CA2256959C - Decorative lighting laminate - Google Patents
Decorative lighting laminate Download PDFInfo
- Publication number
- CA2256959C CA2256959C CA002256959A CA2256959A CA2256959C CA 2256959 C CA2256959 C CA 2256959C CA 002256959 A CA002256959 A CA 002256959A CA 2256959 A CA2256959 A CA 2256959A CA 2256959 C CA2256959 C CA 2256959C
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- CA
- Canada
- Prior art keywords
- decorative
- light source
- layer
- laminate
- light
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
- B60Q3/00—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors
- B60Q3/60—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors characterised by optical aspects
- B60Q3/62—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors characterised by optical aspects using light guides
- B60Q3/64—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors characterised by optical aspects using light guides for a single lighting device
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
- B60Q3/00—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors
- B60Q3/70—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors characterised by the purpose
- B60Q3/78—Arrangement of lighting devices for vehicle interiors; Lighting devices specially adapted for vehicle interiors characterised by the purpose for generating luminous strips, e.g. for marking trim component edges
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/412—Transparent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/414—Translucent
Abstract
The present invention provides a decorative lighting laminate that can be ma de to glow or illuminate while shielding the laminate's light source components from view. The decorative lighting laminate is made from a decorative laminate th at includes a transparent base layer and a thin translucent decorative covering layer. In a preferred embodiment, the base layer is made from a clear polycarbonate material and the decorative covering layer is made from an organic fluoropolymeric, such as a polyvinyl fluoride or a polyvinylidene fluoride polymeric material.
Description
DECORATIVE LIGHTING LAMINATE
Field of the Invention The present invention relates to a decorative lighting laminate and, more particularly, to a decorative laminate that shields light source components from view.
Background of the Invention The design and fabrication of decorative lighted parts is often expensive. The expense is due in part to the design, fabrication, and assembly of optical display lenses into the decorative part. Furthermore, display lenses often reduce the aesthetic appeal of the decorative lighted part. In addition, these lenses require cleaning and maintenance that is both time consuming and ultimately reduces the lifetime of the lens. For decorative lighted parts incorporated into commercial aircraft interiors, display lenses increase the overall weight of the component part, which is economically disadvantageous.
A need exists for decorative lighted parts that can be simply designed and fabricated without the disadvantages associated with display lenses. A need also exists for providing decorative lighted parts having enhanced aesthetics. The present invention seeks to fulfill these needs and provides further related advantages.
Summary of the Invention In accordance with one aspect of the invention, there is provided a decorative lighting laminate that can be made to glow or illuminate while shielding unsightly light source components from view. The decorative lighting laminate may include hidden or shrouded signal lighting that can be illuminated upon demand and when the signal lighting is not illuminated, the light source components are hidden by the laminate's translucent covering. The decorative lighting laminate may be made from a decorative laminate that includes a transparent base layer and a thin translucent decorative covering layer. The base layer may be made from a clear polycarbonate material. The laminate's decorative covering layer may be a light-transmitting layer but, unlike the transparent base layer, the decorative layer may be translucent and may have an opacity sufficient to shield the light source from view when not illuminated.
The decorative layer may be made from a thermoplastic resinous material including, for example, an organic fluoropolymer such as a polyvinyl fluoride or a
Field of the Invention The present invention relates to a decorative lighting laminate and, more particularly, to a decorative laminate that shields light source components from view.
Background of the Invention The design and fabrication of decorative lighted parts is often expensive. The expense is due in part to the design, fabrication, and assembly of optical display lenses into the decorative part. Furthermore, display lenses often reduce the aesthetic appeal of the decorative lighted part. In addition, these lenses require cleaning and maintenance that is both time consuming and ultimately reduces the lifetime of the lens. For decorative lighted parts incorporated into commercial aircraft interiors, display lenses increase the overall weight of the component part, which is economically disadvantageous.
A need exists for decorative lighted parts that can be simply designed and fabricated without the disadvantages associated with display lenses. A need also exists for providing decorative lighted parts having enhanced aesthetics. The present invention seeks to fulfill these needs and provides further related advantages.
Summary of the Invention In accordance with one aspect of the invention, there is provided a decorative lighting laminate that can be made to glow or illuminate while shielding unsightly light source components from view. The decorative lighting laminate may include hidden or shrouded signal lighting that can be illuminated upon demand and when the signal lighting is not illuminated, the light source components are hidden by the laminate's translucent covering. The decorative lighting laminate may be made from a decorative laminate that includes a transparent base layer and a thin translucent decorative covering layer. The base layer may be made from a clear polycarbonate material. The laminate's decorative covering layer may be a light-transmitting layer but, unlike the transparent base layer, the decorative layer may be translucent and may have an opacity sufficient to shield the light source from view when not illuminated.
The decorative layer may be made from a thermoplastic resinous material including, for example, an organic fluoropolymer such as a polyvinyl fluoride or a
-2-polyvinylidene fluoride polymer. The laminate's decorative layer may be affixed to the base layer by an intermediate layer that includes an adhesive material.
In accordance with another aspect of the invention, the decorative laminate may be molded and formed into a variety of shapes and configurations such as a decorative interior part useful for a variety of applications including, for example, commercial aircraft interior parts. In general, one or more light sources may be combined with the molded decorative laminate to form a decorative lighting laminate.
Positioning a light source adjacent the transparent base layer allows the laminate to transmit light while, by virtue of the translucent decorative covering layer, shielding the light source from view.
