Structurally embedded lighting for display panels and method of making the same

Patent metadata

Field	Value
Publication number	US-10099800-B2
Application number	US-201514707652-A
Country	US
Kind code	B2
Filing date	May 8, 2015
Priority date	May 8, 2015
Publication date	Oct 16, 2018
Grant date	Oct 16, 2018

Abstract

A method and an apparatus for forming an embedded light source in a composite panel. A first electrode and a second electrode are associated with a first layer of material. A light source is positioned in electrical communication with the first electrode and the second electrode. An assembly comprising the first layer of material, the first electrode, the second electrode, and the light source is processed to form a multilayer panel with an embedded light source.

First claim

What is claimed is:

1. A method comprising:
placing a first electrode and a second electrode on a first layer of material, wherein the first layer of material is initially uncured;
thereafter placing a shim over all of the first electrode, the second electrode, and the first layer of material;
thereafter pressing the shim into the first layer of material to form a depression in the first layer of material, wherein the first electrode and the second electrode are pressed into the depression by the shim;
thereafter removing the shim;
thereafter inserting a light source into the depression and placing the light source in electrical communication with the first electrode and the second electrode;
thereafter attaching a second layer of material over and to the light source, the first electrode, the second electrode, and the first layer of material, wherein the second layer of material is light transmissible, and wherein together the first layer of material, the second layer of material, the first electrode, the second electrode, and the light source form an assembly.

2. The method of claim 1 further comprising:
applying a surface treatment to at least one of the light source or the first layer of material prior to processing the assembly.

3. The method of claim 1 , wherein placing the first electrode and the second electrode comprises affixing only one of the first electrode or the second electrode to the first layer of material.

4. The method of claim 3 , wherein placing the first electrode and the second electrode further comprises:
positioning an other of the first electrode or the second electrode such that the other of the first electrode or the second electrode is free to move relative to the first layer of material, wherein positioning the other of the first electrode or the second electrode comprises allowing the other electrode to lie on the first layer of material without affixation.

5. The method of claim 3 , wherein affixing comprises at least one of adhering, printing, or integrating conductive fibers into the first layer of material at selective locations.

6. The method of claim 1 , further comprising:
curing the first layer of material after inserting the light source, but before attaching thee second layer.

7. The method of claim 1 , wherein the second layer of material initially comprises an uncured preimpregnated composite material, and wherein processing the assembly comprises:
co-curing the assembly with at least one of applied heat or applied pressure to form a cured panel.

8. The method of claim 7 , wherein processing the assembly further comprises:
applying lamina to the cured panel by attaching additional layers to the assembly.

9. The method of claim 1 further comprising:
applying additional lamina to the assembly.

10. The method of claim 1 further comprising:
wherein the shim has an approximate thickness of the light source.

11. The method of claim 1 , wherein the assembly comprises at least one of cabin lighting, decor, advertising, emergency signage, emergency lighting, entertainment display, seat placards, or safety signage.

12. The method of claim 1 further comprising:
attaching additional lamina to the assembly, wherein a completed assembly is formed;
applying a first sheet of release material to a first side of the completed assembly;
applying a second sheet of release material to a second side of the completed assembly, the second side opposite the first side.

13. The method of claim 12 further comprising:
placing the first sheet, the second sheet, and the completed assembly between a first caul plate and a second caul plate located opposite the first caul plate.

14. The method of claim 13 further comprising:
pressing the completed assembly using the first caul plate and the second caul plate.

15. The method of claim 12 , wherein at least one of the first release sheet and the second release sheet extends past corners and edges of the completed assembly, and wherein the method further comprises:
attaching at least one additional shim to the at least one of the first release sheet and the second release sheet at a location outside of the corners and edges of the completed assembly.

16. The method of claim 15 further comprising:
placing the first sheet, the second sheet, and the completed assembly between a first caul plate and a second caul plate located opposite the first caul plate.

17. The method of claim 16 further comprising:
pressing the completed assembly using the first caul plate and the second caul plate, wherein the at least one additional shim controls a final thickness of the completed assembly.

18. The method of claim 17 further comprising:
co-curing the completed assembly while pressing.

Assignees

• Boeing Co

Inventors

• Kulkarni Abhishek Pradeep
• Wilde John Christopher
• Wang Xiaoxi
• Cuddy Nathanial C

Classifications

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B32B15/14

  next to a fibrous or filamentary layer · CPC title

• B32B9/041

  of metal · CPC title

• B32B27/304

  comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF · CPC title

• B32B9/045

  of synthetic resin · CPC title