LED PERIMETER LIGHTING SYSTEM

[0001] The invention generally relates to a lighting apparatus. More particularly, the invention relates to a lighting apparatus that includes a plurality of LEDs and simulates a neon light.

BACKGROUND

[0002] Neon lights are widely used in architectural lighting systems to draw a viewer's attention to a building. Neon lights are fragile, require high voltage, consume large amounts of energy, and have an inconsistent light pattern. Therefore, many attempts have been made to replace neon lights with a more efficient and longer lasting light source.

[0003] In the art, light emitting diodes ("LEDs") have been used in systems that simulate neon light. These known systems, however, have been found to be difficult to mount to a building. Furthermore, sealing the housing of the system to prevent the ingress of moisture has also been challenging.

SUMMARY OF THE INVENTION

[0004] An LED device that overcomes the shortcomings includes an elongated enclosure, a plurality of LEDs disposed in the enclosure, and a mounting bracket connected to the enclosure. The elongated enclosure in a cross section taken normal to a longitudinal axis of the enclosure includes a curved portion and an integrally formed transverse section that interconnects the curved portion. The mounting bracket is configured for mounting the enclosure to an associated building.

[0005] A method of manufacturing a like device that overcomes the aforementioned shortcomings includes placing a PCB having a plurality of LEDs mounted thereon into a

PCB glide, feeding the PCB glide into an injection molding machine, feeding a formable material into the injection molding machine, and forming an enclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIGURE 1 is a cross-sectional view of an architectural border light device taken normal to a longitudinal axis of the device.

[0007] FIGURES 1A-1 I are cross-sectional views of alternative embodiments of architectural border light devices taken normal to a longitudinal axis of each device.

[0008] FIGURE 2A is a cross-sectional view of an enclosure and a mounting bracket for a light device similar to the light device depicted in FIGURE 1 mounted to a vertical surface.

[0009] FIGURE 2B is another cross-sectional view of the enclosure and bracket shown in FIGURE 2A mounted to a horizontal surface.

[0010] FIGURES 3A and 3B show a close-up view of portions of FIGURES 2A and

2B, respectively, showing a tab that extends from the enclosure engaging a tab on the mounting bracket.

[0011] FIGURE 4A depicts a cross section of an elongated housing of a light device attached to a cam assembly.

[0012] FIGURE 4B is a rear perspective view of the elongated housing shown in

FIGURE 4A and the cam assembly in a first position.

[0013] FIGURE 4C is a rear perspective view of the elongated housing shown in

FIGURE 4A with the cam assembly shown in a second position.

[0014] FIGURES 4D and 4E depict perspective views of the cam assembly of

FIGURE 4A.

[0015] FIGURE 5A is a cross-sectional view of an alternative embodiment of an elongated housing of a light device engaging an alternative embodiment of a cam assembly.

[0016] FIGURES 5B and 5C are rear perspective views of the elongated enclosure and the cam assembly of FIGURE 5A in a first operating position (FIGURE 5B) and a second operating position (FIGURE 5C).

[0017] FIGURES 5D and 5E are perspective views of the cam assembly shown in

FIGURES 5A-5C,

[0018] FIGURE 6 is a perspective view of an end of an elongated housing of a light device and a cap that attaches to the end of the elongated housing.

[0019] FIGURE 7 is a perspective view of an end of an alternative embodiment of an elongated housing of a light device and an alternative embodiment of a cap that attaches to the end of the elongated housing.

[0020] FIGURE 8 depicts an end of a light device and an end cap attached to an end of the enclosure of the light device with a sealant being introduced into the enclosure.

[0021] FIGURE 9 is a perspective view of an end of an elongated enclosure of a light device and a cap that attaches to the end of the enclosure.

[0022] FIGURE 10 is a perspective view of an end of an elongated enclosure of a light device and an alternative embodiment of a cap that attaches to the end of the enclosure.

[0023] FIGURE 11 is a perspective view of an alternative embodiment of a light device.

[0024] FIGURE 12 is a perspective view of a printed circuit board having LEDs mounted thereon which acts as a light source for the light device shown in FIGURE 11.

[0025] FIGURE 13 is a perspective view of an end of the LED device shown in

FIGURE 11 with an end cap removed therefrom.

