Methods of manufacturing illumination systems

Abstract

Methods of manufacturing light panels having at least one re-entrant turning feature. In one embodiment, a method of manufacturing a light panel includes providing a base layer, providing a cover layer, and coupling the cover layer to the base layer to form at least one re-entrant turning feature between the base layer and the cover layer. In another embodiment, a method of manufacturing a light panel includes providing a base layer, forming at least one receiving space in the base layer, providing at least one prismatic block, and coupling at least a portion of the prismatic block into the receiving space such that re-entrant turning features are formed between the prismatic block and the base layer.

1 . A method of manufacturing a light panel, the method comprising:
 providing a base layer having an upper surface, a lower surface opposite the upper surface;   forming at least one receiving space in the upper surface, the at least one receiving space extending from the upper surface toward the lower surface, wherein the at least one receiving space has a first sidewall and a second sidewall, wherein the first sidewall forms a first angle with the lower surface, and wherein the second sidewall forms a second angle with the lower surface;   providing at least one prismatic block, wherein the at least one prismatic block has a third sidewall, a fourth sidewall, and a first planar surface disposed therebetween, wherein the third sidewall forms a third angle with the first planar surface, and wherein the fourth sidewall forms a fourth angle with the first planar surface; and   coupling at least a portion of the at least one prismatic block into the at least one receiving space such that at least a portion of the third sidewall is disposed adjacent to at least a portion of the first sidewall and such that at least a portion of the second sidewall is disposed adjacent to at least a portion of the fourth sidewall such that the first and third sidewalls form a first re-entrant turning feature therebetween, and the second and fourth sidewalls form a second re-entrant turning feature therebetween.   
     
     
         2 . The method of  claim 1 , wherein the base layer comprises a first end for receiving light from a light source and a second end opposite the first end, and wherein the first and second re-entrant turning features are configured to turn at least a portion of light received through the first end toward the lower surface of the base layer. 
     
     
         3 . The method of  claim 1 , wherein the at least one prismatic block comprises a trapezoidal prism. 
     
     
         4 . The method of  claim 3 , wherein the at least one receiving space comprises a trapezoidal trough. 
     
     
         5 . The method of  claim 1 , wherein the first angle is different than the second angle. 
     
     
         6 . The method of  claim 5 , wherein the first angle is different than the third angle. 
     
     
         7 . The method of  claim 5 , wherein the second angle is different than the fourth angle. 
     
     
         8 . The method of  claim 1 , wherein the base layer has an index of refraction characteristic, wherein the at least one prismatic block has an index of refraction characteristic, and wherein the index of refraction characteristic of the at least one prismatic block is about the same as the index of refraction characteristic of the base layer. 
     
     
         9 . The method of  claim 8 , further comprising coupling the at least one prismatic block to the base layer. 
     
     
         10 . The method of  claim 9 , wherein an adhesive is used to couple the at least one prismatic block to the base layer, wherein the adhesive has an index of refraction characteristic that is about the same as the index of refraction characteristic of the base layer. 
     
     
         11 . A method of manufacturing a light panel, the method comprising:
 providing a layer having an upper surface, a lower surface opposite the upper surface, a first end configured to receive light from a light source, and a second end opposite the first end;   providing a first prismatic block, the first prismatic block having a first sidewall, a second sidewall, and a first planar surface disposed therebetween, wherein the first sidewall forms a first angle with the first planar surface, and wherein the second sidewall forms a second angle with the first planar surface;   disposing the first prismatic block on the base layer;   providing a second prismatic block, the second prismatic block having a third sidewall, a fourth sidewall, and a second planar surface disposed therebetween, wherein the third sidewall forms a third angle with the second planar surface, and wherein the fourth sidewall forms a fourth angle with the second planar surface;   disposing the second prismatic block on the base layer such that the first prismatic block and the second prismatic block form a receiving space therebetween, wherein the receiving space is disposed between the second sidewall and the third sidewall;   providing a third prismatic block, the third prismatic block having a fifth sidewall, a sixth sidewall, and a third planar surface disposed therebetween, wherein the fifth sidewall forms a firth angle with the third planar surface, and wherein the sixth sidewall form a sixth angle with the third planar surface; and   disposing at least a portion of the third prismatic block in the receiving space such that at least a portion of the fifth sidewall is disposed adjacent to at least a portion of the second sidewall and such that at least a portion of the sixth sidewall is disposed adjacent to at least a portion of the third sidewall, wherein the second and fifth sidewalls form a first re-entrant turning feature therebetween, wherein the third and sixth sidewalls from a second re-entrant turning feature therebetween.   
     
     
         12 . The method of  claim 11 , wherein the first re-entrant turning feature extends along a first longitudinal axis that forms a first angle with the upper surface. 
     
     
         13 . The method of  claim 12 , wherein the second re-entrant turning feature extends along a second longitudinal axis that forms a second angle with the upper surface. 
     
     
         14 . The method of  claim 13 , wherein the first angle is different than the second angle. 
     
     
         15 . The method of  claim 11 , further comprising coupling the first prismatic block to the base layer. 
     
     
         16 . The method of  claim 15 , further comprising coupling the second prismatic block to the base layer. 
     
     
         17 . The method of  claim 16 , further comprising coupling the third prismatic block to the base layer.