AU2022221452A1

AU2022221452A1 - Lighting Box

Info

Publication number: AU2022221452A1
Application number: AU2022221452A
Authority: AU
Inventors: Carl Merz
Original assignee: Mine Signs Pty Ltd
Current assignee: Mine Signs Pty Ltd
Priority date: 2022-08-24
Filing date: 2022-08-24
Publication date: 2024-03-14

Abstract

Lighting Box This invention relates to an improved lighting box for use as signage to provide identification and greater visibility in all lighting conditions. The lighting box has a housing with a base and a display surface, with the display surface overlying an opening in the housing and opposite the base. A light module has at least one light source for emitting light, the light module is mounted to the base within the housing and is configured to illuminate the display panel by way of the light source. The display surface has a transparent plastic panel with at least one character or shape reverse printed thereon and forming transparent and non-transparent parts on the display surface. The at least one character or shape is reverse printed so that when viewed through the transparent plastic panel it appears in normal view. When the light source illuminates the display surface light shines through the transparent parts from within the case allowing for high visibility during both day and night. 2/15 NC CNN 00 N N 10

Description

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LIGHTING BOX FIELD OF THE INVENTION

This invention relates to a lighting box and in particular to an improved lighting box for use as signage to provide identification and greater visibility in all lighting conditions.

BACKGROUND OF THE INVENTION

It should be noted that reference to the prior art herein is not to be taken as an acknowledgement that such prior art constitutes common general knowledge in the art.

Adequate signage is important in many industries to identify and warn of potential hazards, restrict access or to provide safety directions. Traditionally, safety signs have been constructed of metal with ink or paint applied to the surface. Such signs, when used in industrial or outdoor environments, are subject to wear and damage causing warning statements to fade. This is not only dangerous but costly to business and property owners who must constantly replace worn signage.

In addition safety signs are required to be highly visible in all conditions. Lit safety signs provide high visibility in low light situations and at night. However such lights do not provide high visibility during well-lit conditions. Highly reflective signs are often used as safety signs. Highly reflective material provides high visibility of signs when light is shone directly onto the sign from a distance. The advantage of these types of signs is that can be made to be more visible during well-lit conditions and do not require power. The disadvantage is that in low light conditions it is a requirement that light be shone on them for visibility.

In recent times, illuminated signs with illuminated alphanumeric characters have been developed which are easier to see and read at night.

Illuminated signs are typically in the form of a backlit sign or display which uses a "lighting box" containing one or more white light sources. A front panel of the display has a coloured transparent acrylic sheet, which selectively filters the white light to provide the desired colour light emission, graphic or image. The downside of these panels is that they can appear white or light grey when not illuminated, this can create significant viewing problems during daylight hours. Also, as these devices rely on the transmission rather than reflection of light they perform poorly during daylight conditions and such signs can appear washed-out.

In darker working environments, such as in mines, it is necessary to have highly reflective signage to ensure visibility of the sign in limited lighting. Although there are reflective paints available, reflective signage is commonly made using reflective sheeting with glass beads or specialised micro-prisms which is more effective and provides up to 60% reflectivity of available light. One of the disadvantages of this type of reflective sheeting is that the surface of the sheeting can be easily damaged during construction of the sign or during daily use resulting in deterioration of its reflectivity. Current methods used in an attempt to protect reflective signage include that described in CN 201259556 (Y) which provides a reflecting film for traffic safety signs comprising the following layers: a signage layer, a focusing layer, a layer of glass beads, a layer of polyester resin, a polyvinyl chloride (PVC) resin layer and a protective transparent PET film layer. This method is complicated and requires the application and drying of several liquid layers which can take significant time and can be expensive.

When lighting boxes are mounted to vehicles, and in particular to vehicles used in high-production mining and heavy-duty construction environments they are exposed to significant amounts of vibration. Any vibration or rattling of the lighting box when used to contain light sources can lead to significant reduction in the life of the light sources and also failure of the lighting box. Also, in the mining environment the lighting boxes are subjected to substantial quantities of dust and water and therefore must be able to at least withstand the force of the water cannons used to clean the vehicles and prevent the ingress of dust.

Clearly it would be advantageous if a lighting box for use as signage could be devised that helped to at least ameliorate some of the shortcomings described above. In particular, it would be beneficial to provide a lighting box to provide identification and greater visibility in all lighting conditions or at least provide the public with a useful choice.

SUMMARY OF THE INVENTION

In accordance with a first aspect, the present invention provides a lighting box comprising: a housing with a base and a display surface, the display surface overlying an opening in the housing and opposite the base; a light module having at least one light source for emitting light, the light module is mounted to the base within the housing and is configured to illuminate the display panel by way of the light source; wherein the display surface comprises a transparent plastic panel with at least one character or shape reverse printed thereon and forming transparent and non-transparent parts on the display surface, the at least one character or shape is reverse printed so that when viewed through the transparent plastic panel it appears in normal view; and wherein when the light source illuminates the display surface light shines through the transparent parts from within the housing providing a display surface with high visibility during both day and night.

Preferably, the display surface may be attached to the housing such that a seal between them is water tight. The seal may comprise a gasket for making the seal water tight.

Preferably, the housing may further comprise a mounting flange extending from opposite sides of the housing to provide means for attaching the lighting box to a structure.

Preferably, the light module may comprise a planar panel with a first side and a second side. A plurality of mounting apertures may be positioned around the periphery of the planar panel for mounting the planar panel to the base of the housing.

Preferably, the first side of the planar panel may have a plurality of vibration absorbing tapes attached thereto for mounting the first side of the planar panel to the base of the housing, the vibration absorbing tape distributes dynamic or static stress over the planar surface of the planar panel and provides impact resistance and vibration damping for the light module in the housing.

Preferably, the at least one light source may comprise a plurality of light emitting diodes (LEDs) mounted on the second side of the planar panel of the light module.

Preferably, the plurality of LEDs may be mounted to the second side of the planar panel by a vibration absorbing tape, the vibration absorbing tape distributes dynamic or static stress over the planar surface of the planar panel and provides impact resistance and vibration damping for the plurality of LEDs in the light module. The plurality of LEDs may be mounted in at least one row extending axially between opposite ends of the second side of the planar panel.

Preferably, the vibration absorbing tape may be a double-sided acrylic foam tape.

Preferably, the transparent plastic panel may have a first planar surface and a second planar surface.

Preferably, before the at least one character or shape is reverse printed on the transparent plastic panel a print backing sheet may be attached to the first planar surface of the transparent plastic panel. The transparent plastic panel of the display surface may be a polyvinyl chloride (PVC) panel. The print backing sheet may be a flexible polyester sheet.

Preferably, the print backing sheet may adhere to the first planar surface of the transparent plastic panel through electrostatic attraction with sufficient force to assure that the print backing sheet and the transparent plastic panel will not delaminate on passing through the printer. The adhesion force may be created by a pressure force and surface energies between the first planar surface of the transparent plastic panel being laminated to the print backing sheet.

Preferably, a reflective sheet may be applied to the second planar surface of the reverse printed transparent plastic panel, such that a reflective side of the reflective sheet is visible through the transparent parts of the display surface. The reflective sheet may be a class 1 reflective film, the reflective film may be adhered to the second planar surface of the printed transparent plastic panel with a pressure sensitive double-sided adhesive tape.

Preferably, the double-sided adhesive tape may be an optically clear, acrylic or other high bond double-sided tape.

Preferably, a frosted polycarbonate or acrylic panel may be applied over the reflective film on the second planar surface of the printed transparent panel, the frosted polycarbonate or acrylic panel is adhered to the reflective film with a pressure sensitive double-sided adhesive tape and the print backing sheet may be removed to complete the display surface.

Alternatively, a reflective sheet may be cut to a size less than and in the shape of the at least one character or shape of the transparent part on the display surface. A vinyl blackout layer may be laminated to a non-reflective side of the cut reflective sheet character or shape.