[0026] FIGURE 14 is a cross-sectional view taken normal to a longitudinal axis of the

LED device shown in FIGURE 11.

[0027] FIGURE 15 is a perspective sectional view of the LED device shown in

FIGURE 11.

[0028] FIGURE 16 is a schematic depiction of a manufacturing process for the LED device shown in FIGURE 11.

[0029] FIGURE 17 is a perspective view of another embodiment of an LED light device.

[0030] FIGURE 18 is a perspective view of a printed circuit board having a plurality of LEDs mounted thereon where the printed circuit board is inserted into a PCB glide.

[0031] FIGURE 19 is a schematic cross-sectional view taken normal to a longitudinal axis of the assembly shown in FIGURE 18

|0§32] FIGURE 20 is a sectional view taken along the longitudinal axis of the assembly shown in FIGURE 18.

[0033] FIGURE 21 is a sectional view taken along a longitudinal axis of the light device shown in FIGURE 17.

DETAILED DESCRIPTION OF THE INVENTION

[0034] Figure 1 depicts a cross-sectional view of an architectural border light device 8 (hereinafter referred to as "light device" or "LED device") taken normal a longitudinal axis of the device. The light device 8 includes an extruded elongated enclosure 10 that includes a curved portion 12, which in the depicted embodiment is U-shaped but can take alternative configurations, and an integrally formed transverse section 14 that interconnects opposite ends of the U-shaped portion. The U-shaped portion 12 and the transverse section 14 enclose a printed circuit board ("PCB") 16 (or a plurality of printed circuit boards) and a plurality of light emitting diodes 18 (only one shown) disposed on the printed circuit board along the longitudinal axis of the light device 8 so that, typically, only the ends of the device are open and thus accessible to the elements. These ends are covered in a manner that is described in more detail below. The PCB 16 mounts in corresponding longitudinally running channels 22 that are formed by extensions 24 that extend into the elongated enclosure toward the longitudinal axis. [0035] Portions of the LED device 8 shown in phantom in Figure 1 depict portions of the device that can be altered to incorporate different mounting structures for mounting the LED device 8 to a building. Examples of these concepts are more fully explained in Figures 1A - 11.

[0036] The curved portion 12 of the elongated enclosure 10 typically includes a translucent portion to allow light from the LED 18 to emanate therethrough. Additionally, the translucent portion can include a material having light diffusing properties so that the plurality of point light sources, i.e. the plurality of LEDs 18, appear as a substantially homogeneous lit light source when viewed from a distance after the light travels through the translucent portion. Further explanation of such materials is described in United States Patent Application Publication No US 2005/0180135 Al , which incorporated by reference herein in its entirety

[0037] With reference to Figure 1A, the elongated enclosure 10 is shown connected to a mounting structure, or mounting bracket 30, via a push-together fit. The mounting

bracket 30 includes an elongated U-shaped member 32 having barbs 34 at opposite ends that cooperate with barbs 36 formed on the transverse section 14 of the enclosure (the transverse section in the embodiment in Figure 1A is somewhat U-shaped in cross section). Openings 38 are provided in the mounting bracket centered between the barbs 34 to receive fasteners 40 for attaching the mounting bracket 30 to a building or other architectural structure. To mount the lighting device, first the mounting bracket 30 is attached to the building using the fasteners 40. Next, the elongated housing 10 is pushed onto the mounting bracket 30 so that the barbs 34 of the mounting bracket ride over the barbs 36 of the housing 10 until the barbs 34 of the mounting bracket catch the barbs 36 of the housing thus attaching the housing to the bracket. [0038] Figure 1 B depicts an elongated housing 10 attached to a mounting bracket 50 that includes a base 52 that is parallel to the mounting surface of the building to which the elongated housing 10 will mount. An L-shaped flange 54 extends from the base 52 having a first portion that extends away from the building (when bracket 50 is attached to the building) and is generally perpendicular to the base and a second portion that is generally parallel to the base. An upper L-shaped flange 56 includes a leg that is bent towards the base 52. An opening 58 is provided to receive a fastener 60 to attach the mounting bracket 50 to the building. The elongated housing 10 snaps into the mounting bracket 50 by moving the device in the direction of arrow 62 with respect to the mounting bracket 50. The elongated housing 10 includes a corresponding lower L- shaped flange 64 that is received by the lower L-shaped flange 54 of the mounting bracket 50 and an upper L-shaped flange 66 that is received by the bent L-shaped flange 56.