In accordance with another aspect of the invention there is provided a lighting apparatus. The apparatus includes a light transmitting laminate having a first transparent base layer, a second translucent decorative layer, and a layer including an adhesive material intermediate the base and decorative layers. Light form a light source behind the apparatus passes through the base layer to the decorative layer and the decorative layer has an opacity sufficient to prevent the light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
The base layer may be operable to receive light at a rear face thereof.
The base layer may include clear polycarbonate.
The base layer may include a fiberglass laminate.
The fiberglass laminate may be selected from the group consisting of fiberglass-epoxy and fiberglass-polyester laminates.
The base layer may have a thickness of between about 0.010 inch to about 0.125 inch.
The decorative layer may include a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material.
The decorative layer may have a thickness of between about 0.0015 inch and about 0.0040 inch.
The adhesive material may include an acrylic adhesive.
-2a-The apparatus may include the light source, the light source being mounted to the base layer.
The light source may include a light-emitting diode.
The light source may include an array of light-emitting diodes.
In accordance with another aspect of the invention there is provided a lighting apparatus. The apparatus includes a light transmitting laminate having a first transparent base layer including clear polycarbonate, a second translucent decorative layer including a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material, and a layer including an acrylic adhesive intermediate the base and decorative layers.
Light from a light source behind the apparatus passes through the base layer to the decorative layer and the decorative layer has an opacity sufficient to prevent the light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
The apparatus may include the light source, the light source being mounted to the base layer.
The light source may include at least one light emitting diode.
In accordance with another aspect of the invention there is provided a process for forming a lighting apparatus. The process involves forming a light transmitting laminate by laminating a translucent decorative material onto a transparent base material. Forming involves affixing the decorative material to the base material with an adhesive material intermediate the base material and decorative material.
The process further involves thermoforming the light transmitting laminate on a mold die to form a molded laminate.
The process may involve affixing at least one light source to the molded laminate behind the base material such that light from the light source passes through the base layer to the decorative layer.
Laminating the decorative material may involve laminating to the base material a decorative material having an opacity sufficient to prevent said at least one light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
-2b-Laminating the translucent decorative material onto the transparent base material, may involve laminating a translucent decorative material onto a transparent base material formed of clear polycarbonate.
Laminating the translucent decorative material onto the transparent base material, may involve laminating a translucent decorative material onto a transparent base material formed of fiberglass laminate.
Laminating the translucent decorative material onto a transparent base material, may involve laminating onto the base material a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material.
Affixing the decorative material to the base material may involve affixing the decorative material to the base material with an acrylic adhesive material intermediate the base material and decorative material.
Affixing the at least one light source may involve affixing a light emitting diode to the molded laminate behind the base material such that light from the light source passes through the base layer to the decorative layer.
Affixing the at least one light source may involve affixing an array of light emitting diodes to the molded laminate behind the base material such that light from the light source passes through the base layer to the decorative layer.
Thermoforming the light transmitting laminate on a mold die may involve thermoforming the light transmitting laminate on a textured mold die.
Thermoforming may involve thermoforming the material on a mold die to form a molded aircraft interior part.
Thermoforming may involve thermoforming the material on a mold die to form a molded aircraft interior part selected from the group consisting of door lining, window bezel, door handle escutcheon, emergency route indicator, stowage bin faceplate, stowage bin bullnose, panel, flight deck window lining, console, cup holder, pocket holder, cover, shroud and sign.
In accordance with another aspect of the invention, there is provided an aircraft interior lighting part including a light-transmitting laminate having a first transparent base layer, a second translucent decorative layer, and a layer that includes an adhesive material intermediate the base and decorative layers. The apparatus -2c-further includes a light source positioned behind the base layer, which is operable to illuminate the decorative layer through the base layer, the decorative layer having opacity sufficient to shield the light source from view when not illuminated.
Brief Description of the Drawings The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIGURE 1 is a cross-sectional view of a decorative lighting laminate formed in accordance with the present invention;
FIGURE 2A is a plan view of an illuminated representative decorative lighting laminate, a door handle escutcheon, formed in accordance with the present invention;
FIGURE 2B is a plan view of the nonilluminated escutcheon of FIGURE 2A;
FIGURE 3 illustrates a representative decorative lighting laminate, a door handle escutcheon, formed in accordance with the present invention positioned on the interior surface of an aircraft emergency exit; and FIGURE 4 is a cross-sectional view of a representative decorative lighting laminate, the door handle escutcheon shown in FIGURE 3.
In accordance with another aspect of the invention, the decorative laminate may be molded and formed into a variety of shapes and configurations such as a decorative interior part useful for a variety of applications including, for example, commercial aircraft interior parts. In general, one or more light sources may be combined with the molded decorative laminate to form a decorative lighting laminate.
Positioning a light source adjacent the transparent base layer allows the laminate to transmit light while, by virtue of the translucent decorative covering layer, shielding the light source from view.
In accordance with another aspect of the invention there is provided a lighting apparatus. The apparatus includes a light transmitting laminate having a first transparent base layer, a second translucent decorative layer, and a layer including an adhesive material intermediate the base and decorative layers. Light form a light source behind the apparatus passes through the base layer to the decorative layer and the decorative layer has an opacity sufficient to prevent the light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
The base layer may be operable to receive light at a rear face thereof.
The base layer may include clear polycarbonate.
The base layer may include a fiberglass laminate.
The fiberglass laminate may be selected from the group consisting of fiberglass-epoxy and fiberglass-polyester laminates.
The base layer may have a thickness of between about 0.010 inch to about 0.125 inch.
The decorative layer may include a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material.
The decorative layer may have a thickness of between about 0.0015 inch and about 0.0040 inch.
The adhesive material may include an acrylic adhesive.
