Patent Document

CLAIM TO PRIORITY 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/083,037, filed Jul. 23, 2009, entitled “Photoluminescent Exit Sign,” the entire subject matter of which is hereby incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to photoluminescent EXIT signs, and more particularly to photoluminescent EXIT signs and methods for forming photoluminescent EXIT signs. 
       BACKGROUND OF THE INVENTION 
       [0003]    Photoluminescent EXIT signs have been around for nearly a decade. 
         [0004]    One example of a photoluminescent EXIT signs includes printing the word “EXIT” and the chevrons (arrow indicating either a right direction, a left direction, or both left and right directions) using a non-photoluminescent material such as an opaque ink onto a sheet of photoluminescent material disposed on a plastic material or coated metal material. 
         [0005]    In another example, a negative configuration of the example above, includes providing a sheet of photoluminescent material disposed on a plastic material or coated metal material, and applying an opaque layer on all but the word “EXIT” and the chevrons thereby leaving only the text and chevrons displaying the photoluminescent material. 
         [0006]    In a further example, a sheet of photoluminescent material is placed inside a metal box having a cover or front surface with the word “EXIT” and chevrons cut out. In particular, the sheet of photoluminescent material is placed up against the cover. 
         [0007]    Currently, the photoluminescent material is applied to plastics, or sold as paint for other applications. Green, red, and black offsetting non-photoluminescent colors are sold today and used for the EXIT sign described above. For example, a Glo Brite Photo-Luminescent Exit Signs are manufactured by or available from Seton of Branford, Conn. 
         [0008]    There is a need for further photoluminescent EXIT signs and methods for forming photoluminescent EXIT signs. 
       SUMMARY OF THE INVENTION 
       [0009]    In a first aspect, the present invention is directed to a photoluminescent EXIT sign that includes a generally planar rectangular metallic faceplate comprising a front surface, a rear surface, a length, and a width. The faceplate includes a plurality of openings through the faceplate extending from the front surface to the rear surface defining the word “EXIT.” A periphery of the each of the openings includes a metallic beveled surface extending between the front surface and the rear surface of the faceplate. A colored layer is disposed on the front surface of the faceplate. A generally planar photoluminescent backplate includes a front surface and a rear surface. The front surface of the backplate is disposed tightly against the rear surface of the faceplate so that the lowermost edges of the openings defining the word “EXIT” are disposed tightly against the front surface of the generally planar photoluminescent backplate. The beveled surfaces along the peripheral edge of the openings defining the word “EXIT” being operable to reflect ambient light in lighted conditions and reflect luminescent light emitted from the photoluminescent backplate in dark conditions. 
         [0010]    In a second aspect, the present invention is directed to a method for forming a photoluminescent EXIT sign. The method includes providing a generally planar rectangular metallic faceplate, forming a plurality of openings defining the word “EXIT,” a periphery of the each of the openings comprising a metallic beveled surface extending between the front surface and the rear surface of the faceplate, providing a backplate comprising a photoluminescent material, and disposing the photoluminescent material of the backplate adjacent to the faceplate to result in illuminated letters defining the word “EXIT.” 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, may best be understood by reference to the following detailed description of various embodiments and the accompanying drawings in which: 
           [0012]      FIG. 1  is a perspective view of one embodiment of a photoluminescent EXIT sign in accordance with the present invention; 
           [0013]      FIG. 2  is an enlarged cross-sectional view taken along lines  2 - 2  in  FIG. 1 ; 
           [0014]      FIG. 3  is an enlarged cross-sectional view taken along lines  3 - 3  in  FIG. 1 ; 