[0039] With reference to Figure 1C, the elongated housing 10 attaches to a mounting bracket 70 that includes a base 72, a lower L-shaped flange 74 and an upper flange 76 that is disposed at a downward acute angle with respect to the base. The base 72 includes an opening 78 and a fastener 82 is received through the opening for attaching the mounting bracket 70 to the building. The elongated housing 10 includes a rack 84 having a plurality of teeth 86 that cooperate with an end of the upper flange 78 of the bracket 70. The rack 84 and the transverse section 14 can define a channel 88 that receives a portion of the lower L-shaped flange 74 of the bracket 70. The elongated

housing 10 is pushed downwardly onto the mounting bracket 70 so that the portion of the L-shaped flange that is parallel to the base 72 is received in the channel 88 and the end of the acute flange 76 rides over respective teeth 86 in a type of ratchet engagement. The elongated housing 10 can be removed from the mounting bracket 70 by inserting a screwdriver or other tool between the acute flange 76 and the rack 84 and pressing the end of the V-shaped flange towards the base 72 away from and no longer in engagement with the teeth 86.

[0040] Figure 1D depicts a mounting bracket 90 including an extension 92 and a resilient tab having a protuberance 94. The enclosure 10 includes a tab 96 that hooks over the top of the extension 92 and a bottom flange 98 that snaps over the resilient tab including the protuberance 94. The mounting bracket 90 attaches to the building in a similar manner as the mounting brackets described above, e.g. a fastener. The elongated housing 10 is then hooked over the mounting bracket 90 and rotated about a pivot point generally at the contact point between the extension 92 of the mounting bracket 90 and the extension 96 of the enclosure 10 and then snapped over the protuberance 94.

[0041] With reference to Figure 1 E, the elongated housing 10 attaches to a mounting bracket 110 that includes a lower C-shaped portion 112 and an upper flange 114. The elongated housing 10 includes a cylindrically shaped extension 116 that is received inside the C-shaped portion 112 and a flange 118 that cooperates with the flange 114 of the mounting bracket. The cylindrically shaped portion 116 fits into the C-shaped portion 112 of the mounting structure 110 and the upper flange 118 of the elongated housing 10 hooks over the upper flange 114 of the mounting bracket. [0042] Figure 1 F depicts the elongated light source 10 and the mounting bracket 130 molded or extruded as one piece. A co-molded flexible hinge 132 joins the mounting bracket 130 to the elongated light source 10. The hinge 132 is made from a flexible and/or resilient and/or rubber-like material and the bracket 130 and the housing 10 are made from the same or a similar material, e.g. PVC, The hinge 132 can also be made as a living hinge and can take other configurations that will be described in more detail below. An upper flange 134 is provided on the mounting bracket 130 that cooperates with an upper flange 136 of the elongated housing 10 so that when the elongated

housing is rotated with respect to the mounting bracket 130 about the hinge 132 to close the device, i.e. bring the upper flange 136 of the elongated housing 10 towards the upper flange 134 of the mounting bracket 130, the housing will attach to the bracket with the components of the device appropriately aligned to direct light away from the building.

[0043] Figures 1 G and 1 H depict the elongated housing 10 attaching to a mounting bracket 150 (Figure 1G) and 152 (Figure 1 H) by pushing the elongated housing 10 towards the respective bracket in a direction of arrow A which is shown in both figures. Figure 11 discloses an embodiment similar to Figure 1 E while allowing the elongated housing 10 to pivot and snap into respective receiving features on either the bracket 154 or the elongated envelope 10.