-2a-The apparatus may include the light source, the light source being mounted to the base layer.
The light source may include a light-emitting diode.
The light source may include an array of light-emitting diodes.
In accordance with another aspect of the invention there is provided a lighting apparatus. The apparatus includes a light transmitting laminate having a first transparent base layer including clear polycarbonate, a second translucent decorative layer including a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material, and a layer including an acrylic adhesive intermediate the base and decorative layers.
Light from a light source behind the apparatus passes through the base layer to the decorative layer and the decorative layer has an opacity sufficient to prevent the light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
The apparatus may include the light source, the light source being mounted to the base layer.
The light source may include at least one light emitting diode.
In accordance with another aspect of the invention there is provided a process for forming a lighting apparatus. The process involves forming a light transmitting laminate by laminating a translucent decorative material onto a transparent base material. Forming involves affixing the decorative material to the base material with an adhesive material intermediate the base material and decorative material.
The process further involves thermoforming the light transmitting laminate on a mold die to form a molded laminate.
The process may involve affixing at least one light source to the molded laminate behind the base material such that light from the light source passes through the base layer to the decorative layer.
Laminating the decorative material may involve laminating to the base material a decorative material having an opacity sufficient to prevent said at least one light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
-2b-Laminating the translucent decorative material onto the transparent base material, may involve laminating a translucent decorative material onto a transparent base material formed of clear polycarbonate.
Laminating the translucent decorative material onto the transparent base material, may involve laminating a translucent decorative material onto a transparent base material formed of fiberglass laminate.
Laminating the translucent decorative material onto a transparent base material, may involve laminating onto the base material a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material.
Affixing the decorative material to the base material may involve affixing the decorative material to the base material with an acrylic adhesive material intermediate the base material and decorative material.
Affixing the at least one light source may involve affixing a light emitting diode to the molded laminate behind the base material such that light from the light source passes through the base layer to the decorative layer.
Affixing the at least one light source may involve affixing an array of light emitting diodes to the molded laminate behind the base material such that light from the light source passes through the base layer to the decorative layer.
Thermoforming the light transmitting laminate on a mold die may involve thermoforming the light transmitting laminate on a textured mold die.
Thermoforming may involve thermoforming the material on a mold die to form a molded aircraft interior part.
Thermoforming may involve thermoforming the material on a mold die to form a molded aircraft interior part selected from the group consisting of door lining, window bezel, door handle escutcheon, emergency route indicator, stowage bin faceplate, stowage bin bullnose, panel, flight deck window lining, console, cup holder, pocket holder, cover, shroud and sign.
In accordance with another aspect of the invention, there is provided an aircraft interior lighting part including a light-transmitting laminate having a first transparent base layer, a second translucent decorative layer, and a layer that includes an adhesive material intermediate the base and decorative layers. The apparatus -2c-further includes a light source positioned behind the base layer, which is operable to illuminate the decorative layer through the base layer, the decorative layer having opacity sufficient to shield the light source from view when not illuminated.
Brief Description of the Drawings The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIGURE 1 is a cross-sectional view of a decorative lighting laminate formed in accordance with the present invention;
FIGURE 2A is a plan view of an illuminated representative decorative lighting laminate, a door handle escutcheon, formed in accordance with the present invention;
FIGURE 2B is a plan view of the nonilluminated escutcheon of FIGURE 2A;
FIGURE 3 illustrates a representative decorative lighting laminate, a door handle escutcheon, formed in accordance with the present invention positioned on the interior surface of an aircraft emergency exit; and FIGURE 4 is a cross-sectional view of a representative decorative lighting laminate, the door handle escutcheon shown in FIGURE 3.
-3- . .
Detailed Description of the Preferred Embodiment In one aspect, the present invention provides a decorative, light-transmitting laminate that is useful for forming decorative lighted interior parts, for example, commercial aircraft interior parts. When formed into an interior part, the molded laminate can be combined with one or more light sources to provide a decorative lighting laminate that can be made to glow or illuminate on demand. When not illuminated, the laminate has an opacity sufficient to hide or shield the light source component from view.
The decorative laminate of the present invention is a light-transmitting laminate that includes a transparent, light-transmitting base layer and a translucent, light-transmitting decorative covering layer. The decorative layer is affixed to the base layer by an intermediate layer that includes an adhesive material. The transparent base layer and translucent decorative covering are made from moldable, thermoplastic resinous materials. Both the base layer and decorative covering layer are light transmitting; the base layer being substantially transparent (i.e., made from one or more transparent or semitransparent plastic materials) and the decorative covering being translucent. The laminate's decorative covering has an opacity sufficient to shield from view a light source component positioned adjacent the base layer.
The laminate's transparent, light-transmitting base layer imparts structural integrity to the laminate. The base layer can be made from any suitably transparent and moldable thermoplastic resinous material. In a preferred embodiment, the base layer is made from a clear polycarbonate sheet. Alternatively, the base layer can be prepared from the consolidation of several plies of fiberglass-polyester prepreg, a fibrous material, in the form of a sheet or on a mandrel, onto which resin is applied to create a reinforced plastic product. Other transparent thermoplastic materials suitable for the base layer include Lexan polycarbonate (PC) (General Electric), Declar polyether ketone ketone (PEKK) (DuPont), and Radel polyphenylene sulfone (PPS) (Amoco Performance Products). The base layer can also be a fiberglass laminate such as a molded fiberglass-epoxy or fiberglass-polyester laminate having from one to about ten plies (each ply having a thickness of about 0.01 inch). Preferably, the base layer has a thickness in the range between from about 0.010 inch to about 0.125 inch.