Preferably, the reflective side of the cut reflective sheet character or shape may be adhered to the corresponding character or shape on the second planar surface of the reverse printed transparent plastic panel, such that the reflective side of the cut reflective sheet character or shape is visible through the transparent parts with a transparent outline between the cut reflective sheet character or shape and the non-transparent part of the display surface.

Preferably, the cut reflective sheet may be a class 1 reflective film, the cut reflective film may be adhered to the transparent parts of the second planar surface of the printed transparent plastic panel with a pressure sensitive double sided adhesive tape.

Preferably, the print backing sheet may be removed, and a pressure sensitive optically clear double-sided tape may be applied to the second planar surface of the printed transparent plastic panel. A frosted polycarbonate or acrylic panel may be applied to the pressure sensitive optically clear double sided tape to complete the display surface.

Preferably, a coloured translucent film may be applied to the frosted polycarbonate or acrylic panel, wherein a colour of the coloured translucent film determines the colour of light emitted through the transparent outline between the cut reflective sheet character or shape and the transparent part of the display surface.

Alternatively, the at least one light source may be a neon light tube.

Preferably, an interior of the housing may be reflective for reflecting the light from the at least one light source towards the display surface.

Preferably, the structure to which the lighting box may be attached to is a vehicle. The lighting box may be electrically connected to the vehicles electrical system. Preferably, the vehicles electrical system may be a 12 or 24 V DC system.

Alternatively, the structure to which the lighting box may be attached to is a post.

In accordance with a further aspect, the present invention provides a light emitting and reflecting sign comprising: a lighting box with a housing, a base located within the housing and a light module positioned on the base within the lighting box housing and operable to generate light; and a display surface overlaying an opening in the lighting box housing; wherein the light module comprises: a planar panel with a first side and a second side; a plurality of vibration absorbing tapes adhered to the first side of the planar panel for mounting between the planar panel and the base of the housing; a plurality of mounting apertures positioned around the periphery of the planar panel for mounting the planar panel to the base of the housing; a plurality of vibration absorbing tapes on the second side of the planar panel, the vibration absorbing tape arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel; and a plurality of light emitting diodes (LEDs) mounted on the rows of vibration absorbing tapes on the second side of the planar panel; wherein the display surface comprises: a transparent plastic panel with a first planar surface and a second planar surface; an image reverse printed onto the transparent plastic panel, the image having a transparent part and a non-transparent part; at least one character or shape is formed in the spaces of the transparent part of the display surface; a reflective sheet is adhered to the second planar surface of the printed transparent plastic panel, such that a reflective side of the reflective sheet is visible through the transparent parts of the display surface; and a frosted polycarbonate or acrylic panel is adhered over the reflective sheet on the second planar surface of the printed transparent panel; wherein the reflective sheet is configured to absorb at least a portion of the light generated by the LEDs and, in response, to emit light through the at least one character or shape of the display surface; and wherein the reflective sheet is configured to reflect wavelengths of light from sunlight.

In accordance with a still further aspect, the present invention provides a light emitting and reflecting sign comprising: a lighting box with a housing, a base located within the housing and a light module positioned on the base within the lighting box housing and operable to generate light; and a display surface overlaying an opening in the lighting box housing; wherein the light module comprises: a planar panel with a first side and a second side; a plurality of vibration absorbing tapes adhered to the first side of the planar panel for mounting between the planar panel and the base of the housing; a plurality of mounting apertures positioned around the periphery of the planar panel for mounting the planar panel to the base of the housing; a plurality of vibration absorbing tapes on the second side of the planar panel, the vibration absorbing tape arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel; and a plurality of light emitting diodes (LEDs) mounted on the rows of vibration absorbing tapes on the second side of the planar panel; wherein the display surface comprises: a transparent plastic panel with a first planar surface and a second planar surface; an image reverse printed onto the transparent plastic panel, the image having a transparent part and a non-transparent part; at least one character or shape is formed in the spaces of the transparent part of the display surface; a reflective sheet is cut to a size less than and in the shape of the at least one character or shape; a vinyl blackout layer is laminated to a non-reflective side of the cut reflective sheet character or shape and the reflective side of the cut reflective sheet character or shape is then adhered to the corresponding character or shape formed in the spaces of the transparent part of the display surface; an outline is formed between the reflective sheet character or shape and the non-transparent part of the display surface; a pressure sensitive optically clear double-sided tape is applied to the second planar surface of the printed transparent plastic panel; a frosted polycarbonate or acrylic panel is adhered over the reflective sheet on the second planar surface of the printed transparent panel; and a coloured translucent film is adhered to the frosted polycarbonate or acrylic panel; and wherein the light generated by the LEDs emits light through the transparent outline between the cut reflective sheet character or shape and the non transparent part of the display surface in a colour of the coloured translucent film; and wherein the reflective sheet is configured to reflect wavelengths of light from sunlight.

Preferably, the vibration absorbing tape may distribute dynamic or static stress over the planar surface of the plastic panel and provides impact resistance and vibration damping for the plurality of LEDs in the light module.

Preferably, before the image is reverse printed on the transparent plastic panel a print backing sheet may be attached to the first planar surface of the transparent plastic panel. The transparent plastic panel of the display surface may be a polyvinyl chloride (PVC) panel, and the print backing sheet may be a flexible polyester sheet.

Preferably the print backing sheet may be removed after the frosted polycarbonate or acrylic panel is adhered over the reflective film on the second planar surface of the display surface.

Alternatively, the print backing sheet may be removed before the pressure sensitive optically clear double-sided tape is applied to the second planar surface of the printed transparent plastic panel.

Preferably, the reflective sheet may be a class 1 reflective film, the reflective film is adhered to the transparent parts of the second planar surface of the printed transparent plastic panel with a pressure sensitive double-sided adhesive tape.

Preferably, the structure to which the lighting box is attached to may be a vehicle. The lighting box may be electrically connected to the vehicles electrical system, the vehicles electrical system may be a 12 or 24 V DC system.

Alternatively, the structure to which the lighting box is attached to may be a post.

In accordance with a still further aspect, the present invention provides a method of producing a light emitting and reflecting sign, the method comprising the steps of: i) providing a lighting box with a housing, a base and an opening in the housing opposite the base; ii) providing a light module with a planar panel having a first side and a second side, a plurality of vibration absorbing tapes adhered to the first side of the planar panel for mounting between the planar panel and the base of the housing, a plurality of vibration absorbing tapes on the second side of the planar panel, the vibration absorbing tape arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel, and a plurality of light emitting diodes (LEDs) mounted on the rows of vibration absorbing tapes on the second side of the planar panel; iii) providing a display surface overlaying the opening in the lighting box housing, providing the display surface comprising the steps of: a) laminating a print backing sheet to a first planar surface of a transparent plastic panel using electrostatic attraction with sufficient force to assure that the print backing sheet and the transparent plastic panel will not delaminate on passing through a printer; b) printing a reverse image onto the transparent plastic panel, the image having a transparent part and a non-transparent part with at least one character or shape formed in the spaces of the transparent part of the printed image; c) adhering a reflective sheet to the second planar surface of the printed transparent plastic panel, such that a reflective side of the reflective sheet is visible through the transparent parts of the display surface; and d) adhering a frosted polycarbonate or acrylic panel over the reflective sheet on the second planar surface of the printed transparent panel; iv) during daylight hours the reflective sheet of the sign is configured to reflect wavelengths of light from sunlight; and v) during non-daylight hours the reflective sheet is configured to absorb at least a portion of the light generated by the LEDs and, in response, to emit light through the at least one character or shape of the display surface.

