# US 9,435,511 B1 · Corrugated lens LED light band

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- Number: US 9,435,511 B1
- Document ID: US9435511B1
- Status: Granted
- Kind: B1
- Application number: 14/197,963
- Filed: 2014-03-05
- Granted: 2016-09-06
- Earliest claimed: 2014-03-05
- Assignees: Lektron LED Technologies, LLC
- Applicants: Lektron LED Technologies, LLC
- Inventors: Larry G. Ward, Jr.
- Web page: https://patentgrep.com/patent/US9435511B1

## CPC

- F21V 5/045: {the lens having discontinuous faces, e.g. Fresnel lenses}
- B29D 11/00326: {having particular surface properties, e.g. a micropattern}
- F21S 10/00: Lighting devices or systems producing a varying lighting effect
- B29D 11/00317: {Production of lenses with markings or patterns}
- F21V 7/0016: {on lighting devices that also provide for direct lighting, e.g. by means of independent light sources, by splitting of the light beam, by switching between both lighting modes}
- F21Y 2115/10: Light-emitting diodes [LED]
- F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- F21S: NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21Y: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED

## Abstract

An LED light band has a thin elongated housing with an open front face covered by an elongated transversely corrugated polycarbonate lens having crests and nadirs spaced at a first predetermined interval. A linear array of LEDs extending behind and along the bottom edge of the lens are spaced at a second predetermined interval different from the first. Because of the difference in the intervals, the light dispersion from the lens appears to the eye to be random so that, for example, a red lens can be used to suggest the presence of licking flames. The polycarbonate lens can be made by pressing long narrow lengths of flat polycarbonate in a sheet metal press.

## Claims

### Claim 1

For making an elongated polycarbonate lens having transverse corrugations with crests and nadirs at a predetermined interval, a method comprising the steps of:
starting with a roll of flat polycarbonate stock;
unrolling the flat polycarbonate stock in sequential increments into a press having a die contoured to impress the transverse corrugations with crests and nadirs at a predetermined interval;
pressing each increment unrolled into the die press to impress the transverse corrugations with crests and nadirs at a predetermined interval into the increment;
relaxing the press to release the pressed increment and receive the next unrolled increment of polycarbonate stock; and
winding the released increments of pressed polycarbonate stock onto a coiler as they exit the press.

### Claim 2 (depends on 1)

A method according to claim 1 further comprising the steps of:
unwinding the wound polycarbonate stock to a desired length; and
cutting the unwound polycarbonate stock to a desired length.

### Claim 3 (depends on 1)

A method according to claim 1, said step of unrolling the flat polycarbonate stock in sequential increments into a press further comprising the sub-step of limiting the unrolling of each increment so as to permit the die to overlap a trailing end of a previous increment.