The laminate's decorative covering layer can be made from a suitably translucent and moldable thermoplastic resinous material. Preferred thermoplastic materials include fluorinated organic polymeric materials such as, for example, polyvinyl fluoride (PVF) and polyvinylidene fluoride (PVDF) polymeric materials.
Detailed Description of the Preferred Embodiment In one aspect, the present invention provides a decorative, light-transmitting laminate that is useful for forming decorative lighted interior parts, for example, commercial aircraft interior parts. When formed into an interior part, the molded laminate can be combined with one or more light sources to provide a decorative lighting laminate that can be made to glow or illuminate on demand. When not illuminated, the laminate has an opacity sufficient to hide or shield the light source component from view.
The decorative laminate of the present invention is a light-transmitting laminate that includes a transparent, light-transmitting base layer and a translucent, light-transmitting decorative covering layer. The decorative layer is affixed to the base layer by an intermediate layer that includes an adhesive material. The transparent base layer and translucent decorative covering are made from moldable, thermoplastic resinous materials. Both the base layer and decorative covering layer are light transmitting; the base layer being substantially transparent (i.e., made from one or more transparent or semitransparent plastic materials) and the decorative covering being translucent. The laminate's decorative covering has an opacity sufficient to shield from view a light source component positioned adjacent the base layer.
The laminate's transparent, light-transmitting base layer imparts structural integrity to the laminate. The base layer can be made from any suitably transparent and moldable thermoplastic resinous material. In a preferred embodiment, the base layer is made from a clear polycarbonate sheet. Alternatively, the base layer can be prepared from the consolidation of several plies of fiberglass-polyester prepreg, a fibrous material, in the form of a sheet or on a mandrel, onto which resin is applied to create a reinforced plastic product. Other transparent thermoplastic materials suitable for the base layer include Lexan polycarbonate (PC) (General Electric), Declar polyether ketone ketone (PEKK) (DuPont), and Radel polyphenylene sulfone (PPS) (Amoco Performance Products). The base layer can also be a fiberglass laminate such as a molded fiberglass-epoxy or fiberglass-polyester laminate having from one to about ten plies (each ply having a thickness of about 0.01 inch). Preferably, the base layer has a thickness in the range between from about 0.010 inch to about 0.125 inch.
The laminate's decorative covering layer can be made from a suitably translucent and moldable thermoplastic resinous material. Preferred thermoplastic materials include fluorinated organic polymeric materials such as, for example, polyvinyl fluoride (PVF) and polyvinylidene fluoride (PVDF) polymeric materials.
-4-Preferably, the decorative covering layer has a thickness from about 0.0015 inch to about 0.0040 inch. In a preferred embodiment, the decorative covering is a thermoplastic film such as a PVF or a PVDF film. A preferred PVF film is commercially available from E.I. DuPont de Nemours & Co. (Wilmington, DE) under the designation Tedlar . A preferred PVDF film is commercially available from Avery Dennison (Schererville, IN) under the designation Avimark .
In one preferred embodiment, the decorative light-transmitting laminate of the present invention has a transparent base layer made from clear polycarbonate and a translucent decorative covering made from a fluorinated organic polymeric material selected from PVF and PVDF polymeric materials.
The decorative laminate of the invention is a thermoplastic sheet material that can be prepared by press laminating the translucent decorative covering onto a surface of the transparent base layer. For example, in a preferred embodiment, a thin film of translucent Tedlar is press laminated onto a clear transparent polycarbonate sheet.
After the decorative laminate sheet material is prepared, the sheet material can be thermoformed onto a mold die to provide a molded decorative laminate (i.e., a decorative laminate part). The mold die can be, for example, a textured mold die.
Thus, depending on the particular mold die, the decorative laminate sheet material can be formed into a variety of decorative parts including, for example, decorative parts for commercial aircraft interiors. Examples of commercial aircraft interior parts that can be readily formed from the decorative laminate sheet material include door linings and window bezels, door handle escutcheons, emergency route indicator strips, stowage bin faceplates/bullnoses, passenger service unit (PSU) spacer panels, flight deck interior-window linings, consoles, instrument panels, cup holders, and pocket holders for sunvisors and reference manuals. Other decorative parts including panels, covers, escutcheons, and shrouds can also be similarly prepared using the decorative laminate sheet material of the present invention.
When combined with one or more light sources, a molded decorative laminate part formed from the decorative laminate sheet material provides a decorative fighting laminate (i.e., a decorative lighting laminate part) that can be made to glow or illuminate on demand while shielding light source components from view. As noted above, such a decorative lighting laminate is particularly useful in commercial aircraft interiors for illuminating emergency routes, exits, and exit door and/or window handles. Because the light source components of these decorative lighting laminates
In one preferred embodiment, the decorative light-transmitting laminate of the present invention has a transparent base layer made from clear polycarbonate and a translucent decorative covering made from a fluorinated organic polymeric material selected from PVF and PVDF polymeric materials.
The decorative laminate of the invention is a thermoplastic sheet material that can be prepared by press laminating the translucent decorative covering onto a surface of the transparent base layer. For example, in a preferred embodiment, a thin film of translucent Tedlar is press laminated onto a clear transparent polycarbonate sheet.
After the decorative laminate sheet material is prepared, the sheet material can be thermoformed onto a mold die to provide a molded decorative laminate (i.e., a decorative laminate part). The mold die can be, for example, a textured mold die.