In accordance with a still further aspect, the present invention provides a method of producing a light emitting and reflecting sign, the method comprising the steps of: i) providing a lighting box with a housing, a base and an opening in the housing opposite the base; ii) providing a light module with a planar panel having a first side and a second side, a plurality of vibration absorbing tapes adhered to the first side of the planar panel for mounting between the planar panel and the base of the housing, a plurality of vibration absorbing tapes on the second side of the planar panel, the vibration absorbing tape arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel, and a plurality of light emitting diodes (LEDs) mounted on the rows of vibration absorbing tapes on the second side of the planar panel; iii) providing a display surface overlaying the opening in the lighting box housing, providing the display surface comprising the steps of: a) laminating a print backing sheet to a first planar surface of a transparent plastic panel using electrostatic attraction with sufficient force to assure that the print backing sheet and the transparent plastic panel will not delaminate on passing through a printer; b) printing a reverse image onto the transparent plastic panel, the image having a transparent part and a non-transparent part with at least one character or shape formed in the spaces of the transparent part of the printed image; c) cutting a reflective sheet to a size less than and in the shape of the at least one character or shape; d) laminating a vinyl blackout layer to a non-reflective side of the cut reflective sheet character or shape and the reflective side of the cut reflective sheet character or shape; e) adhering the cut reflective sheet character or shape to the corresponding character or shape formed in the spaces of the transparent part of the display surface; f) forming an outline between the reflective sheet character or shape and the non-transparent part of the display surface; g) applying a pressure sensitive optically clear double-sided tape to the second planar surface of the printed transparent plastic panel; h) adhering a frosted polycarbonate or acrylic panel over the reflective sheet on the second planar surface of the printed transparent panel; and i) adhering a coloured translucent film to the frosted polycarbonate or acrylic panel; and iv) during daylight hours the reflective sheet of the sign is configured to reflect wavelengths of light from sunlight; and v) during non-daylight hours the light generated by the LEDs emits light through the transparent outline between the cut reflective sheet character or shape and the non-transparent part of the sign in a colour of the coloured translucent film.

Preferably, step iii) a) may further comprise: cutting the transparent plastic panel to a pre-determined size; allowing a pre-set time for the transparent plastic panel to shrink in size; placing the shrunk transparent plastic panel on a vacuum table, the vacuum table holding the shrunk transparent plastic panel in place for the laminating process; placing the print backing sheet on top of the transparent plastic panel; applying an adhesion force created by a roller attached to the vacuum table to electrostatically laminate the transparent plastic panel to the print backing sheet; and cleaning the printing surface of the transparent plastic panel with a cleaning alcohol before the reverse printing process.

Any one or more of the above embodiments or preferred features can be combined with any one or more of the above aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be understood more fully from the detailed description given hereinafter and from the accompanying drawings of the preferred embodiment of the present invention, which, however, should not be taken to be limitative to the invention, but are for explanation and understanding only.

Fig. 1 shows a perspective view of a lighting box in accordance with an embodiment of the present invention; Fig. 2 shows a cutaway perspective view of the lighting box of Fig. 1; Fig. 3 illustrates a light module for the lighting box of Fig. 1; Fig. 4 shows an enlarged cutaway of the light module mounted on the base of the lighting box of Fig. 1; Figs. 5 to 7 illustrate a display surface of the lighting box in accordance with an embodiment of the present invention; Fig. 8 to 12 illustrate a display surface of the lighting box in accordance with a further embodiment of the present invention; Fig. 13 shows the lighting box of Fig. 1 mounted to the steps of a truck;

Fig. 14 shows the lighting box of Fig. 1 in accordance with the present invention mounted to a truck showing the lighting response from external lights shining on the lighting box at night; Fig. 15 shows a further embodiment of the lighting box mounted in a three-sided arrangement; and Fig. 16 shows the lighting box of Fig. 15 mounted on earth moving equipment.

DETAILED DESCRIPTION OF THE INVENTION

The following description, given by way of example only, is described to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments.

It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. Additionally, unless otherwise specified, it is to be understood that discussion of a particular feature or component extending in or along a given direction or the like does not mean that the feature or component follows a straight line or axis in such a direction or that it only extends in such direction or on such a plane without other directional components or deviations, unless otherwise specified.

Reference will now be made to the drawings in which the various elements of embodiments will be given numerical designations and in which embodiments will be discussed to enable one skilled in the art to make and use the invention. It will be further noted that the figures are schematic and provided for guidance to the skilled reader and are not necessarily drawn to scale. Rather, the various drawing scales, aspect ratios, and numbers of components shown in the figures may be purposely distorted to make certain features or relationships easier to understand. Descriptions of well-known components and processing techniques are omitted to not unnecessarily obscure the embodiments herein.

The present invention in its broadest form provides a lighting box 20 with a housing 25 formed by the base 28 and four walls 26 extending upwardly from the base 28. An opening is formed in the housing 25 at the top of the walls 26, the display surface 30 overlies the opening in the housing 25 and opposite the base 28. A cover 21 is secured by fasteners 22 to the top of the walls 26 which seals the display surface 30 to the top of the housing 25 and covers the opening in the housing 25. A light module 50 having at least one light source 53 for emitting light is mounted to the base 28 within the housing 25 and is configured to illuminate the display panel 30 by way of the light source 53. The display surface 30 has a transparent plastic panel 36 with at least one character or shape 32 reverse printed on the transparent plastic panel 36 forming both transparent and non-transparent parts on the display surface 30. The at least one character or shape 32 is reverse printed so that when viewed through the transparent plastic panel 36 it appears in normal view. When the light source 53 illuminates the display surface 30 light shines through the transparent parts from within the housing 25 providing the display surface 30 with high visibility during both day and night.

Fig. 1 shows a perspective view of a lighting box 20 in accordance with an embodiment of the present invention. The lighting box 20 has a cover 21 which closes the opening formed within the four upstanding walls 26 in the housing 25. The cover 21 has an opening through which the display surface 30 can be seen. In Fig. 1 the display surface 30 shows the characters 32 with an outline 31. The display surface 30 will be described in more detail below in relation to Figs. 8 to 12. When the cover 21 is secured by fasteners 22 to the housing 25, a gasket or seal 33 placed between the underside of the cover 21 and the top of the walls 26 seals the interior 80 of the lighting box 20 from the ingress of any liquids. The display surface 30 is also sealed to the underside of the cover 21 by a gasket or seal. A mounting flange 70 extends perpendicular from opposite end walls 26 of the housing 25. Each flange 70 has a pair of mounting apertures 27 for receiving a fastener therethrough to allow the lighting box 20 to be mounted to a structure. The structure could be a fixed structure such as a flood water sign or a mobile structure such as a truck as shown in Figs. 13 and 14.

The housing 25 and cover 21 of the lighting box 20 can be fabricated from angle iron, sheet metal, aluminium, molded from a plastics material or constructed from any other suitable material. The inner surface of the walls 26 of the lighting box 20 may have a light reflective coating applied to the surfaces which reflects light towards the display surface 30.

Fig. 2 illustrates a cut-away perspective view of the lighting box 20 of Fig. 1. The light module 50 is shown mounted to the base 28 of the housing 25 by fasteners 52 located in each corner of the light module 50. The light module 50 consists of a planar panel 51 with a front surface to which the plurality of LEDs 53 are mounted on in rows, and a rear surface which is mounted facing the base 28 of the housing 25. Attached to the rear surface of the planar panel 51 are strips of vibration absorbing tape 54. Located on the front surface of the planar panel 51 and beneath each row of LEDs are further strips of vibration absorbing tape 54A. The strips of vibration absorbing tape 54, 54A provides impact resistance and vibration damping for the light module 50 when it is mounted to the base 28 of the housing 25.

The strips of vibration absorbing tape 54 distributes dynamic or static stress over the planar surface of the planar panel 51 and the base 28 of the lighting box 20. The strips of vibration absorbing tape 54A distributes dynamic or static stress over the front surface of the planar panel 51 and provide an impact resistance and vibration damping mounting surface for the LED modules 53 located on the front surface of the light module 50. By way of example only, the vibration absorbing tape 54, 54A may be a double-sided pressure sensitive acrylic foam tape such as a 2.8mm thick 3MTM VHBTM tape or any other like vibration tapes.