[0044] With reference to Figure 2A, the elongated light source is shown attached to a mounting structure, or bracket 160, via a hinge 162. In this embodiment, the enclosure 10 for the elongated light source and the mounting structure 160 are coextruded and the hinge 162 is a living hinge, e.g. a weakened section of plastic or similar material. In this embodiment, the enclosure 10, the bracket 160 and the hinge 162 are all made from the same material, e.g. PVC. In the depicted embodiment a Y-shaped cut 164 is provided so that the enclosure, which includes the curved portion 12 and the transverse section 14, pivots away from the mounting structure 160 so that fasteners can be used to attach the mounting structure to a wall. The Y-shaped cut 164 is provided to allow more than 90°, and preferably close to 180°, of rotation of the enclosure 10 with respect to the bracket 160 about the hinge 162. This allows the enclosure 10 to hang (or be moved) out of the way of the bracket 160 as the bracket is being fastened to the wall or other architectural structure. After the mounting structure 160 has been attached to the wall, the enclosure 10 of the elongated light source can be pivoted such that a tab 166 that extends from the transverse section 14 can cooperate with a tab 168 that extends from the mounting structure 160. With reference to Figure 2B the light source is depicted attaching to a horizontal surface of a wail.

[0045] With reference to Figures 3B and 3C ₁ cooperation between the tab 166 that connects to the transverse section 14 of the elongated housing 10 and the tab 168 that extends from mounting bracket 160 is shown. Figure 3A is a close up view of the

structure shown in Figure 2A. Figure 3B is an alternative configuration that would provide a more permanent attachment when the elongated enclosure 10 is rotated towards the mounting structure 160. As can be seen in Figure 3B, the tab 166 includes a slanted forward face and a vertical rearward face and, similarly, the tab 168 of the mounting structure 160 also includes a slanted forward face and a vertical rearward face. The slanted forward faces facilitate attachment by allowing the slanted faces to ride over one another when the elongated housing 10 is rotated towards the mounting structure 160. The vertical faces inhibit detachment of the elongated light source from the mounting structure once the two have been fastened together as shown in Figure 3B.

[0046] Figure 4A depicts the elongated housing 10 attached to a cam assembly 180, which is in turn attached to the wall. As more easily seen in Figures 4D and 4E, the cam assembly includes a base 182 having a cylindrical boss 184 extending upwardly from the base. An opening 186 extends through the boss 184 and the base 182 to receive a fastener 188 (Figure 4A) for attaching the cam assembly 180 to the wall. A cam 192 surrounds the cylindrical boss 184. An arm 194 attaches to the cam 192 for rotating the cam about the cylindrical boss 184. As seen in Figure 4E, the arm 194 can be omitted, and a tool can be used to rotate the cam 192. As seen in Figures 4B and 4C, the cam is selectively received in channels 196 formed in the elongated enclosure 10 of the elongated light source. With the arm 194 in the generally vertical position, the cam 192 is not received in the respective channels 196 so that the light source then can be removed from cam assembly 180. The arm 194 is then rotated 90° thus rotating the cam 192 into the respective channels 196 locking the elongated housing 10 to the cam assembly 180 and thus to the wall to which the cam assembly is attached. [0047] Figures 5A through 5E show an alternative embodiment of a cam assembly 200 connecting to the elongated housing 10 of an illuminated light source. As more clearly seen in Figures 5D and 5E, the cam assembly 200 includes a base 202 having a flange that defines a channel 204 at a lower end and a cylindrical boss 206 extending upwardly from the base, An opening 208 is formed through the cylindrical boss 206 and the base 202. The opening 208 receives a fastener 210 (Figure 5A) for attaching the cam assembly 200 to a wall. A cam 212 is received over the cylindrical boss 206. An

attachment arm 214 connects to the cam 212 to allow for rotation of the cam. As seen in Figure 5E, the arm 214 can be omitted and a tool can be used to rotate, e.g. unlock, the cam.

[0048] With reference to Figures 5B and 5C, the cam assembly 200 is attached to a wall by a fastener 210 (Figure 5A) received through the opening 208. The elongated housing 10 having channels 216 is hung from the cam assembly so that the lower channel 216 cooperates with the lower channel 204 (Figure 5D) of the base 202. The arm 214 can then be rotated 90° so that the cam 212 moves into the upper channel 216 thus retaining the elongated light source 10 to the cam assembly 200 and thus to the wall.

