Light guide mechanism, star ceiling and manufacturing method

Abstract

The present application relates to a kind of light guide mechanism, starry sky ceiling and manufacturing method, starry sky ceiling includes light guide mechanism, ceiling framework and face finish layer, light guide mechanism includes light inlet end, connecting portion and light outlet end, the light inlet end includes plug-in part, the plug-in part is provided with the plug-in cavity for inserting optical fiber, the light outlet end is perpendicular to the light inlet end setting, the connecting portion is connected between light inlet end and light outlet end, the length of the connecting portion is set as the 10-100 times of the cross-sectional diameter of connecting portion;The ceiling framework includes first surface and second surface, the light inlet end is connected to second surface, and the ceiling framework is provided with through hole along the thickness direction, the light outlet end is inserted into through hole, and the face finish layer is connected to first surface.The starry sky ceiling provided by the present application, the connecting portion of the light guide mechanism can produce certain elastic deformation, in turn, can prevent the rigid contact of passenger and optical fiber or light outlet end and produce the feeling of hand touch, can also ensure good light emitting effect.

Description

Technical Field

[0001] This invention relates to the field of starry sky ceiling technology, specifically to a light guide mechanism, a starry sky ceiling, and a manufacturing method. Background Technology

[0002] A starry sky headliner is a product that integrates fiber optic cables into the interior headliner of a car, using the fibers to guide light and create a starry sky effect. The typical procedure for retrofitting a starry sky headliner involves covering the existing headliner with a layer of suede fabric. Then, holes are drilled in the headliner where the light spots will be created. Fiber optic cables extending from the optical engine pass through these holes, protruding from the front of the headliner. The cables are then secured to the back of these holes, and any excess cable is trimmed from the front to make it as flush as possible with the headliner surface.

[0003] To achieve a pleasant tactile feel, ceiling fabrics typically have a sponge layer that slightly sinks when run over by fingers. Therefore, even if the fiber optic cable is trimmed flush with the ceiling surface, it can still feel rough to the touch. When pressed, the fabric sinks noticeably, making the fiber optic cable feel prickly.

[0004] Furthermore, optical fibers are typically trimmed and shaped, resulting in rough ends that can feel prickly, especially when the fiber extends beyond the ceiling fabric. Even if it doesn't feel prickly, it still affects the tactile experience. If the fiber doesn't extend beyond the fabric, the light will be blocked by the fabric. One current solution is to adjust the size of the holes in the fabric to be larger than the diameter of the optical fiber. This way, even if the fiber is below the fabric, it won't be blocked. However, this solution results in holes that affect the aesthetics.

[0005] Therefore, there is an urgent need for a starry sky canopy that can simultaneously ensure the brightness of the optical fibers, the comfortable feel of the canopy surface, and the aesthetic appeal of the canopy. Summary of the Invention

[0006] The purpose of this invention is to provide a light guiding mechanism, a starry sky canopy, and a manufacturing method, which can solve the technical problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a light guiding mechanism for a starry sky ceiling, comprising an input end, a connecting part, and an output end. The input end includes a plug-in part, which is provided with a plug-in cavity for inserting optical fibers. The output end is arranged perpendicular to the input end. The connecting part connects the input end and the output end for connecting the input end and the output end. The length of the connecting part is set to 10-100 times the cross-sectional diameter of the connecting part.

[0008] As a preferred embodiment, the connecting part is made of an elastic material, such as an organic polymer material, preferably a transparent plastic material.

[0009] As a preferred embodiment, the cross-sectional diameter of the connecting part is set to 0.5-2.0 mm.

[0010] As a preferred embodiment, the light guiding mechanism further includes a fixing part connected to the insertion part. The fixing part is configured with a pointed bottom structure, which allows the fixing part to be inserted into the ceiling frame to fix the relative position of the light input end and the ceiling frame.

[0011] As a preferred embodiment, the number of fixing parts is at least one, or can be multiple, to ensure sufficient connection stability.

[0012] As a preferred embodiment, the root of the fixing part is configured as a necking structure, which ensures that the fixing part and the ceiling frame are tightly connected and will not easily come off.

[0013] The present invention also provides a technical solution for a starry sky ceiling, including the light guiding mechanism described in any of the above solutions, and further including a ceiling frame and a surface layer. The ceiling frame includes a first surface and a second surface, the light-incident end is connected to the second surface, the ceiling frame has a through hole along the thickness direction, and the light-emitting end is inserted into the through hole; the surface layer is connected to the first surface.

[0014] As a preferred embodiment, the length of the light-emitting end is greater than the thickness of the ceiling frame. After the light-emitting end is assembled into the through hole, the light-emitting end protrudes from the first surface of the ceiling frame in a free state.