Thus, depending on the particular mold die, the decorative laminate sheet material can be formed into a variety of decorative parts including, for example, decorative parts for commercial aircraft interiors. Examples of commercial aircraft interior parts that can be readily formed from the decorative laminate sheet material include door linings and window bezels, door handle escutcheons, emergency route indicator strips, stowage bin faceplates/bullnoses, passenger service unit (PSU) spacer panels, flight deck interior-window linings, consoles, instrument panels, cup holders, and pocket holders for sunvisors and reference manuals. Other decorative parts including panels, covers, escutcheons, and shrouds can also be similarly prepared using the decorative laminate sheet material of the present invention.
When combined with one or more light sources, a molded decorative laminate part formed from the decorative laminate sheet material provides a decorative fighting laminate (i.e., a decorative lighting laminate part) that can be made to glow or illuminate on demand while shielding light source components from view. As noted above, such a decorative lighting laminate is particularly useful in commercial aircraft interiors for illuminating emergency routes, exits, and exit door and/or window handles. Because the light source components of these decorative lighting laminates
-5- . .
are hidden from view, these decorative parts have enhanced aesthetic appeal compared to other decorative parts having light sources that are observable.
Suitable light sources useful in the decorative lighting laminate of the present invention include point light sources, such as light bulbs and light-emitting diodes (LEDs), and diffuse light from remote light sources. The light sources generally provide signal lighting, for example, emergency signal lighting. In one preferred embodiment, the decorative lighting laminate part includes an array of LEDs.
Alternatively, the light source can include a remote light source coupled to one or more optical fibers that terminate at the transparent base layer of the decorative laminate.
A layer containing an adhesive material affixes the decorative layer to the base layer. Referring to FIGURE 1, decorative layer 20 is affixed to base layer 30 by adhesive-containing layer 22. Layer 22 can include any adhesive material suitable for affixing the decorative layer to the base layer. Suitable adhesive materials include thermoplastic and thermosetting adhesive materials such as acrylic and polyurethane adhesive materials. In a preferred embodiment, the adhesive material is an acrylic adhesive having a thickness of about 0.2 mils, commercially available from DuPont under the designation 68080 or 68040 acrylic adhesive. Thermoplastic and thermosetting adhesives are particularly preferred for laminates of the present invention that are formed by thermoforming methods.
Other suitable adhesive materials include pressure-sensitive and heat-activatable adhesive materials. Pressure-sensitive adhesive materials can be applied as a film or coating. Suitable pressure-sensitive adhesives include, for example, a 3-6 mil thick adhesive available from the 3M Company (Knoxville, IA) under the designation 468MPF. In a preferred embodiment, the pressure-sensitive adhesive is a 3 mil thick adhesive available from Bostik Inc. (Middleton, MA) under the designation S408-4084. Alternatively, the adhesive material can be a heat-activatable adhesive.
Preferred heat-activatable adhesives include thermosetting and thermoplastic adhesives. Thermosetting adhesives can be combined with solvents and applied by spraying. The laminate's decorative layer can be affixed to the base layer by heating to cure the adhesive material. In a preferred embodiment, the heat-activatable adhesive is a 1.5 mil thick thermoplastic adhesive film available from Bostik under the designation 10-309-1.5. The pressure-sensitive and heat-activatable adhesives are particularly preferred for the laminates of the present invention formed by wrapping
are hidden from view, these decorative parts have enhanced aesthetic appeal compared to other decorative parts having light sources that are observable.
Suitable light sources useful in the decorative lighting laminate of the present invention include point light sources, such as light bulbs and light-emitting diodes (LEDs), and diffuse light from remote light sources. The light sources generally provide signal lighting, for example, emergency signal lighting. In one preferred embodiment, the decorative lighting laminate part includes an array of LEDs.
Alternatively, the light source can include a remote light source coupled to one or more optical fibers that terminate at the transparent base layer of the decorative laminate.
A layer containing an adhesive material affixes the decorative layer to the base layer. Referring to FIGURE 1, decorative layer 20 is affixed to base layer 30 by adhesive-containing layer 22. Layer 22 can include any adhesive material suitable for affixing the decorative layer to the base layer. Suitable adhesive materials include thermoplastic and thermosetting adhesive materials such as acrylic and polyurethane adhesive materials. In a preferred embodiment, the adhesive material is an acrylic adhesive having a thickness of about 0.2 mils, commercially available from DuPont under the designation 68080 or 68040 acrylic adhesive. Thermoplastic and thermosetting adhesives are particularly preferred for laminates of the present invention that are formed by thermoforming methods.
Other suitable adhesive materials include pressure-sensitive and heat-activatable adhesive materials. Pressure-sensitive adhesive materials can be applied as a film or coating. Suitable pressure-sensitive adhesives include, for example, a 3-6 mil thick adhesive available from the 3M Company (Knoxville, IA) under the designation 468MPF. In a preferred embodiment, the pressure-sensitive adhesive is a 3 mil thick adhesive available from Bostik Inc. (Middleton, MA) under the designation S408-4084. Alternatively, the adhesive material can be a heat-activatable adhesive.
Preferred heat-activatable adhesives include thermosetting and thermoplastic adhesives. Thermosetting adhesives can be combined with solvents and applied by spraying. The laminate's decorative layer can be affixed to the base layer by heating to cure the adhesive material. In a preferred embodiment, the heat-activatable adhesive is a 1.5 mil thick thermoplastic adhesive film available from Bostik under the designation 10-309-1.5. The pressure-sensitive and heat-activatable adhesives are particularly preferred for the laminates of the present invention formed by wrapping
-6-the decorative layer onto a base layer formed from a molded fiberglass laminate, for example, a fiberglass-epoxy laminate.
