lamps ( 130 ,  132 ,  134 ,  136 ,  138 ,  140 ,  142 ,  144 ) are thus formed. Each lamp structure is then connected via connectors  150  and can be flashed or sequenced as desired. 
     Other uses of the structure of this invention will become apparent to those skilled in the art. 
     The use of a split electrode EL lamp structure such as Light Tape® has many advantages over neon, incandescent, LED and fluorescent light fixtures. The EL light structure of the present invention is flexible and has a low profile, contains no mercury or gases, has extremely low operation cost, has low maintenance and is easily installed, is vibration and shock resistant, can be custom cut and spliced in the field, is lightweight, is cool to the touch (no heat), is visible through smoke and fog, can be powered by AC or low voltage batteries, provides a continuous uniform light, has no glass that is breakable, and can be custom cut into intricate shapes. Since the lamp structure has a thin profile, it reduces the hazards in areas of pedestrian traffic, even if the light structure is mounted in a position lower than usual. 
     Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to but that further changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.