Fig. 3 shows the light module 50 removed from the housing 25 of the lighting box 20. As described above the LEDs 53 are arranged in five rows and mounted with vibration absorbing tape 54A to the front surface of the planar panel 51. Each LED module 53 consists of three LEDs connected to further LED modules 53 to form a row of five LED modules 53. Each row of LED modules is connected to the next row of LED modules by an electrical wire 55 to form a series circuit. A power connector 56 connects the first string of LED modules 53 to the last string to make the series circuit and allows the light module 50 to be connected to a power source. While the present invention has been illustrated to contain 25 LED modules 53 in five rows, it should be understood that the present invention is not limited to any particular number of LED modules 53 or number of rows forming the light module 50. It should also be understood that while the LEDs have been configured as a series circuit, a parallel circuit could also be designed to operate and power the light module 50.

Each LED module 53 has a strip of double sided mounting tape attached to the bottom of each module 53, the tape mounts each module 53 to the strips of vibration absorbing tape 54A positioned in rows on the front side of the planar panel 51. By way of example only, the LED modules 53 may be a Samsung three LED module which are either 12 V or 24 V DC powered. When 24 V DC modules 53 are used and in the configuration as illustrated in Fig. 3, the light module 50 draws current in the range of 2 to 3 A DC.

The planar panel 51 is secured to the base 28 by fasteners 52 passing through apertures 52A located adjacent each corner of the planar panel 51. Four strips of vibration absorbing tape 54 is positioned on the rear side of the planar panel 51 for mounting the planar panel 51 to the base 28 of the housing 25.

The planar panel 51 is a planar sheet of plastics material and is formed as any polygon shape with one corner cut off to allow the power connector 56 to pass therethrough and out of an aperture in the housing 25. The plastics material forming the planar panel 51 is any of the wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. For example, planar panel 51 may be a high-density polyethylene (HDPE), polyethylene terephthalate (PET), polyethylene, polyvinyl chloride (PVC) or any other plastics material.

Fig. 4 shows an enlarged sectional view of the lighting box 20 of Fig. 1. Shown attached to the base 28 is the planar panel 51 with the strip of vibration absorbing tape 54 positioned on the rear side of the planar panel 51 and another strip of vibration absorbing tape 54A is positioned on the front side of the planar panel 51. The LED module 53 is adhered to the strip of vibration absorbing tape 54A with one of the interconnecting wires 55 also shown which connect each string of LED modules 53 together. At the junction between the base 28 and the mounting flange 70, a wall 26 of the housing 25 extends upwardly. At the top of the wall 26 is a recessed portion 26A which is adapted to receive an edge portion of the display panel 30. The recessed portion 26A supports the edge portion of the display panel 30 around all four sides of the housing 25.

The display panel 30 is sealed to the top of the wall 26 by a gasket 33 positioned between the top side of the display panel 30 and the underside of the cover 21. The gasket 33 forms a water tight seal between the top side of the display panel 30 and the cover 21. This configuration ensures that liquid is prevented from entering the inside of the lighting box 20 through the parts of the lighting box 20 where the cover 21 is attached to the housing 25. The gasket 33 may be a liquid gasket, such as a silicone sealant, a rubber gasket, such as an open or closed cell sponge rubber material, a butyl rubber gasket, a nitrile rubber gasket or the like. Alternatively, the gasket 33 may be a cork or foam gasket, where the cork may be a cork/rubber composite or cork/EPDM composite gasket.

The display panel 30, the walls 26 and the base 28 form an enclosed housing 25 with a cavity 80 formed between the rear side of the display panel 30 and the light module 50.

Figs. 5 to 7 illustrate an embodiment of the display panel 30A which comprises a number of layers that form a sign which is clearly visible in all lighting conditions. As shown in Fig. 5, the display panel 30A has characters 32 in the form of the numbers "351" reverse printed onto the PVC plastic sheet 36. Each character "351" forms a transparent part 37 which is surrounded by the non-transparent parts 38 of the display surface 30A. Before the image is reverse printed, the transparent plastic panel 36 is electrostatically adhered to the print backing sheet 35. The print backing sheet 35 is removed once the sign forming the display panel 30A is completed. By way of example only, the transparent plastic panel 36 is a polyvinyl chloride (PVC) panel and the print backing sheet 35 is a flexible polyester sheet.

The electrostatic attraction which adheres the print backing sheet 35 to one side of the transparent plastic panel 36 is sufficient to assure that the print backing sheet 35 and the transparent plastic panel 36 will not delaminate during the printing process.

Fig. 6 shows the next step in which the reflective sheet 39 and the frosted plastic polycarbonate layer 41 are attached to the display surface 30A. The reflective sheet 39 is a 3MTM Diamond GradeTM DG3 reflective sheet with a pressure-sensitive adhesive on the non-reflective side of the reflective sheet 39. The reflective sheet 39 is a class 1 reflective film. The pressure-sensitive adhesive is an optically clear adhesive. Backing sheet or liner 39A covers the reflective side of the reflective sheet 39 and backing sheet or liner 39B covers the adhesive side on the non-reflective side. A pressure sensitive optically clear double-sided tape or adhesive is applied to rear surface of the printed transparent plastic panel 36. The liner 39A is removed from the reflective side of the reflective sheet 39 and the reflective sheet 39 is then adhered to the optically clear double-sided tape or adhesive on the back side of the transparent plastic panel 36. In this configuration the reflective surface of the reflective sheet 39 covers the transparent parts 37 of the sign 30A so that the characters 32 are formed as reflective numbers "351". The liner 39B is then removed from the non-reflective side of the reflective sheet 39. Another optically clear double sided tape or adhesive is adhered to the non-reflective side of the reflective sheet 39 to allow the frosted plastic polycarbonate layer 41 to be attached to the non-reflective side of the reflective panel 39. The frosted plastic polycarbonate layer 41 and the reflective sheet 39 allows light from the light module 50 to illuminate the numbers "351" during night time or poor light conditions. The highly efficient retroreflective optics on the reflective surface of the reflective sheet 39 are seen through each integer 32 in the transparent parts 37 of the display surface 30A which provides a clear reflected image during sunny or daylight conditions.

The frosted plastic polycarbonate panel 41 may be an opal white polycarbonate sheet. The opaqueness in the opal white polycarbonate sheet 41 filters the light from the LEDs 53 to provide a display panel 30A which is highly durable and functional in all applications. Alternatively, the layer 41 may be a frosted acrylic panel 41.

Fig. 7 shows the completed display surface 30A with the print backing sheet 35 removed. The image is reverse printed on the transparent plastic panel 36 so that when the display surface 30A is viewed from the front the characters 32 are correctly formed.

Figs 8 to 12 show a further embodiment of the display surface 30 which comprises a number of layers that form a sign which is clearly visible in all lighting conditions. Fig. 8 is substantially the same as Fig. 5 with the exception that in the reverse printed image the characters 32 have an outline 31 extending around the periphery and spaced from the outer edge of each character 32. The display panel 30 has characters 32 with an outline 31 forming the numbers "351" reverse printed onto the PVC plastic sheet 36. Each character "351" forms a transparent part 31, 32 which is surrounded by the non-transparent parts 38 of the display surface 30. Before the image is reverse printed, the transparent plastic panel 36 is electrostatically adhered to the print backing sheet 35.

Fig. 9 shows the application of the reflective integers 80 to the transparent parts 32 of the reverse printed image. A reflective sheet 80 is cut to a size less than and in the shape of the characters 32 in the display surface 30. As previously with the display surface 30A, the reflective sheet 80 is a 3M T M Diamond Grade TM DG3 reflective sheet with an optically clear pressure-sensitive adhesive on the non-reflective side of the reflective sheet 80. A backing sheet or liner covers the adhesive and another backing sheet or liner covers the reflective side of the reflective sheet 80. A pressure sensitive optically clear double-sided tape or adhesive is applied to rear surface of the printed transparent plastic panel 36. The rear liner on the non-reflective side of the cut reflective sheet 80 is removed and a vinyl blackout layer 80B is laminated to the non-reflective side of the cut reflective sheet 80. The vinyl blackout layer 80B prevents light from the LEDs 53 being transmitted to the outside. The vinyl blackout layers 80B are cut to the desired shape of the characters 32 which are to be visible to the viewer.