[0049] Figures 6-10 depict different manners in which the ends of the elongated illuminated light source can be sealed and/or covered to prevent the ingress of moisture. Figure 6 depicts an end cap 220 where the edge of the end cap is outside of the enclosure 10 of the elongated illuminated light source. The cap is made of vinyl.

[0050] Figure 7 depicts an end cap 230 where there is a flush seam between the outer surface of the enclosure of the elongated housing 10 of the illuminated light source and the outer surface of the end cap 230. The end cap includes a plurality of fins that are pushed into the enclosure for a friction fit.

[0051] Figure 8 depicts the end cap 230 including two openings that communicate with an internal channel. Sealant is introduced into the first opening 232 and moves through the channel until coming out of the second opening 234.

[0052] Figure 9 depicts an end cap 240 having pre-applied sealant disposed on an inner surface thereof. The pre-applied sealant 242 is protected by a removable protective cover 244 so that when the end cap 240 is to be applied to the enclosure 10 of the elongated light source, the protective cover 244 is removed thus exposing the pre-applied sealant 242 which can attach the end cover 240 to the enclosure.

[0053] Figure 10 depicts an end cover 250 including a pre-applied foam gasket 252

The gasket presses against the end of the enclosure of the elongated light source 10

|©054] Openings can be provided in each of the above-described end caps to receive wires for connection to the printed circuit boards disposed in the end caps.

[0055] Figure 11 depicts another embodiment of an elongated illuminated device 300 that simulates a neon light. The device 300 includes an elongated housing 310 and a mounting bracket 312 hingedly attached to the enclosure. Figure 12 depicts a printed circuit board 314 having a plurality of LEDs 316. Electrical cords 318 attach to the printed circuit board 314 to provide power to the LEDs 316. With reference back to Figure 11 , a plurality of printed circuit boards 314 including LEDs 316 can be provided in a single enclosure 310. The power cords 318 connect to an electrical connector 322 (which can either be a female or male connector).

[0056] Figure 13 depicts a close-up view of an end of the elongated illumination device 300 with an end cap 324 (Figure 11 ) being removed therefrom. The mounting bracket 312 does not run the length of the enclosure 310, but instead is offset from each end of the enclosure to accommodate the end cap 324.

[0057] Figure 14 discloses a cross-sectional view taken normal to a longitudinal axis of the device 300. The bracket 312 is permanently, e.g., non-removably, attached to the elongated enclosure 310 via a hinge 326. In this embodiment, the hinge is made from a soft resilient material, having properties similar to rubber. Accordingly, the enclosure 310 is made from a first material, typically PVC, and the mounting bracket 312 is also made from a similar material, typically PVC. The hinge 326, however, is made from a dissimilar material that can be coextruded with the elongated enclosure 310 and the mounting bracket 312 during manufacturing. End portions of the mounting bracket can be cut away to accommodate the end caps 324 (Figure 11 ) as described above. Alternatively, the hinge 326 can also be made from a PVC material, but it can include cuts or other weakened sections to provide a living hinge between the mounting bracket 312 and the elongated enclosure 310.

[0058] In Figure 14, the elongated illuminated device 300 is shown in a closed position, which is typically the final stage of assembly after the illumination device has been mounted to an architectural structure, such as a building. In this closed position, the elongated housing 310 connects to the mounting bracket 312 at two locations located on opposite sides of a longitudinal axis of the elongated illuminated device 300 A first attachment point is provided at the permanent attachment of the hinge 326

connecting the elongated housing 310 to the mounting bracket 312. A selective attachment point is provided on an opposite side of the longitudinal axis. [0059] The mounting bracket includes a base 332 that is typically planar that abuts a surface of the building or other architectural structure to which the elongated illuminated device 300 will be mounted. A fastener 334 (depicted in phantom in Figure 14) is used to attach the mounting bracket 312 to the building. The fastener 334 extends through the base 332 of the mounting bracket. A leg 336 extends generally perpendicular to the base 332 and away from the building (as per the orientation depicted in Figure 14). A support 338 extends outwardly from the leg 336 and generally parallel to the base 332. The leg 336 includes a barb 342 at a distal end. The barb 342 and the support 338 define a receiving channel 344 that receives the elongated housing 310 when the elongated housing is moved into the closed position. In the closed position, the printed circuit board 314 and the LEDs 316 disposed on the printed circuit board are arranged with respect to the building so that light is directed away from the building to simulate neon lighting.

