Display device with molded light guide

Abstract

A display device includes a base with at least one light device. A conductive layer is provided on the base and is electrically coupled to the light device. A light guide is formed the base and the conductive layer, and includes an aperture surrounding the light device and having a profile for directing light from the light source outwardly from the base.

1 . A display device, comprising: 
 a base;    at least one light device coupled to the base;    a conductive layer provided on at least a portion of the base and electrically coupled to the light device; and    a light guide formed on the base and the conductive layer, and having at least one aperture surrounding the light device.    
   
   
       2 . The display device of  claim 1  wherein the base includes at least one opening configured to receive a material used in the formation of the light guide.  
   
   
       3 . The display device of  claim 2  wherein the opening is a plurality of cylindrical openings disposed adjacent the light source.  
   
   
       4 . The display device of  claim 2  wherein the conductive layer extends at least partially through the opening.  
   
   
       5 . The display device of  claim 2  wherein the light guide is molded in a securing relationship with the opening.  
   
   
       6 . The display device of  claim 1  wherein at least one conductive pad is provided on an underside of the base and configured to provide electrical connectivity with the light device.  
   
   
       7 . The display device of  claim 1  wherein the conductive layer provides a circuit.  
   
   
       8 . The display device of  claim 7  wherein the circuit includes a cathode and at least one anode for connecting the light device.  
   
   
       9 . The display device of  claim 8  wherein the light device is substantially centered within the aperture.  
   
   
       10 . The display device of  claim 1  wherein the aperture is defined by side walls having a truncated cone shape.  
   
   
       11 . The display device of  claim 1  wherein the light device is a single color LED.  
   
   
       12 . The display device of  claim 1  wherein the light device is a multicolor LED.  
   
   
       13 . The display device of  claim 1  further comprising a contrasting coating provided on the light guide.  
   
   
       14 . The display device of  claim 1  further comprising an optical coating.  
   
   
       15 . The display device of  claim 1  wherein the light device is encapsulated within the aperture by a fill material.  
   
   
       16 . The display device of  claim 1  wherein the display assembly is a one of a sign, a display panel and a message board.  
   
   
       17 . The display device of  claim 1 , wherein the display assembly is adapted to provide a message in a first language and a second language.  
   
   
       18 . The display device of  claim 1 , wherein the display assembly is a retrofit display assembly adapted to replace an existing display.  
   
   
       19 . The display device of  claim 1 , wherein the display assembly is a taxiway sign.  
   
   
       20 . A display device, comprising a base with at least one light source atop the base, and a layer of material disposed on the base, the layer of material having at least one aperture surrounding the light source and defining a profile for directing light from the light source outwardly from the base.  
   
   
       21 . The display device of  claim 20  wherein the base includes at least one opening configured to receive a portion of the layer of material.  
   
   
       22 . The display device of  claim 20  wherein the profile comprises a truncated cone shape.  
   
   
       23 . The display device of  claim 20  wherein the profile comprises a parabolic shape.  
   
   
       24 . The display device of  claim 20  further comprising a conductive material disposed on the base to provide a circuit configured for electrical connection with the light source.  
   
   
       25 . The display device of  claim 24  wherein the base and the conductive material are configured to form a circuit board.  
   
   
       26 . The display device of  claim 20  wherein the light source is an LED.  
   
   
       27 . The display device of  claim 26  wherein the LED is a multicolor LED.  
   
   
       28 . The display device of  claim 26  wherein the LED is a monochromatic LED.  
   
   
       29 . The display device of  claim 20  further comprising a fill material disposed within the aperture.  
   
   
       30 . The display device of  claim 20  wherein the light source comprises a plurality of light sources, and the base and the layer of material and the light sources are configured for separation into a plurality of pixels.  
   
   
       31 . The display device of  claim 30  wherein the plurality of pixels are configured for separation by a dicing saw.  
   
   
       32 . The display device of  claim 30  wherein the pixels are evaluated to establish a grade according to a set of performance characteristics.  
   
   
       33 . The display device of  claim 32  wherein the pixels are grouped into one or more groups according to the grade.  
   
   
       34 . The display device of  claim 33  wherein the pixels from one of the one or more groups are assembled into one or more display blocks of the pixels.  
   
   
       35 . The display device of  claim 34  wherein the one or more display blocks of the pixels are assembled into a display assembly.  
   
   
       36 . The display device of  claim 35  wherein the display assembly is one of a sign, a message board and an information display.  
   
   
       37 . The display device of  claim 35  wherein the display assembly is a retrofit display assembly.