The liner on the front and covering the reflective side 80A of the reflective sheet 80 is then removed and the cut reflective sheet 80 is then adhered to the optically clear double-sided tape or adhesive on the back side of the transparent plastic panel 36. The reflective side 80A of the cut reflective sheets 80 are made of a reflective type material which reflects light in a highly visible way. When light is directed at the lighting box 20 the reflective side 80A in the reflective sheets 80 reflects this light back so that it is highly visible in all light conditions.

Each cut reflective sheet character 80 with the reflective side 80A is adhered to the corresponding character 32 on the rear side of the reverse printed transparent plastic panel 36. The reflective side 80A of the cut reflective sheet character 80 is visible through the transparent part 32 with a transparent outline 31 between the cut reflective sheet character 80 and the non-transparent part 38 of the display surface 30.

Fig. 10 shows the print backing sheet 35 is removed, and a pressure sensitive optically clear double-sided tape 40 is applied to rear surface of the printed transparent plastic panel 36. The double-sided tape 40 has liners 40B, 40C on opposite sides of the double-sided tape 40, the liner 40B is removed to adhere the double-sided tape 40 to the printed transparent plastic panel 36.

Fig. 11 shows the application of the frosted polycarbonate panel 41 which is applied to the pressure sensitive optically clear double-sided tape 40 to complete the display surface 30. The liner 40C is first removed and the frosted polycarbonate panel 41 is adhered to the backside of the printed transparent plastic panel 36.

Fig. 12 shows the completed display surface 30. The image is reverse printed on the transparent plastic panel 36 so that when the display surface 30 is viewed from the front the characters 32 are correctly formed. In this embodiment the characters are formed by the reflective side 80A with an outline 31 extending around each of the integers "351". As the vinyl blackout layer 80B is applied to the rear side of each of the characters "351", light from the light module 50 only illuminates the outline 31 of the characters "351". Therefore during night time or poor light conditions the outline 31 is illuminated to show the characters "351". The highly efficient retroreflective optics on the reflective surface 80A of the cut reflective sheet 70 in the shape of the characters "351" are seen on the display surface 30 which are clearly visible due to the reflection of ambient daylight.

An alternative display surface 30 may have a coloured translucent film (not shown) adhered to the frosted polycarbonate panel 41. This will illuminate the outline 31 in the selected colour of the coloured translucent film.

Figs. 13 to 16 show the lighting box 20 in use attached to different structures. Fig. 13 shows an enlarged view of the lighting box 20 as attached to the access stairs 11 of a truck 10. Fasteners 29 are inserted through the apertures 27 in the mounting flanges 70 to secure the lighting box 20 to the frame members 12. The frame members 12 mount the lighting box 20 to the access stairs 11 on one side and to the ladder frame 13 on the opposite side.

The lighting box 20 is electrically connected to the truck 10 power system. The connector 56 from the light module 50 which extends externally of the housing 25 allows a corresponding connector on the truck 10 to provide 24 VDC power to the lighting box 20. The lighting box 20 power is connected to a control switch in the cabin of the truck 10 to allow the operator to switch the lighting box on and off when required.

Fig. 14 shows a representation of the lighting box 20 with the display surface 30 in operation at night whilst the truck 10 is not in operation. A light source (not shown) is assumed to be emanating from the viewer's direction. The light source from the viewer's direction shines on the reflective layer 80 and is reflected back to the viewer in a highly visible way. If the truck 10 is in operation with the lighting box 20 electrically connected to the truck 11, the LEDs 53 in the light module 50 shines light through the outline regions 31 of the display surface 30 rendering the outline of the characters "237" highly visible in all light conditions.

Figs. 15 and 16 illustrate another embodiment of the present invention in which the lighting sign 60 is mounted to the cabin 16 roof structure of the earth moving equipment 15. In this embodiment three lighting boxes 20 are fitted to each of the parallelogram sides of a triangular prism. A mounting flange 61 extends from the bottom of the lighting sign 60 to mount the lighting sign 60 to the roof of the cabin 16.

The lighting box 20 provides high visibility of the desired display surface 30, 30A in any ambient lighting conditions. This is highly desirable in the case of signage required for safety.

A further use of the lighting box 20 not illustrated is the ability to incorporate a lighting box 20 into a sign board. For example, use the sign boards to display a "Flooded Road" warning for users of a road. Wiring electrically connects the sign boards with the lighting box 20 to an electrical storage device. The electrical storage device could be a lead acid accumulator or other such rechargeable battery device. A solar electricity panel could be utilised to provide electricity to charge the electrical storage device.

The present invention also extends to a method of producing a light emitting and reflecting sign. A lighting box 20 is provided with a housing 25, a base 28 and an opening in the housing 25 opposite the base 28. The lighting box has a light module 50 with a planar panel 51 having a first side and a second side. A plurality of vibration absorbing tapes 54 are adhered to the first side of the planar panel 51 for mounting between the planar panel 51 and the base 28 of the housing 25. A further plurality of vibration absorbing tapes 54A are adhered to the second side of the planar panel 51, the vibration absorbing tape 54A is arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel 51. A plurality of light emitting diodes (LEDs) 53 are mounted on the rows of vibration absorbing tapes 54A on the second side of the planar panel 51.

The lighting box 20 has a display surface 30, 30A overlaying the opening in the lighting box housing 25. As described above the display surface is provided in a first embodiment were an outline 31 provides a keyline display surface 30 and a second embodiment were the reflective sheet 32 is illuminated to form a standard display surface 30A. The processes for producing the respective display surfaces 30, 30A has certain similar steps and some steps which distinguish each display surface 30, 30A from the other.

In both processes the first step is to cut the transparent plastic panel 36 to a pre-determined size required for the light emitting and reflective sign. The cut transparent plastic panel 36 is then allowed to sit for a pre-set time of at least 24 hours. Allowing the cut transparent plastic panel 36 time to shrink ensures that a stable printing surface is provided. Once the pre-set time is expired the shrunk transparent plastic panel 36 is placed on a vacuum table, the vacuum table holds the shrunk transparent plastic panel 36 in place for the laminating process. The print backing sheet 35 is then placed on top of the transparent plastic panel 36 and the two are laminated together using an adhesion force and electrostatic attraction. The adhesion force is created by a roller attached to the vacuum table. The roller moves over the print backing sheet 35 and the transparent plastic panel 36 to provide the adhesion force which electrostatically laminates the transparent plastic panel 36 to the print backing sheet 35. Once laminated the product is turned over and the transparent plastic panel 36 which forms the printing surface is cleaned with a cleaning alcohol before the reverse printing process.

Next the image is reverse printed onto the transparent plastic panel 36. The image has both transparent and non-transparent parts with at least one character or shape formed in the spaces of the transparent part of the printed image. Dependent upon which embodiment of the display surface 30, 30A is used, differ only in that the display surface 30 has an outline 31 printed inside of the character or shape printed in the transparent part of the image.

A pressure sensitive optically clear double-sided tape or adhesive is then applied to rear surface of the printed transparent plastic panel 36 before the attachment of the reflective sheet to the display surface 30, 30A for the light emitting and reflecting sign.

For the display surface 30A, a reflective sheet 39 is adhered to the optically clear double-sided tape or adhesive on the second side surface of the printed transparent plastic panel 36. The reflective side of the reflective sheet 39 is visible through the transparent parts of the printed image. The reflective sheet 39 has an optically clear pressure sensitive adhesive applied to the non reflective side of the reflective sheet 39 which is covered until use by liner 39A. Another pressure sensitive optically clear double-sided tape or adhesive is then applied to non-reflective side of the reflective panel 39 on the rear surface of the printed transparent plastic panel 36. Finally, the display surface 30A is completed with a frosted polycarbonate panel 41 adhered to the optically clear double-sided tape or adhesive over the reflective sheet 39 on the second side surface of the printed transparent panel 36 and the print backing sheet 35 is removed from the first side of the printed transparent panel 36.