           [0015]      FIG. 4  is an enlarged front view of a portion of the photoluminescent EXIT sign of  FIG. 1  illustrating the contrast between the front surface and the cutout of the right chevron; 
           [0016]      FIG. 5  is a perspective view of another embodiment of a photoluminescent EXIT sign in accordance with the present invention; 
           [0017]      FIG. 6  is an enlarged cross-sectional view taken along lines  6 - 6  in  FIG. 5 ; 
           [0018]      FIG. 7  is an enlarged cross-sectional view taken along lines  7 - 7  in  FIG. 5 ; 
           [0019]      FIG. 8  is an enlarged front view of a portion of the photoluminescent EXIT sign of  FIG. 5  illustrating the contrast between the front surface and the cutout of the right chevron; 
           [0020]      FIG. 9  is a perspective view of another embodiment of a photoluminescent EXIT sign in accordance with the present invention; 
           [0021]      FIG. 10  is an enlarged cross-sectional view taken along lines  10 - 10  in  FIG. 9 ; 
           [0022]      FIG. 11  is an enlarged cross sectional view taken along lines  10 - 10  in  FIG. 9 ; 
           [0023]      FIG. 12  is a perspective view of another embodiment of a photoluminescent EXIT sign in accordance with the present invention; 
           [0024]      FIG. 13  is an enlarged cross-sectional view taken along lines  13 - 13  in  FIG. 12 ; and 
           [0025]      FIG. 14  is an enlarged cross-sectional view taken along lines  14 - 14  in  FIG. 12 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    In one aspect, the present invention is directed to improve highly visible architecturally pleasing photoluminescent EXIT signs. This non-electrical EXIT sign&#39;s purpose is to guide people to exits in both normal and emergency conditions. The use of a photoluminescent back panel enables the sign to be seen when loss of power occurs. 
         [0027]      FIGS. 1-3  illustrate one embodiment of a photoluminescent EXIT sign  10  in accordance with the present invention, which generally includes two component parts. Photoluminescent EXIT sign  10  may include a faceplate  20  with a plurality of cutouts having beveled edges or angled surface openings defining the word “EXIT” and optional chevrons, and a photoluminescent backplate  50  (best shown in  FIGS. 2 and 3 ). 
         [0028]    For example, faceplate  20  may be a planar member such as an elongated planer member, e.g., a rectangular planar member, having a front side  22  ( FIGS. 2 and 3 ), a rear side  24  ( FIGS. 2 and 3 ), a top edge  26 , a bottom edge  27 , a right side edge  28 , and a left side edge  29 . Faceplate  20  may be formed from a metallic material such as an aluminum plate in which the cutouts are milled or formed with a plurality of peripherally-extending angled or beveled edges  30  ( FIGS. 1 and 3 ) that exposes the bright natural or bare metallic material around the edge of the letters. 
         [0029]    Faceplate  20  may further include a colored coating  40  such as a dark solid color coating disposed on front surface  22 . The solid colored surface may be a red or black polymer or anodized coating. The contrast between the front coated surface of the faceplate and the cutouts is best illustrated in  FIG. 4  which shows a portion of the faceplate having a dark black color which surrounds the right chevron cutouts through which light may be emitted therethrough from the photoluminescent backplate  50 . 
         [0030]    As best shown in  FIGS. 1 and 2 , in faceplate  20 , the periphery of each of the openings defining the letters and each of the directional chevrons may be defined by a beveled edge  30 . For example, beveled edges  30  may extend around the entire periphery of each of the letters and each of the directional chevrons. In addition, the beveled edges may extend from front surface  22  to rear surface  24 . The beveled edges may further be disposed on an angle of about 45-degree relative to front surface  22  of faceplate  20 . For example, faceplate  20  may have a thickness of about 1/16-inch. The cutouts or openings may be formed with a machining tool that produces a beveled edge of about 45-degrees relative to the front surface and extending from the front surface to the rear surface resulting in an exposed beveled surface about 1.5 mm wide. 
