Durel Corporation

Ralph M McGuigan

Rodney T Eckersley

Dee Lynn Johnson

Walter J Paciorek

Robert J Krafcik

Douglas T Wheeler

Harold T Munson

Will M Hooke

Sharlyn R Stocker

Edward L Kinnally

A method for forming an electroluminescent lamp unit. A multi-layer sheet form electroluminescent lamp, the multi-layer sheet form lamp includes a pair of sheet-form conductive layers, one of which is transparent for transmitting light emitted from the particles, an electroluminescent sheet-form layer disposed between the pair of sheet-form conductive layers and having electroluminescent particles, and a carrier substrate for supporting the pair of sheet-form conductive layers and electroluminescent sheet-form layer. The multi-layer sheet form lamp is heated at a temperature sufficient for maintaining the operational integrity of said carrier substrate and said thermoplastic layers. The multi-layer sheet form lamp is them formed into a desired three-dimensional shape.

Electroluminescent lamp devices and their manufacture

An electroluminescent lamp assembly includes electroluminescent lamps of selected limited size placed and secured upon a larger printed circuit substrate employing surface mount techniques. The electroluminescent lamp assembly includes a substrate having a relatively large lamp receiving surface and relatively smaller lamps. At least one of these smaller lamps is a multi-layer sheet-form electroluminescent lamp having a sheet-form layer containing electroluminescent particles, the layer disposed between a pair of sheet-form conductive layers, one of which is transparent for transmitting light emitted from the particles. The electroluminescent lamps each have conductors exposed for engagement and connection with conductive traces on the lamp receiving surface of the substrate in a surface mounted face-to-face arrangement and are distributed in spaced-apart relationship according to a preselected illumination pattern and connected to the conductive traces.

An EL lamp includes hole for receiving fitting attached to a printed circuit board. The fitting has a base, a head, and a neck connecting the head to the base. The diameter of the head is slightly larger than the diameter of the hole and the head fits though the hole by temporarily stretching the lamp. The lamp includes a substrate, a front electrode, a phosphor layer, and a rear electrode. The rear electrode faces the base. Contact to the front electrode is made through a first aperture in the rear electrode and in the phosphor layer. A second aperture, through the front electrode and the phosphor layer, exposes a portion of the substrate that is covered by the rear electrode. The apertures are aligned with two of the holes in the lamp.

Electrical, solderless snap connector for EL lamp

An EL lamp has a perimeter that is beveled such that the rear electrode is smaller in area than the front electrode due to the bevel. The lamp is made by placing an EL panel on a concave die with the rear electrode in contact with the die and shearing the edge of the lamp at an acute angle between 30.degree. and 60.degree., preferably 45.degree.. For circular or nearly circular lamps, the entire perimeter of the lamp can be cut in a single stroke.

EL lamp with beveled edge

An electroluminescent lamp unit includes a flat deformable substrate of preselected size having smaller sheet-form flexible electroluminescent lamps secured face-to-face at preselected positions on a surface of the substrate, the lamps connected with conductive traces on the substrate. The flat substrate with secured lamps can be deformed into a desired shape to provide a relatively inexpensive and reliable electroluminescent lamp unit applicable for a wide variety of applications. The flexible electroluminescent lamps of the unit can be individually addressable and may have different colors or intensities. A method of manufacture of such units employs surface mount technology in an automated version, pick and place robots select and place the lamps as instructed, followed by ultrasonic welding or mechanical or adhesive fastening.

An EL lamp has a perimeter that is beveled and said rear electrode is smaller in area than said front electrode due to said bevel. The lamp is made by placing an EL panel on a concave die with the rear electrode in contact with the die and shearing the edge of the lamp at an acute angle. The angle is between 30.degree. and 60.degree. and is preferably 45.degree.. The die has a radius of curvature that is 50-150 times the thickness of the panel to prevent deformation of the panel. For circular or nearly circular lamps, the entire perimeter of the lamp can be cut in a single stroke.

An EL panel has the material around each lamp removed to form a first rail and a second rail and a plurality of lamps mechanically isolated from each other and located on predetermined centers between the rails. Each lamp is connected to each rail by an arm and each arm includes a hole for locating the panel in a fixture. The arms are collinear and intersect the rails at an angle of 45.degree.. The panel is located in a fixture by pins through the holes in the arms and laminated to a backing plate or other device, also located in the fixture.

Laminated EL display

Electroluminescent modular lamp unit

An electroluminescent sheet-form lamp with a main portion of a conductive layer isolated from an edge region susceptible to detrimental conductive pathways by isolation provided along at least a portion of the perimeter of the lamp as a result of removal of a preapplied conductive coating such that, at the region of the isolation, the main portion of the one conductive layer which forms the respective electrode commences at a line spaced inwardly from the outer edge of the lamp. The preapplied conductive coating material may be removed to form a line of interruption that leaves in place a narrow margin of conductive coating in the edge region which is electrically isolated from the main portion of the coating forming the first electrode. The lamp may be formed by exposing preselected portions of the preapplied conductive coating to laser radiation sufficient to remove the preselected portions and form the region of isolation. A scribing technique or a mask, which may be a printed functional layer of the lamp, are employed.

Electroluminescent lamp with novel edge isolation

An electroluminescent sheet-form lamp comprising a transparent insulation layer, a transparent first conductive layer below the insulation layer forming a first electrode, a layer of phosphor material below the first conductive layer, a layer of dielectric material below the phosphor layer, a second conductive layer below the dielectric layer forming a second electrode, and electrical connection means for applying an electrical potential between the conductive layers to cause the phosphor to transmit light through the transparent conductive layer and the transparent insulation layer, one of the conductive layers having been formed as a general conductive coating preapplied over a panel of larger dimension than the lamp, from which the lamp has been cut. The lamp provides an improved electrical connection, wherein the one conductive layer has a line of interruption which isolates a localized region of the one conductive layer from electrical continuity with a main portion of the one conductive layer, the main portion of the one conductive layer forming the respective electrode and being connected to one of the connection means to apply electrical potential thereto without applying electrical potential to the localized region, the connection means for the other of the conductive layers which forms the other of the electrodes being located in coincidence with the area of the localized region, one of the connection means employing deformation of the sheet-form lamp, whereby the electrical isolation of the localized region prevents electrical shorting between the conductive layers as a result of the deformation.

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Phoenix, AZ, United States of America

Ralph M McGuigan