The present invention also provides a method for forming a decorative lighting laminate (e.g., an aircraft interior light part). In a method, a translucent decorative layer is formed onto a transparent base layer by, for example, press lamination. In the press lamination method, an adhesive layer is included intermediate the decorative and base layers. The resulting light-transmitting laminate can then be thermoformed on a mold die (e.g., an aircraft interior lighting part mold die including, for example, textured mold dies that impart surface texture to the laminate's surface) to provide a molded, light-transmitting laminate. Alternatively, Tedlar capped sheets of transparent base materials (e.g., Declar, commercially available from DuPont, and Lexan, commercially available from General Electric) can be thermoformed directly.
In another method, the translucent decorative layer can be laminated onto an already molded transparent base layer. For example, the decorative layer can be hand wrapped onto a molded base layer made from a fiberglass laminate, such as a fiberglass-epoxy laminate, coated with an adhesive material. The final decorative lighting laminate or part is assembled by affixing at least one light source (e.g., an LED or an array of LEDs) to the molded laminate adjacent the base layer.
A cross-sectional view of a portion of the decorative lighting laminate formed in accordance with the present invention is shown in FIGURE 1. Referring to FIGURE 1, decorative lighting laminate 10 includes a translucent decorative covering layer 20, intermediate layer 22, and transparent base layer 30. As described above, a moldable decorative laminate sheet comprising base layer 30 and decorative covering 20 can be formed by, for example, thermoforming. Once the decorative laminate is molded to a particular shape and configuration defining, for example, an aircraft interior lighting part, one or more light sources 40 can be added to the part by, for example, mounting the light source to base layer 30. Power to light source 40 is provided by supply line 42.
A plan view of a representative decorative lighting laminate part formed in accordance with the present invention, a door handle escutcheon, is shown in FIGURES 2A and 2B. FIGURE 2A illustrates illuminated escutcheon 50 and FIGURE 2B illustrates the nonilluminated escutcheon. As shown in FIGURE 2B and discussed above, the decorative lighting laminate's light sources are not visually observable when the light sources are not illuminated.
The present invention also provides a method for forming a decorative lighting laminate (e.g., an aircraft interior light part). In a method, a translucent decorative layer is formed onto a transparent base layer by, for example, press lamination. In the press lamination method, an adhesive layer is included intermediate the decorative and base layers. The resulting light-transmitting laminate can then be thermoformed on a mold die (e.g., an aircraft interior lighting part mold die including, for example, textured mold dies that impart surface texture to the laminate's surface) to provide a molded, light-transmitting laminate. Alternatively, Tedlar capped sheets of transparent base materials (e.g., Declar, commercially available from DuPont, and Lexan, commercially available from General Electric) can be thermoformed directly.
In another method, the translucent decorative layer can be laminated onto an already molded transparent base layer. For example, the decorative layer can be hand wrapped onto a molded base layer made from a fiberglass laminate, such as a fiberglass-epoxy laminate, coated with an adhesive material. The final decorative lighting laminate or part is assembled by affixing at least one light source (e.g., an LED or an array of LEDs) to the molded laminate adjacent the base layer.
A cross-sectional view of a portion of the decorative lighting laminate formed in accordance with the present invention is shown in FIGURE 1. Referring to FIGURE 1, decorative lighting laminate 10 includes a translucent decorative covering layer 20, intermediate layer 22, and transparent base layer 30. As described above, a moldable decorative laminate sheet comprising base layer 30 and decorative covering 20 can be formed by, for example, thermoforming. Once the decorative laminate is molded to a particular shape and configuration defining, for example, an aircraft interior lighting part, one or more light sources 40 can be added to the part by, for example, mounting the light source to base layer 30. Power to light source 40 is provided by supply line 42.
A plan view of a representative decorative lighting laminate part formed in accordance with the present invention, a door handle escutcheon, is shown in FIGURES 2A and 2B. FIGURE 2A illustrates illuminated escutcheon 50 and FIGURE 2B illustrates the nonilluminated escutcheon. As shown in FIGURE 2B and discussed above, the decorative lighting laminate's light sources are not visually observable when the light sources are not illuminated.
-7-Decorative lighting laminates formed in accordance with the present invention are useful as parts for commercial and military aircraft interiors as well as for automotive, trucking, railway, and bus interiors. FIGURE 3 illustrates a representative decorative lighting laminate, door escutcheon 50, positioned on aircraft emergency exit 60. A cross-sectional view of escutcheon 50 is shown in FIGIJRE
4.
Referring to FIGURE 4, escutcheon 50 ir.cludes translucent decorative covering layer 20, intermediate layer 22, transparent base layer 30, and light sources 40 (having supply leads 42).
The present invention provides a decorative, light-transmitting laminate that can be molded and formed into aircraft interior components or parts that can be made to illuminate on demand. These interior parts are decorative in that there is no visual indication of display until light sources associated with the part are illuminated. The decorative lighting laminates formed in accordance with the present invention include no lenses and have no optical surfaces. Thus, the laminate parts require no optimization of light transmission. Decorative lighted laminates formed in accordance with the present invention are particularly useful for indicating exits and routes in commercial aircraft interiors under emergency conditions. The decorative lighting laminate can also be used for nonemergency applications including, for example, displaying an airline's logo or trademark.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
. . ; ._.._.__
4.
Referring to FIGURE 4, escutcheon 50 ir.cludes translucent decorative covering layer 20, intermediate layer 22, transparent base layer 30, and light sources 40 (having supply leads 42).