         [0031]    Backplate  50  may comprise a photoluminescent impregnated polymer sheet such as a photoluminescent impregnated thermoplastic polymer sheet, e.g., a photoluminescent impregnated polymer PVC (polyvinylchloride) sheet. Backplate  50  includes a front surface  52  and a rear surface  54 , and may have a length and width which corresponds to the length and width of the faceplate. Front surface  52  of backplate  50  is abutted and disposed tightly against rear surface  54  of faceplate  20  so that lowermost edges  32  ( FIG. 2 ) of beveled edges  30  rests on the front surface of backplate  50 . For example, front surface  52  may be adhesively bonded to rear surface  24  of faceplate  20 . The photoluminescent impregnated polymer sheet desirably has a luminance of at least about 50 mcd/m2 at 60 minutes after exposure to 1000 lux xenon arc lamp for 5 minutes. A suitable photoluminescent impregnated polymer sheet is available from Jalite USA of Milford, Pa., model number JLUME. 
         [0032]    The rear surface of the backplate is typically disposed against a wall or other surface such as above a door or doorway. For example, when photoluminescent EXIT sign  10  is installed in a desired location, an installer may attach the rear surface to the wall using a suitable adhesive or bonding agent which is applied between the rear surface of the backplate and the wall. Alternatively, one or more adhesive materials may be disposed on the rear surface of the backplate. For example, as shown in  FIG. 3 , one or more adhesive strips  70  having a release sheet  75  may be disposed on the rear surface of the backplate. Alternatively, an optional frame may be used to secure the photoluminescent EXIT sign to the wall or the EXIT sign may be operably supported to hang from the ceiling. 
         [0033]      FIGS. 5-7  illustrate another embodiment of a photoluminescent EXIT sign  100  in accordance with the present invention, which generally includes three component parts. Photoluminescent EXIT sign  100  may include a faceplate  120  with a plurality of cutouts having beveled edges or angled surface openings defining the word “EXIT” and optional chevron(s), a backplate  150 , and a photoluminescent layer  160  (best shown in  FIGS. 6 and 7 ). 
         [0034]    For example, faceplate  120  may be a planar member such as an elongated planer member, e.g., a rectangular planar member, having a front side  122  ( FIGS. 6 and 7 ), a rear side  124  ( FIGS. 2 and 3 ), a top edge  126 , a bottom edge  127 , a right side edge  128 , and a left side edge  129 . Faceplate  120  may be formed from a metallic material such as an aluminum plate in which the cutouts are milled or formed with a plurality of peripherally-extending angled or beveled edges  130  ( FIGS. 5 and 6 ) that expose the bright natural or bare metallic material around the edge of the letters. 
         [0035]    Faceplate  120  may further include a colored coating  140  such as a dark solid color coating disposed on front surface  122 . For example, the solid colored surface may be a suitable red or black polymer or anodized coating. The contrast between the front coated surface of the faceplate and the cutouts is best illustrated in  FIG. 8  which is shows a portion of the faceplate having a dark black color which surrounds the right chevron cutout through which light may be emitted therethrough from the photoluminescent layer  160 . 
         [0036]    As best shown in  FIGS. 5 and 6 , in faceplate  120 , the periphery of each of the openings defining the letters and each of the directional chevrons may be defined by beveled edge  130 . For example, beveled edges  130  may extend around the entire periphery of each of the letters and each of the directional chevrons. In addition, the beveled edges may extend from front surface  122  to rear surface  124 . The beveled edges may further be disposed on an angle of about 45-degree relative to front surface  122  of faceplate  120 . For example, faceplate  120  may have a thickness of about 1/16-inch. The cutouts or openings may be formed with a machining tool that produces a beveled edge of about 45-degrees relative to the front surface and extending from the front surface to the rear surface resulting in an exposed beveled surface about 1.5 mm wide. 
         [0037]    Backplate  150  may comprise a metal or plastic planar layer such as formed from a PVC plastic or aluminum material. Photoluminescent layer  160  may be a sheet of photoluminescent material or a photoluminescent coating. For example, backplate  150  and photoluminescent layer  160  may be a photoluminescent lacquer-coated aluminum plate. 