For the display surface 30, a reflective sheet is cut into the shapes or characters of the printed image but of a size which is smaller than the shape or character in the image so that when the reflective sheet 80 is applied to the transparent plastic panel 36 an outline or keyline 31 is formed. As before, each character or shape of cut reflective film 80 has an optically clear pressure sensitive adhesive applied to the non-reflective side of the reflective film 80 which is covered until use by a liner. The non-reflective side has a vinyl blackout layer 80B laminated to the cut reflective sheet 80 character or shape. A pressure sensitive optically clear double-sided tape or adhesive is then applied to rear surface of the printed transparent plastic panel 36. The reflective side 80A of the cut reflective sheet 80 character or shape is then adhered to the optically clear double-sided tape or adhesive and in the corresponding character or shape formed in the spaces of the transparent part of the display surface 30 leaving the outline 31 between the reflective sheet 80 character or shape and the non-transparent part 38 of the display surface 30.

The print backing sheet 35 is now removed from the first side of the printed transparent panel 36. A pressure sensitive optically clear double-sided tape 40 is applied to the second side surface of the printed transparent plastic panel 36 covering the printed image. The pressure sensitive optically clear double-sided tape 40 has a liner 40B which is removed to laminate the tape 40 to the transparent plastic panel 36. Once the pressure sensitive optically clear double-sided tape 40 is adhered to the transparent plastic panel 36, the second liner 40C is then removed to allow a frosted polycarbonate panel 41 to be laminated over the second side surface of the printed transparent panel 36. Finally a coloured translucent film (not shown) may be adhered over the frosted polycarbonate panel 41.

The display surface 30 when used in the lighting box 20 of the light emitting and reflecting sign provides a sign which during daylight hours the reflective side 80A of the reflective sheet 80 of the sign is configured to reflect wavelengths of light from sunlight and during non-daylight hours the light generated by the LEDs 53 on the light module 50 emit light through the transparent outline 31 between the cut reflective sheet character or shape and the non-transparent part of the sign in a colour of the coloured translucent film.

The display surface 30A when used in the lighting box 20 of the light emitting and reflecting sign provides a sign which during daylight hours the reflective sheet 39 of the sign is configured to reflect wavelengths of light from sunlight and during non-daylight hours the reflective sheet 39 is configured to absorb at least a portion of the light generated by the LEDs 53 in the light module

50 and, in response, to emit light through the at least one character or shape of the display surface 30A.

In the present invention LEDs 53 used in the light module 50 have been illustrated and described as sets of three LEDs in each LED module 53. The light source used in the light module 50 may include different light sources including but not limited to single LED modules, multiple LED modules, different coloured LEDs, neon light tubes and any other like sources.

When the LED modules 53 are connected in series and powered by a DC voltage source, the lighting box 20 may also include a constant current LED driver (not shown). The constant current LED driver ensures that the current supplied to each LED module 53 remains constant with varying supply voltages.

The print backing sheet 35 would adhere to the transparent plastic panel 36 by electrostatic attraction with sufficient force to assure that the sheets 35, 36 will not delaminate on passing through the printer machinery. In addition, the attraction must not be so great that the sheets 35, 36 cannot be manually separated without damaging the printed image on the transparent plastic panel 36.

The electrostatic force with which the transparent plastic panel 36 is bound to the print backing sheet 35 is determined by the dielectric constant of the print backing sheet 35 surface that is in contact with the transparent plastic panel 36. Accordingly, the preferred embodiment of the present invention utilises a flexible polyester print backing sheet 35 that has a high dielectric constant that is greater than that of paper and which also interacts electrostatically with the transparent plastic panel 36. In a preferred embodiment of the present invention, the print backing sheet 35 may have a coating material that is a mixture of polymers applied to the surface which comes into contact with the transparent plastic panel 36.

In one embodiment of the present invention, the transparent plastic panel 36 is polyvinyl chloride (PVC) plastic sheet which is electrostatically laminated onto the print backing sheet 35 by bringing the two sheet 35, 36 materials in contact and applying pressure through a rubber-coated roller. This places the sheets 35, 36 under elastic tension. As described above, the adhesive force which laminates the sheets is a combination of an electrostatic force and applied pressure or elastic tension. The magnitude of the electrostatic force is related to the dielectric constant of the print backing sheet 35 and the electrostatic charge of the PVC plastic panel 36.

The transparent plastic panel 36 has a printing surface which accepts ink during the printing process. The printing surface may include one or more coating layers that aid in the absorption of ink. Such layers are particularly useful when water-based inks such as those utilised in inkjet printers are used. In one embodiment, the transparent plastic panel 36 is formed from a plastic polymer, such as polyvinyl chloride, polyethylene, polypropylene or polyester.

The reflective sheet 39, 80 is a 3MMT Diamond Grade MT DG3 reflective sheet with a pressure-sensitive adhesive on the non-reflective side of the reflective sheet 39, 80. The reflective sheet 39, 80 is a class 1 reflective film which uses full-cube microprism technology to create bright, reflective signs in all light conditions.

ADVANTAGES

A number of advantages are apparent in the present invention. It is robust and weatherproof which allows its use both indoors and outdoors in any weather condition. The weatherproofing is particularly advantageous when the lighting box is used on mining vehicles which are cleaned using water cannons. Additionally, it is small enough to be able to be used on mobile structures such as motor vehicles. It also provides high visibility signage in all lighting conditions by employing both reflective material and an innate light source.

By distributing the dynamic or static stress over the planar surfaces of the light module and the housing, and also under the LEDs, the strips of vibration absorbing tape provide the light module of the lighting box with impact resistance and vibration damping required when the lighting box is mounted to vehicles, and in particular to vehicles used in high-production mining and heavy duty construction environments. The strips of vibration absorbing tape extend the life of the light sources and reduces the maintenance required on the lighting boxes.

Allof these features provide a universally useful device for use in signage in any environmental conditions.

VARIATIONS

It will be realized that the foregoing has been given by way of illustrative example only and that all other modifications and variations as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth.

As used herein the term "and/or" means "and" or "or", or both.

As used herein "(s)" following a noun means the plural and/or singular forms of the noun.

In this specification, adjectives such as first and second, left and right, top and bottom, and the like may be used solely to distinguish one element or action from another element or action without necessarily requiring or implying any actual such relationship or order. Where the context permits, reference to an integer or a component or step (or the like) is not to be interpreted as being limited to only one of that integer, component, or step, but rather could be one or more of that integer, component, or step etc.

The above description of various embodiments of the present invention is provided for purposes of description to one of ordinary skill in the related art. It is not intended to be exhaustive or to limit the invention to a single disclosed embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. The invention is intended to embrace all alternatives, modifications, and variations of the present invention that have been discussed herein, and other embodiments that fall within the scope of the above described invention.

In the specification the term "comprising" shall be understood to have a broad meaning similar to the term "including" and will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the term "comprising" such as "comprise" and "comprises".

Claims

1. A lighting box comprising: a housing with a base and a display surface, the display surface overlying an opening in the housing and opposite the base; a light module having at least one light source for emitting light, the light module is mounted to the base within the housing and is configured to illuminate the display panel by way of the light source; wherein the display surface comprises a transparent plastic panel with at least one character or shape reverse printed thereon and forming transparent and non-transparent parts on the display surface, the at least one character or shape is reverse printed so that when viewed through the transparent plastic panel it appears in normal view; and wherein when the light source illuminates the display surface light shines through the transparent parts from within the housing providing the display surface with high visibility during both day and night.

2. A lighting box as claimed in claim 1, wherein the display surface is attached to the housing such that a seal between them is water tight.

3. A lighting box as claimed in claim 2, wherein the seal comprises a gasket for making the seal water tight.

4. A lighting box as claimed in claim 1, wherein the housing further comprises a mounting flange extending from opposite sides of the housing to provide means for attaching the lighting box to a structure.