[0060] The elongated enclosure 310 includes an outer U-shaped portion 350 that is integrally formed with a transverse section 352 that interconnects distal ends of the U- shaped portion. At least a portion of the U-shaped portion 350 is translucent to define a primary light transmissive and light diffusing member. A secondary light transmissive and light diffusing portion 354 is also integrally formed with the U-shaped portion 350 and the transverse portion 352. The secondary portion 354 includes a light receiving surface 356 and light emitting surface 358. Similarly, the primary member 350 includes a light receiving portion 362 and a light emitting portion 364. The light receiving portion 356 of the secondary member 354 is spaced from the transverse section 352 as well as the LED 316. Accordingly, a void 366 is defined between the transverse section 352 and the light receiving surface 356. The printed circuit board 314 that includes the LEDs 316 is received in the void 366. A secondary void 368 is defined between the light transmitting surface 358 of the secondary member 354 and the light receiving surface 362 of the primary member 350,

[0061] L-shaped fingers 372 extend upwardly from the transverse section 352 towards the secondary member 350. The L-shaped fingers 372 define a channel that

receives the printed circuit board 314. The L-shaped fingers retain a printed circuit board in a fixed location with respect to both the secondary light transmitting portion 354 and the primary light transmitting portion 350 of the elongated enclosure 310. [0062] To mount the elongated illuminated device 300 to a building, the elongated enclosure 310 is rotated with respect to the mounting bracket 312 in a direction depicted by arrow R in Figure 14. With the elongated enclosure 310 disposed away from the mounting bracket 312, the base 332 of the mounting bracket is exposed so that fasteners 334 can be used to attach the mounting bracket 312 to the building. When the mounting bracket 312 has been attached to the building, the elongated enclosure 310 is then rotated in an opposite direction to arrow R (counterclockwise in Figure 14) so that a barb 374 that extends from the transverse section 352 engages the barb 342 of the leg 336 of the mounting bracket 312. The distal end of the leg 336 flexes outwardly to receive the barb 374 of the elongated illuminated housing 310 and then flexes back inwardly when the barb rides over the distal barb 342 of the leg 336. The support 338 provides a stop, which stops the rotation of the elongated housing 310 with respect to the mounting bracket 312.

[0063] With reference back to Figure 11 , preferably the elongated illumination device 300 is sealed to protect the printed circuit board 314 and the LEDs 316 (Figure 12) from moisture and the elements. The elongated enclosure 310 provides protection in a radial direction about a longitudinal axis of the enclosure. The end caps 324 provide protection at the longitudinal ends of the enclosure 310.

[0064] With reference back to Figure 14, the printed circuit board 314 and the LEDs 316 can also be sealed using a silicone material 380 that can be injected into the void 366. Accordingly, one end cap 324 can be overmolded onto the elongated illuminating housing 310 and then the silicone material 380 can be introduced into the void 366 covering and protecting the electrical devices found on the printed circuit board 314, which include the LEDs. The second end cap 324 can then be inserted onto the elongated illuminated housing 310 (the ends caps 324 can be similar to the end caps described above). Accordingly, a robust device where much of the electrical circuitry is sealed from moisture is provided. The fingers 372 retain the printed circuit board 314 in its desired location with respect to the primary light diffusing member and the secondary

light diffusing member 354 during the filling of the void 366 with silicone material 380. Alternatively, the printed circuit board 314 and the LEDs 316 can be covered with the silicone material and the silicone material can be allowed to cure prior to insertion of the printed circuit board 314 into the void 366 between the fingers 372. The silicone material is desirable in that it provides a flexible structure that weatherproofs the printed circuit board 314. The silicone 380 does not harden into a rigid structure, but instead remains resilient after curing.

[0065] The enclosures described above can include a light diffusing film placed in the extruded enclosure and located between the LEDs and the light emitting surface of the enclosure to act as a lens. Preferably, the optical film contacts the light receiving surface of the enclosure. The optical film can be a preferentially light spreading film to assist in creating uniformity along the linear array of LEDs. The optical film can blend the light that is emitted from the plurality of point light sources, i.e. the LEDs, to eliminate "hot spots" so that the point light sources are not noticeable. Example of such optical films are OptiGrafix DFxx Grade Diffuser Film and LBxx Diffuser Film available from Grafix Plastics of Cleveland, Ohio.