         [0038]    Backplate  150  includes a front surface  152  and a rear surface  154 , and may have a length and width which corresponds to the length and width of the faceplate. Photoluminescent layer  160  is disposed on backplate  150 . A front surface of photoluminescent layer  160  is abutted and disposed tightly against rear surface  124  of faceplate  120  so that lowermost edges  132  ( FIG. 6 ) of beveled edges  130  rests on the front surface of photoluminescent layer  160 . For example, rear surface of the faceplate may be adhesively bonded to front surface of photoluminescent layer  160 . Photoluminescent layer  160  desirably has a luminance of at least about 50 mcd/m2 at 60 minutes after exposure to 1000 lux xenon arc lamp for 5 minutes. A suitable photoluminescent impregnated polymer sheet is available from Jalite USA of Milford, Pa., model number JLUME. 
         [0039]    The rear surface of the backplate is typically disposed against a wall or other surface such as above a door or doorway. For example, when photoluminescent EXIT sign  100  is installed in a desired location, an installer may attach the rear surface to the wall using a suitable adhesive or bonding agent which is applied between the rear surface of the backplate and the mounting surface. Alternatively, one or more adhesive materials may be disposed on the rear surface of the backplate. For example, as shown in  FIG. 7 , one or more adhesive strips  170  having a release sheet  175  may be disposed on the rear surface of the backplate. 
         [0040]      FIGS. 9-11  illustrate another embodiment of a photoluminescent EXIT sign  200  in accordance with the present invention, which generally includes two component parts. Photoluminescent EXIT sign  200  may include a faceplate  220  with a plurality of beveled cutouts or angled surface openings defining the word “EXIT” and optional chevrons, and a backplate  250  of photoluminescent material. 
         [0041]    For example, faceplate  220  may be a planar member such as an elongated planer member, e.g., a rectangular planar member, having a front side  222 , a rear side  224  ( FIGS. 10 and 11 ), a top edge  226 , a bottom edge  227 , a right side edge  228 , and a left side edge  229 . Faceplate  220  may be formed from a metallic material such as an aluminum plate in which the cutouts are milled or formed with a peripherally-extending angled or beveled edge that exposes the bright natural metallic material around the edge of the letters and optional chevrons. 
         [0042]    Faceplate  220  may further include a colored coating  240  such as a dark solid color coating disposed on front surface  222 . The solid colored surface may be a red or black polymer or anodized coating. The contrast between the front coated surface of the faceplate and the cutouts may be similar to that shown in  FIGS. 4 and 8 . 
         [0043]    As best shown in  FIGS. 9 and 10 , in faceplate  220 , the periphery of each of the openings defining the letters and each of the directional chevrons may be defined by a beveled edge  230 . For example, beveled edges  230  may extend around the entire periphery of each of the letters and each of the directional chevrons. In addition, the beveled edges may extend between front surface  222  and rear surface  224 . The beveled edges may further be disposed on an angle of about 45-degree relative to front surface  222  of faceplate  220 . For example, faceplate  220  may be about ⅛-inch in thickness. The cutouts or openings may be formed with a machining tool that produces a beveled edge of 45-degrees relative to the front surface and extending from the front surface to about the middle of the faceplate, e.g., half of the cut ( 1/16-inch depth). A straight or normal edge  235  disposed at 90-degrees relative to the front or rear surface of the faceplate extends from the beveled edge to the rear surface for the remaining half of the cut ( 1/16-inch depth). 