5. A lighting box as claimed in claim 1, wherein the light module comprises a planar panel with a first side and a second side.

6. A lighting box as claimed in claim 5, wherein a plurality of mounting apertures are positioned around the periphery of the planar panel for mounting the planar panel to the base of the housing.

7. A lighting box as claimed in claim 5 or claim 6, wherein the first side of the planar panel has a plurality of vibration absorbing tapes attached thereto for mounting the first side of the planar panel to the base of the housing, the vibration absorbing tape distributes dynamic or static stress over the planar surface of the planar panel and provides impact resistance and vibration damping for the light module in the housing.

8. A lighting box as claimed in any one of the preceding claims, wherein the at least one light source comprises a plurality of light emitting diodes (LEDs) mounted on the second side of the planar panel of the light module.

9. A lighting box as claimed in claim 8, wherein the plurality of LEDs are mounted to the second side of the planar panel by a vibration absorbing tape, the vibration absorbing tape distributes dynamic or static stress over the planar surface of the planar panel and provides impact resistance and vibration damping for the plurality of LEDs in the light module.

10. A lighting box as claimed in claim 8 or claim 9, wherein the plurality of LEDs are mounted in at least one row extending axially between opposite ends of the second side of the planar panel.

11. A lighting box as claimed in claims 7 to 10, wherein the vibration absorbing tape is a double-sided acrylic foam tape.

12. A lighting box as claimed in claim 1, wherein the transparent plastic panel has a first planar surface and a second planar surface.

13. A lighting box as claimed in claim 12, wherein before the at least one character or shape is reverse printed on the transparent plastic panel a print backing sheet is attached to the first planar surface of the transparent plastic panel.

14. A lighting box as claimed in claim 13, wherein the transparent plastic panel of the display surface is a polyvinyl chloride (PVC) panel.

15. A lighting box as claimed in claim 13, wherein the print backing sheet is a flexible polyester sheet.

16. A lighting box as claimed in any one of claims 13 to 15, wherein the print backing sheet adheres to the first planar surface of the transparent plastic panel through electrostatic attraction with sufficient force to assure that the print backing sheet and the transparent plastic panel will not delaminate on passing through the printer.

17. A lighting box as claimed in claim 16, wherein the adhesion force is created by a pressure force and surface energies between the first planar surface of the transparent plastic panel being laminated to the print backing sheet.

18. A lighting box as claimed in any one of claims 12 to 17, wherein a reflective sheet is applied to the second planar surface of the reverse printed transparent plastic panel, such that a reflective side of the reflective sheet is visible through the transparent parts of the display surface.

19. A lighting box as claimed in claim 18, wherein the reflective sheet is a class 1 reflective film, the reflective film is adhered to the second planar surface of the printed transparent plastic panel with a pressure sensitive double-sided adhesive tape.

20. A lighting box as claimed in claim 19, wherein the double-sided adhesive tape is an optically clear, acrylic or other high bond double-sided tape.

21. A lighting box as claimed in any one of claims 12 to 19, wherein a frosted polycarbonate or acrylic panel is applied over the reflective film on the second planar surface of the printed transparent panel, the frosted polycarbonate or acrylic panel is adhered to the reflective film with a pressure sensitive double sided adhesive tape and the print backing sheet is removed to complete the display surface.

22. A lighting box as claimed in any one of claims 12 to 17, wherein a reflective sheet is cut to a size less than and in the shape of the at least one character or shape of the transparent part on the display surface.

23. A lighting box as claimed in claim 22, wherein a vinyl blackout layer is laminated to a non-reflective side of the cut reflective sheet character or shape.

24. A lighting box as claimed in claim 22 or claim 23, wherein the reflective side of the cut reflective sheet character or shape is then adhered to the corresponding character or shape on the second planar surface of the reverse printed transparent plastic panel, such that the reflective side of the cut reflective sheet character or shape is visible through the transparent parts with a transparent outline between the cut reflective sheet character or shape and the non-transparent part of the display surface.

25. A lighting box as claimed in any one of claims 22 to 24, wherein the cut reflective sheet is a class 1 reflective film, the cut reflective film is adhered to the transparent parts of the second planar surface of the printed transparent plastic panel with a pressure sensitive double-sided adhesive tape.

26. A lighting box as claimed in claim 25, wherein the double-sided adhesive tape is an optically clear, acrylic or other high bond double-sided tape.

27. A lighting box as claimed in any one of claims 22 to 26, wherein the print backing sheet is removed, and a pressure sensitive optically clear double-sided tape is applied to the second planar surface of the printed transparent plastic panel.

28. A lighting box as claimed in claim 27, wherein a frosted polycarbonate or acrylic panel is applied to the pressure sensitive optically clear double-sided tape to complete the display surface.

29. A lighting box as claimed in any one of claims 24 to 28, wherein a coloured translucent film is applied to the frosted polycarbonate or acrylic panel, wherein a colour of the coloured translucent film determines the colour of light emitted through the transparent outline between the cut reflective sheet character or shape and the transparent part of the display surface.

30. A lighting box as claimed in any one of claims 1 to 7, wherein the at least one light source is a neon light tube.

31. A lighting box as claimed in any one of the preceding claims, wherein an interior of the housing is reflective for reflecting the light from the at least one light source towards the display surface.

32. A lighting box as claimed in claim 4, wherein the structure to which the lighting box is attached to is a vehicle.

33. A lighting box as claimed in claim 32, wherein the lighting box is electrically connected to the vehicles electrical system.

34. A lighting box as claimed in claim 32 or claim 33, wherein the vehicles electrical system is a 12 or 24 V DC system.

35. A lighting box as claimed in claim 4, wherein the structure to which the lighting box is attached to is a post.

36. A light emitting and reflecting sign comprising: a lighting box with a housing, a base located within the housing and a light module positioned on the base within the lighting box housing and operable to generate light; and a display surface overlaying an opening in the lighting box housing; wherein the light module comprises: a planar panel with a first side and a second side; a plurality of vibration absorbing tapes adhered to the first side of the planar panel for mounting between the planar panel and the base of the housing; a plurality of mounting apertures positioned around the periphery of the planar panel for mounting the planar panel to the base of the housing; a plurality of vibration absorbing tapes on the second side of the planar panel, the vibration absorbing tape arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel; and a plurality of light emitting diodes (LEDs) mounted on the rows of vibration absorbing tapes on the second side of the planar panel; wherein the display surface comprises: a transparent plastic panel with a first planar surface and a second planar surface; an image reverse printed onto the transparent plastic panel, the image having a transparent part and a non-transparent part; at least one character or shape is formed in the spaces of the transparent part of the display surface; a reflective sheet is adhered to the second planar surface of the printed transparent plastic panel, such that a reflective side of the reflective sheet is visible through the transparent parts of the display surface; and a frosted polycarbonate or acrylic panel is adhered over the reflective sheet on the second planar surface of the printed transparent panel; wherein the reflective sheet is configured to absorb at least a portion of the light generated by the LEDs and, in response, to emit light through the at least one character or shape of the display surface; and wherein the reflective sheet is configured to reflect wavelengths of light from sunlight.