[0066] Figure 16 depicts a schematic representation of the manufacturing process for an LED device similar to the ones described above. A PCB 416 having a plurality of LEDs 418 mounted on it is placed in a PCB glide 420 and this assembly (PCB 416, LEDs 418 and PCB glide 420) is fed into an injection molding machine 400. Material, e.g. PVC or similar formable material, is then fed into the injection molding machine 400 and the assembly is overmolded, which forms an enclosure 410 that surrounds the assembly. With reference to Figure 18, a perspective view of the assembly that is run through the injection molding machine 420 is depicted. Electrical cords 422 attach to the printed circuit board 416 to provide power to the LEDs 418. A plurality of printed circuit boards 416 including LEDs 418 can be provided in a single enclosure 410. The power cords 422 connect to an electrical connector 424 (which can either be a female or male connector). The PCB 416, the LEDs 418 and the power cords 422 are similar to those that have been described above.

[0067] Figure 17 depicts a perspective view of the LED device 408. The LEDs are connected in parallel on the PCB 416, which allows the LED device to be cut normal to

the longitudinal axis of the device. This allows an installer of the LED device 408 to cut the device to a desired length when installing the LED device in the field, i.e. the installation site.

[0068] Figure 19 depicts a cross-sectional view of the assembly shown in Figure 18 taken normal to the longitudinal axis of the assembly. The PCB glide 420 in the depicted embodiment is an elongated transparent PVC piece. The PCB glide 420 is an extruded piece and the PCB 416 slides into the glide by pushing the PCB in a direction along the longitudinal axis of the PCB glide. As seen in Figure 19, the PCB glide 420 is generally U-shaped in cross section and receives the PCB 416.

[0069] The PCB glide 420 locates the LEDs 418 and other electrical components of the LED device (circuitry and the like) inside the injection molding machine 400 during the injection molding process. The injection molding machine does not contact the PCB 416 or the LEDs 418 during the injection molding process, which allows the plastic material, i.e. the enclosure 410, to surround the entire assembly (PCB 416, LEDs 418 and PCB glide 420 and other electrical components) thus preventing water ingress, which minimizes the sealing required by the installer. With reference to Figure 21 , the space between the top of each LED 418 and the outermost surface of the enclosure 410 is filled with the overmolded material so that no voids (or substantially no voids) exist between the LEDs 418, the PCB 416 and the outermost surface of the enclosure 410. Thus, the enclosure 410 not only diffuses the light emitted by the plurality of LEDs, which act as point light sources, so the LED device 410 more closely simulates a neon light, but the enclosure also completely (or very nearly completely) encapsulates the LEDs and the PCB to prevent moisture from contacting the electrical components of the LED device. The overmolded material also completely (or very nearly completely) encapsulates the underside of the PCB 416, as seen in Figure 21. Holes can be provided in either the PCB 416 or the PCB glide 420 to allow material to flow between the underside of the PCB and the PCB glide during the overmolding process. [Q07QJ With continued reference to Figure 21 , an end of the PCB 416 is spaced from an end of the enclosure 410 to accommodate an end cap 430. The end cap 430 can be integrally formed, e.g. extruded, with a remaining portion of the extruded enclosure 410. In such an instance, two molds would be used with the molding machine 400: a first

mold would be used to form the end cap 430 and a portion of the enclosure for a predetermined length (designated by length / in Figure 21 ) and a second mold would be used to form the remaining long straight runs of the enclosure. Additional end caps (not shown) can be shipped with the light device 410 so that if the device were to be cut at the installation site, the installer would attach the end cap to the cut end of the device to seal the device and prevent the ingress of moisture. A suitable waterproof sealant would be used to attach the end cap to the enclosure.

[0071] An elongated illuminated device that simulates neon lighting has been described with reference to different embodiments disclosed above. The invention is not limited to only those embodiments described. It is intended that the invention cover all modifications and alterations that would occur to those who are skilled in the art upon reading and understanding the detailed description provided above.