         [0044]    Backplate  250  may comprise a photoluminescent impregnated polymer sheet such as a photoluminescent impregnated thermoplastic polymer sheet, e.g., a photoluminescent impregnated polymer PVC (polyvinylchloride) sheet. Backplate  250  includes a front surface  252  and a rear surface  254 , and may have a length and width which corresponds to the length and width of the faceplate. Front surface  252  of backing plate  250  is abutted and disposed tightly against rear surface  224  of faceplate  220  so that lowermost edges  232  ( FIG. 10 ) of normal edges  235  rests on the front surface of backplate  250 . For example, front surface  252  may be adhesively bonded to rear surface  224  of faceplate  250 . The photoluminescent impregnated polymer sheet desirably has a luminance of at least about 50 mcd/m2 at 60 minutes after exposure to 1000 lux xenon arc lamp for 5 minutes. A suitable photoluminescent impregnated polymer sheet is available from Jalite USA of Milford, Pa., model number JLUME. 
         [0045]    The rear surface of the backplate is typically disposed against a wall or other surface such as above a door or doorway. For example, when photoluminescent EXIT sign  200  is installed in a desired location, an installer may attach the rear surface to the wall using a suitable adhesive or bonding agent which is applied between the rear surface of the backplate. Alternatively, one or more adhesive materials may be disposed on the rear surface of the backplate. For example, as shown in  FIG. 11 , one or more adhesive strips  270  having a release sheet  275  may be disposed on the rear surface of the backplate. Alternatively, an optional frame may be used to secure the photoluminescent EXIT sign to the wall or the EXIT sign may be operably supported to hang from the ceiling. 
         [0046]      FIGS. 12-14  illustrate another embodiment of a photoluminescent EXIT sign  300  in accordance with the present invention, which generally includes three component parts. Photoluminescent EXIT sign  300  may include a faceplate  320  with a plurality of cutouts having beveled edges or angled surface openings defining the word “EXIT” and optional chevrons, and a backplate  350  and photoluminescent layer  360  (best shown in  FIGS. 13 and 14 ). 
         [0047]    For example, faceplate  320  may be a planar member such as an elongated planer member, e.g., a rectangular planar member, having a front side  322  ( FIGS. 13 and 14 ), a rear side  324  ( FIGS. 13 and 14 ), a top edge  326 , a bottom edge  327 , a right side edge  328 , and a left side edge  329 . 
         [0048]    Faceplate  320  may be formed from a metallic material such as an aluminum plate in which the cutouts are milled or formed with a plurality of peripherally-extending angled or beveled edges  330  ( FIGS. 5 and 6 ) that exposes the bright natural or bare metallic material around the edge of the letters. Faceplate  320  may be formed from a metallic material such as an aluminum plate in which the cutouts are milled or formed with a peripherally-extending angled or beveled edge that exposes the bright natural metallic material around the edge of the letters and optional chevrons. 
         [0049]    Faceplate  320  may further include a colored coating  340  such as a dark solid color coating disposed on front surface  322 . For example, the solid colored surface may be a suitable red or black polymer or anodized coating. The contrast between the front coated surface of the faceplate and the cutouts may be similar to that shown in  FIGS. 4 and 8 . 
         [0050]    As best shown in  FIG. 13 , in faceplate  320 , the periphery of each of the openings defining the letters and each of the directional chevrons may be defined by beveled edge  330 . For example, beveled edges  330  may extend around the entire periphery of each of the letters and each of the directional chevrons. In addition, the beveled edges may extend between front surface  322  and rear surface  324 . The beveled edges may further be disposed on an angle of about 45-degree from front surface  322  of faceplate  320 . For example, faceplate  320  may be about ⅛-inch in thickness. The cutouts or openings may be formed with a machining tool that produces beveled edge  330  of 45-degrees relative to the front surface and extending from the top surface to about the middle of the faceplate, e.g., half of the cut ( 1/16-inch depth). A straight or normal edge  335  disposed at 90-degrees relative to the front or rear surface of the faceplate extends from the beveled edge to the rear surface for the remaining half of the cut ( 1/16-inch depth). 
         [0051]    Backplate  350  may comprise a metal or plastic planar layer such as formed from a PVC plastic or aluminum material. Photoluminescent layer  360  may be a sheet of photoluminescent material or a photoluminescent coating. For example, backplate  350  and photoluminescent layer  360  may be a photoluminescent lacquer-coated aluminum plate. 