The present invention provides a decorative, light-transmitting laminate that can be molded and formed into aircraft interior components or parts that can be made to illuminate on demand. These interior parts are decorative in that there is no visual indication of display until light sources associated with the part are illuminated. The decorative lighting laminates formed in accordance with the present invention include no lenses and have no optical surfaces. Thus, the laminate parts require no optimization of light transmission. Decorative lighted laminates formed in accordance with the present invention are particularly useful for indicating exits and routes in commercial aircraft interiors under emergency conditions. The decorative lighting laminate can also be used for nonemergency applications including, for example, displaying an airline's logo or trademark.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
. . ; ._.._.__
Claims (28)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A lighting apparatus, the apparatus comprising:
a light transmitting laminate having:
a first transparent base layer;
a second translucent decorative layer; and a layer comprising an adhesive material intermediate said base layer and said decorative layers;
wherein light form a light source behind said apparatus passes through said base layer to said decorative layer and wherein said decorative layer has an opacity sufficient to prevent the light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
a light transmitting laminate having:
a first transparent base layer;
a second translucent decorative layer; and a layer comprising an adhesive material intermediate said base layer and said decorative layers;
wherein light form a light source behind said apparatus passes through said base layer to said decorative layer and wherein said decorative layer has an opacity sufficient to prevent the light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
2. The apparatus of Claim 1 wherein said base layer is operable to receive light at a rear face thereof.
3. The apparatus of Claim 1 wherein said base layer comprises clear polycarbonate.
4. The apparatus of Claim 1 wherein said base layer comprises a fiberglass laminate.
5. The apparatus of Claim 4 wherein said fiberglass laminate is selected from the group consisting of fiberglass-epoxy and fiberglass-polyester laminates.
6. The apparatus of Claim 1 wherein said base layer has a thickness of between about 0.010 inch to about 0.125 inch.
7. The apparatus of Claim 1 wherein said decorative layer comprises a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material.
8. The apparatus of Claim 1 wherein said decorative layer has a thickness of between about 0.0015 inch and about 0.0040 inch.
9. The apparatus of Claim 1 wherein said adhesive material comprises an acrylic adhesive.
10. The apparatus of Claim 1 further comprising said light source, said light source being mounted to said base layer.
11. The apparatus of Claim 1 wherein said light source includes a light-emitting diode.
12. The apparatus of Claim 1 wherein said light source comprises an array of light-emitting diodes.
13. A lighting apparatus, the apparatus comprising:
a light transmitting laminate having:
a first transparent base layer comprising clear polycarbonate;
a second translucent decorative layer comprising a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material; and a layer comprising an acrylic adhesive intermediate said base layer and said decorative layer;
wherein light from a light source behind said apparatus passes through said base layer to said decorative layer and wherein said decorative layer has an opacity sufficient to prevent the light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
a light transmitting laminate having:
a first transparent base layer comprising clear polycarbonate;
a second translucent decorative layer comprising a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material; and a layer comprising an acrylic adhesive intermediate said base layer and said decorative layer;
wherein light from a light source behind said apparatus passes through said base layer to said decorative layer and wherein said decorative layer has an opacity sufficient to prevent the light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
14. The apparatus of claim 13 further comprising said light source, said light source being mounted to said base layer.
15. The apparatus of claim 14 wherein said light source comprises at least one light emitting diode.
16. A process for forming a lighting apparatus, the process comprising:
forming a light transmitting laminate by laminating a translucent decorative material onto a transparent base material, wherein forming involves affixing said decorative material to said base material with an adhesive material intermediate said base material and decorative material; and thermoforming said light transmitting laminate on a mold die to form a molded laminate.
forming a light transmitting laminate by laminating a translucent decorative material onto a transparent base material, wherein forming involves affixing said decorative material to said base material with an adhesive material intermediate said base material and decorative material; and thermoforming said light transmitting laminate on a mold die to form a molded laminate.
17. The process of claim 16 further comprising affixing at least one light source to said molded laminate behind said base material such that light from said light source passes through said base layer to said decorative layer.
18. The process of Claim 17 wherein laminating said decorative material comprises laminating to said base material, a decorative material having an opacity sufficient to prevent said at least one light source from being seen when the apparatus is viewed from a front side thereof, when the light source is inactive.
19. The process of claim 18 wherein laminating said translucent decorative material onto said transparent base material, comprises laminating a translucent decorative material onto a transparent base material formed of clear polycarbonate.
20. The process of claim 18 wherein laminating said translucent decorative material onto said transparent base material, comprises laminating a translucent decorative material onto a transparent base material formed of fiberglass laminate.
21. The process of claim 18 wherein laminating said translucent decorative material onto said transparent base material, comprises laminating onto said base material a fluorinated organic polymeric material selected from the group consisting of a polyvinyl fluoride and a polyvinylidene fluoride polymeric material.
22. The process of claim 18 wherein affixing said decorative material to said base material comprises affixing said decorative material to said base material with an acrylic adhesive material intermediate said base material and decorative material.
23. The process of claim 18 wherein affixing said at least one light source comprises affixing a light emitting diode to said molded laminate behind said base material such that light from said light source passes through said base layer to said decorative layer.
24. The process of claim 18 wherein affixing said at least one light source comprises affixing an array of light emitting diodes to said molded laminate behind said base material such that light from said light source passes through said base layer to said decorative layer.
25. The process of claim 16 wherein thermoforming said light transmitting laminate on a mold die comprises thermoforming said light transmitting laminate on a textured mold die.
26. The process of claim 18 wherein thermoforming comprises thermoforming said material on a mold die to form a molded aircraft interior part.
27. The process of claim 18 wherein thermoforming comprises thermoforming said material on a mold die to form a molded aircraft interior part selected from the group consisting of door lining, window bezel, door handle escutcheon, emergency route indicator, stowage bin faceplate, stowage bin bullnose, panel, flight deck window lining, console, cup holder, pocket holder, cover, shroud and sign.