37. A light emitting and reflecting sign comprising: a lighting box with a housing, a base located within the housing and a light module positioned on the base within the lighting box housing and operable to generate light; and a display surface overlaying an opening in the lighting box housing; wherein the light module comprises: a planar panel with a first side and a second side; a plurality of vibration absorbing tapes adhered to the first side of the planar panel for mounting between the planar panel and the base of the housing; a plurality of mounting apertures positioned around the periphery of the planar panel for mounting the planar panel to the base of the housing; a plurality of vibration absorbing tapes on the second side of the planar panel, the vibration absorbing tape arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel; and a plurality of light emitting diodes (LEDs) mounted on the rows of vibration absorbing tapes on the second side of the planar panel; wherein the display surface comprises: a transparent plastic panel with a first planar surface and a second planar surface; an image reverse printed onto the transparent plastic panel, the image having a transparent part and a non-transparent part; at least one character or shape is formed in the spaces of the transparent part of the display surface; a reflective sheet is cut to a size less than and in the shape of the at least one character or shape; a vinyl blackout layer is laminated to a non-reflective side of the cut reflective sheet character or shape and the reflective side of the cut reflective sheet character or shape is then adhered to the corresponding character or shape formed in the spaces of the transparent part of the display surface; an outline is formed between the reflective sheet character or shape and the non-transparent part of the display surface; a pressure sensitive optically clear double-sided tape is applied to the second planar surface of the printed transparent plastic panel; a frosted polycarbonate or acrylic panel is adhered over the reflective sheet on the second planar surface of the printed transparent panel; and a coloured translucent film is adhered to the frosted polycarbonate or acrylic panel; and wherein the light generated by the LEDs emits light through the transparent outline between the cut reflective sheet character or shape and the non-transparent part of the display surface in a colour of the coloured translucent film; and wherein the reflective sheet is configured to reflect wavelengths of light from sunlight.

38. A light emitting and reflecting sign as claimed in claim 36 or claim 37, wherein the vibration absorbing tape distributes dynamic or static stress over the planar surface of the planar panel and provides impact resistance and vibration damping for the plurality of LEDs in the light module.

39. A light emitting and reflecting sign as claimed in claims 38, wherein the vibration absorbing tape is a double-sided acrylic foam tape.

40. A light emitting and reflecting sign as claimed in claim 36 or claim 37, wherein before the image is reverse printed on the transparent plastic panel a print backing sheet is attached to the first planar surface of the transparent plastic panel.

41. A light emitting and reflecting sign as claimed in claim 40, wherein the transparent plastic panel of the display surface is a polyvinyl chloride (PVC) panel, and the print backing sheet is a flexible polyester sheet.

42. A light emitting and reflecting sign as claimed in claim 40 or claim 41, wherein the print backing sheet adheres to the first planar surface of the transparent plastic panel through electrostatic attraction with sufficient force to assure that the print backing sheet and the transparent plastic panel will not delaminate on passing through the printer.

43. A light emitting and reflecting sign as claimed in claim 42, wherein the adhesion force is created by a pressure force and surface energies between the first planar surface of the transparent plastic panel being laminated to the print backing sheet.

44. A light emitting and reflecting sign as claimed in any one of claims 40 to 42 and when dependent upon claim 36, wherein the print backing sheet is removed after the frosted polycarbonate or acrylic panel is adhered over the reflective film on the second planar surface of the display surface.

45. A light emitting and reflecting sign as claimed in any one of claims 40 to 42 and when dependent upon claim 37, wherein the print backing sheet is removed before the pressure sensitive optically clear double-sided tape is applied to the second planar surface of the printed transparent plastic panel.

46. A light emitting and reflecting sign as claimed in claim 36 or claim 37, wherein the reflective sheet is a class 1 reflective film, the reflective film is adhered to the transparent parts of the second planar surface of the printed transparent plastic panel with a pressure sensitive double-sided adhesive tape.

47. A light emitting and reflecting sign as claimed in any one of claims 36 to 46, wherein the housing further comprises a mounting flange extending from opposite sides of the housing to provide means for attaching the lighting box to a structure.

48. A light emitting and reflecting sign as claimed in claim 47, wherein the structure to which the lighting box is attached to is a vehicle.

49. A light emitting and reflecting sign as claimed in claim 48, wherein the lighting box is electrically connected to the vehicles electrical system, the vehicles electrical system is a 12 or 24 V DC system.

50. A light emitting and reflecting sign as claimed in claim 47, wherein the structure to which the lighting box is attached to is a post.

51. A method of producing a light emitting and reflecting sign, the method comprising the steps of: i) providing a lighting box with a housing, a base and an opening in the housing opposite the base; ii) providing a light module with a planar panel having a first side and a second side, a plurality of vibration absorbing tapes adhered to the first side of the planar panel for mounting between the planar panel and the base of the housing, a plurality of vibration absorbing tapes on the second side of the planar panel, the vibration absorbing tape arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel, and a plurality of light emitting diodes (LEDs) mounted on the rows of vibration absorbing tapes on the second side of the planar panel; iii) providing a display surface overlaying the opening in the lighting box housing, providing the display surface comprising the steps of: a) laminating a print backing sheet to a first planar surface of a transparent plastic panel using electrostatic attraction with sufficient force to assure that the print backing sheet and the transparent plastic panel will not delaminate on passing through a printer; b) printing a reverse image onto the transparent plastic panel, the image having a transparent part and a non-transparent part with at least one character or shape formed in the spaces of the transparent part of the printed image; c) adhering a reflective sheet to the second planar surface of the printed transparent plastic panel, such that a reflective side of the reflective sheet is visible through the transparent parts of the display surface; and d) adhering a frosted polycarbonate or acrylic panel over the reflective sheet on the second planar surface of the printed transparent panel; iv) during daylight hours the reflective sheet of the sign is configured to reflect wavelengths of light from sunlight; and v) during non-daylight hours the reflective sheet is configured to absorb at least a portion of the light generated by the LEDs and, in response, to emit light through the at least one character or shape of the display surface.

52. A method of producing a light emitting and reflecting sign, the method comprising the steps of: i) providing a lighting box with a housing, a base and an opening in the housing opposite the base; ii) providing a light module with a planar panel having a first side and a second side, a plurality of vibration absorbing tapes adhered to the first side of the planar panel for mounting between the planar panel and the base of the housing, a plurality of vibration absorbing tapes on the second side of the planar panel, the vibration absorbing tape arranged in spaced apart rows extending axially between opposite ends of the second side of the planar panel, and a plurality of light emitting diodes (LEDs) mounted on the rows of vibration absorbing tapes on the second side of the planar panel; iii) providing a display surface overlaying the opening in the lighting box housing, providing the display surface comprising the steps of: a) laminating a print backing sheet to a first planar surface of a transparent plastic panel using electrostatic attraction with sufficient force to assure that the print backing sheet and the transparent plastic panel will not delaminate on passing through a printer; b) printing a reverse image onto the transparent plastic panel, the image having a transparent part and a non-transparent part with at least one character or shape formed in the spaces of the transparent part of the printed image; c) cutting a reflective sheet to a size less than and in the shape of the at least one character or shape; d) laminating a vinyl blackout layer to a non-reflective side of the cut reflective sheet character or shape and the reflective side of the cut reflective sheet character or shape; e) adhering the cut reflective sheet character or shape to the corresponding character or shape formed in the spaces of the transparent part of the display surface; f) forming an outline between the reflective sheet character or shape and the non-transparent part of the display surface; g) applying a pressure sensitive optically clear double-sided tape to the second planar surface of the printed transparent plastic panel; h) adhering a frosted polycarbonate or acrylic panel over the reflective sheet on the second planar surface of the printed transparent panel; and i) adhering a coloured translucent film to the frosted polycarbonate or acrylic panel; and iv) during daylight hours the reflective sheet of the sign is configured to reflect wavelengths of light from sunlight; and v) during non-daylight hours the light generated by the LEDs emits light through the transparent outline between the cut reflective sheet character or shape and the non-transparent part of the sign in a colour of the coloured translucent film.

53. A method as claimed in claim 51 or claim 52, wherein step iii) a) further comprises: cutting the transparent plastic panel to a pre-determined size; allowing a pre-set time for the transparent plastic panel to shrink in size; placing the shrunk transparent plastic panel on a vacuum table, the vacuum table holding the shrunk transparent plastic panel in place for the laminating process; placing the print backing sheet on top of the transparent plastic panel; applying an adhesion force created by a roller attached to the vacuum table to electrostatically laminate the transparent plastic panel to the print backing sheet; and cleaning the printing surface of the transparent plastic panel with a cleaning alcohol before the reverse printing process.

21 31 20 32 27 31

31

26 1/15

70 32

27 21

22 25 28 26 FIG. 1 30