         [0052]    Backplate  350  includes a front surface  352  and a rear surface  354 , and may have a length and width which corresponds to the length and width of the faceplate. Photoluminescent layer  360  is disposed on backplate  350 . A front surface of photoluminescent layer  360  is abutted and disposed tightly against rear surface  324  of faceplate  320  so that lowermost edges  332  ( FIG. 13 ) of edge  335  rests on the front surface of photoluminescent layer  360 . For example, rear surface of the faceplate may be adhesively bonded to front surface of photoluminescent layer  360 . Photoluminescent layer  360  desirably has a luminance of at least about 50 mcd/m2 at 60 minutes after exposure to 1000 lux xenon arc lamp for 5 minutes. A suitable photoluminescent impregnated polymer sheet is available from Jalite USA of Milford, Pa., model number JLUME. 
         [0053]    The rear surface of the backplate is typically disposed against a wall or other surface such as above a door or doorway. For example, when photoluminescent EXIT sign  300  is installed in a desired location, an installer may attach the rear surface to the wall using a suitable adhesive or bonding agent which is applied between the rear surface of the backplate. Alternatively, one or more adhesive materials may be disposed on the rear surface of the backplate. For example, as shown in  FIG. 14 , one or more adhesive strips  370  having a release sheet  375  may be disposed on the rear surface of the backplate. Alternatively, an optional frame may be used to secure the photoluminescent EXIT sign to the wall or the EXIT sign may be operably supported to hang from the ceiling. 
         [0054]    The exposed metallic material around the peripheral edges of the cutout letters defining the word “EXIT” and optional chevrons creates contrast between the design and the anodized black or red color of the faceplate as well as heightened contrast between the photoluminescent material and the faceplate increasing visibility and conspicuity under normal lighting. 
         [0055]    In visibility tests of the embodiment described with reference to  FIGS. 1-4 , the photoluminescent EXIT sign, performed by Underwriter&#39;s Laboratory (UL), the beveled natural aluminum edge of the sign functioned to increase the visibility of the EXIT sign&#39;s directional chevron indicator. In the completely dark test conditions stipulated by UL, the EXIT sign&#39;s beveled metal edge reflected the luminance of the photoluminescent material and the test participants could easily describe the indicated direction of travel indicated by the EXIT sign&#39;s chevron at the required 40 feet viewing distance. Chevrons made from material having the same luminance properties as the EXIT sign&#39;s photoluminescent backing plate and having similar and even slightly larger sizes, were not able to have their direction differentiated by the test participants at the required 40 feet viewing distance when a beveled edge faceplate was not used. Thus, the aesthetic design enhancement of the beveled edge gives an attractive depth dimension to a photoluminescent EXIT sign in light conditions, and has also become a distinctive technical differentiator, giving the EXIT sign higher visibility in dark conditions. 
         [0056]    From the present description, photoluminescent EXIT signs in accordance with the present invention may have one, two, or no directional chevrons resulting in four different designs, e.g., EXIT signs with right pointing chevron, EXIT signs with left pointing chevron, EXIT signs with both left and right pointing chevrons, and EXIT signs with no chevrons. 
         [0057]    The 1/16-inch and ⅛-inch thick architectural grade aluminum material also exhibits a significantly improved aesthetic design when compared to other existing photoluminescent EXIT signs giving it greater appeal for use by those designing the interior space of high-end buildings. In addition, the EXIT signs may be readily attached to a wall such as above a door with adhesive, suitable fasteners or optional frame. 
         [0058]    While the above description of the invention is directed to EXIT signs, it will be appreciated that signs having other words, letters, indicia, or designs, may incorporate the techniques of the present invention. 
         [0059]    Thus, while various embodiments of the present invention have been illustrated and described, it will be appreciated to those skilled in the art that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.

Technology Category: 3