28. An aircraft interior lighting part comprising:
a light-transmitting laminate having a first transparent base layer, a second translucent decorative layer, and a layer comprising an adhesive material intermediate said base and decorative layers; and a light source positioned behind said base layer and operable to illuminate said decorative layer through said base layer; and wherein said decorative layer has an opacity sufficient to shield the light source from view when not illuminated.
a light-transmitting laminate having a first transparent base layer, a second translucent decorative layer, and a layer comprising an adhesive material intermediate said base and decorative layers; and a light source positioned behind said base layer and operable to illuminate said decorative layer through said base layer; and wherein said decorative layer has an opacity sufficient to shield the light source from view when not illuminated.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/016,057 US6092915A (en) | 1998-01-30 | 1998-01-30 | Decorative lighting laminate |
| US09/016,057 | 1998-01-30 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2256959A1 CA2256959A1 (en) | 1999-07-30 |
| CA2256959C true CA2256959C (en) | 2007-05-29 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002256959A Expired - Lifetime CA2256959C (en) | 1998-01-30 | 1998-12-23 | Decorative lighting laminate |
Country Status (6)
| Country | Link |
|---|---|
| US (1) | US6092915A (en) |
| EP (1) | EP0933256B2 (en) |
| CN (1) | CN1115506C (en) |
| CA (1) | CA2256959C (en) |
| DE (1) | DE69937509T3 (en) |
| ES (1) | ES2300131T5 (en) |
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| DE2536654A1 (en) * | 1975-08-16 | 1977-02-17 | Messerschmitt Boelkow Blohm | PLASTIC PART WITH WEAR-RESISTANT PAINT LAYER AND METHOD FOR MANUFACTURING IT |
| DE2613024A1 (en) † | 1976-03-26 | 1977-09-29 | Siemens Ag | Front plate for optical character display - has opaque layer except in character zones which have translucent coating |
| FR2352359A1 (en) † | 1976-05-17 | 1977-12-16 | Int Vibration Engineer | LUMINOUS PANEL |
| DE3010143C2 (en) * | 1980-03-15 | 1982-05-06 | Bayer Ag, 5090 Leverkusen | Plastic composite laminate, its manufacture and uses |
| US4521835A (en) * | 1983-05-17 | 1985-06-04 | Gulf & Western | Flexible elongated lighting system |
| JPS6155684A (en) * | 1984-08-27 | 1986-03-20 | 三菱レイヨン株式会社 | Light diffuser |
| EP0278685A3 (en) * | 1987-02-06 | 1989-08-02 | The Standard Oil Company | Polymer laminates employing photocurable adhesives and process for bonding fluoropolymers to substrates |
| US4946640A (en) † | 1989-04-17 | 1990-08-07 | Shell Oil Company | Method for forming preformed material |
| US5352532A (en) * | 1989-08-03 | 1994-10-04 | Glass Alternatives Corp. | Panel and method of making same |
| DE4142174A1 (en) † | 1991-12-20 | 1993-06-24 | Hella Kg Hueck & Co | Flat display device for aircraft - has light bodies divided into separate regions to be simultaneously illuminated and diodes of neighbouring regions emit different colours |
| US5665450A (en) † | 1992-08-21 | 1997-09-09 | The Curators Of The University Of Missouri | Optically transparent composite material and process for preparing same |
| US5353154A (en) † | 1992-11-02 | 1994-10-04 | The Dow Chemical Company | Polymeric reflective materials utilizing a back light source |
| DE4300480A1 (en) * | 1993-01-11 | 1994-07-14 | Kunert Heinz | Safety glass element with thermal insulation properties |
| US5571598A (en) † | 1995-02-27 | 1996-11-05 | Butler; Delicia M. | Decorative light transmitting panel and method for its fabrication |
| DE19514160C2 (en) † | 1995-04-15 | 2000-11-09 | Mannesmann Vdo Ag | Clock face |
| JP3233554B2 (en) * | 1995-06-21 | 2001-11-26 | アルプス電気株式会社 | Illuminated knob |
| US5976671A (en) * | 1997-10-20 | 1999-11-02 | The Boeing Company | Polyvinylidene fluoride-based decorative laminate |
-
1998
- 1998-01-30 US US09/016,057 patent/US6092915A/en not_active Expired - Lifetime
- 1998-12-23 CA CA002256959A patent/CA2256959C/en not_active Expired - Lifetime
-
1999
- 1999-01-06 EP EP99200023A patent/EP0933256B2/en not_active Expired - Lifetime
- 1999-01-06 ES ES99200023T patent/ES2300131T5/en not_active Expired - Lifetime
- 1999-01-06 DE DE69937509T patent/DE69937509T3/en not_active Expired - Lifetime
- 1999-01-19 CN CN99101318A patent/CN1115506C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| ES2300131T5 (en) | 2011-11-21 |
| EP0933256A3 (en) | 2001-11-21 |
| EP0933256B2 (en) | 2011-09-14 |
| CN1228519A (en) | 1999-09-15 |
| CA2256959A1 (en) | 1999-07-30 |
| US6092915A (en) | 2000-07-25 |
| ES2300131T3 (en) | 2008-06-01 |
| DE69937509T2 (en) | 2008-09-18 |
| EP0933256B1 (en) | 2007-11-14 |
| DE69937509T3 (en) | 2012-02-09 |
| DE69937509D1 (en) | 2007-12-27 |
| EP0933256A2 (en) | 1999-08-04 |
| CN1115506C (en) | 2003-07-23 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKEX | Expiry |
Effective date: 20181224 |