[0015] As a preferred option, the surface layer is a translucent skin.

[0016] As a preferred embodiment, the surface finish layer is provided with a hole that matches the outer diameter of the light-emitting end, the light-emitting end passes through the hole and protrudes from the surface finish layer, and the portion of the light-emitting end protruding from the surface finish layer is rounded.

[0017] This invention provides a method for manufacturing a starry sky ceiling, comprising the following steps:

[0018] To construct the ceiling frame, drill through holes along the thickness direction of the ceiling frame.

[0019] The first composite finish layer of the ceiling frame is made of a translucent skin.

[0020] Install a light guide mechanism on the second side of the ceiling frame, insert the light-emitting end of the light guide mechanism into the through hole, and insert the fixing part into the ceiling frame.

[0021] Insert the optical fiber of the optical engine into the light input end of the light guiding mechanism.

[0022] As a preferred embodiment, the method for manufacturing a starry sky canopy includes the following steps:

[0023] Step 1: Make the ceiling frame and drill through holes along the thickness of the ceiling frame.

[0024] Step 2: Apply a composite finish layer to the first surface of the ceiling frame, wherein the finish layer is a translucent skin.

[0025] Step 3: Install a light guide mechanism on the second side of the ceiling frame, insert the light-emitting end of the light guide mechanism into the through hole, and insert the fixing part into the ceiling frame;

[0026] Step four: Insert the optical fiber of the optical engine into the light input end of the light guiding mechanism.

[0027] As a preferred embodiment, the method for manufacturing a starry sky canopy includes the following steps:

[0028] Step 1: Make the ceiling frame and drill through holes along the thickness of the ceiling frame.

[0029] Step 2: Install a light guide mechanism on the second side of the ceiling frame, insert the light-emitting end of the light guide mechanism into the through hole and expose it from the first side of the ceiling frame, and insert the fixing part into the ceiling frame.

[0030] Step 3: Apply a composite finish layer to the first surface of the ceiling frame, wherein the finish layer is a translucent skin;

[0031] Step four: Insert the optical fiber of the optical engine into the light input end of the light guiding mechanism.

[0032] This invention also provides a method for manufacturing a starry sky ceiling, comprising the following steps:

[0033] Construct the ceiling frame;

[0034] A composite surface finish layer on the first surface of the ceiling frame;

[0035] Along the thickness direction of the ceiling frame, through holes are drilled where light needs to be emitted, and the through holes extend to the surface layer. A light guide mechanism is installed on the second side of the ceiling frame, the light-emitting end of the light guide mechanism is inserted into the through hole, and the fixing part is inserted into the ceiling frame.

[0036] Insert the optical fiber of the optical engine into the light input end of the light guiding mechanism.

[0037] Compared with the prior art, the beneficial effects of the present invention are:

[0038] 1. The starry sky canopy provided by the present invention optimizes the coordination between the various structures of the light guide mechanism, the length setting of the connecting parts, and the elastic material used, so that the connecting parts of the light guide mechanism can produce a certain elastic deformation, thereby preventing the sharp touch caused by the rigid contact between the occupants and the optical fiber or the light output end, and also ensuring good light output effect.

[0039] 2. Furthermore, by connecting a light-transmitting surface layer to the ceiling frame, the light guide mechanism or optical fiber does not need to pass through the surface layer, and its light can pass through the surface layer. At the same time, due to the obstruction of the surface layer, the connection part of the light guide mechanism can be deformed to a certain extent. This deformation causes stress, which makes the light-emitting end of the light guide mechanism make close contact with the surface layer, thereby ensuring that clear and bright light spots are formed on the surface layer. This solution fundamentally solves the problem of the rough touch, while ensuring the overall aesthetics of the ceiling.

[0040] 3. The starry sky canopy provided by the present invention can control the size of the light spot and the luminous flux by adjusting the inner diameter of the light guide elbow insertion cavity and the diameter of the light output end. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the overall structure of the starry sky ceiling in this invention;

[0042] Figure 2 This is a schematic diagram of the structure of the starry sky ceiling without composite surface layer in this invention;

[0043] Figure 3 This is a schematic diagram of the structure of Comparative Example 1 in this invention;

[0044] Figure 4 This is a schematic diagram of the structure of Comparative Example 2 in this invention;

[0045] Figure 5 This is a schematic diagram of the structure of Comparative Example 3 in this invention;

[0046] Figure 6 This is a schematic diagram of the structure of Comparative Example 4 in this invention.

[0047] The meanings of the labels in the diagram are as follows:

[0048] 1. Ceiling frame; 101. First surface; 102. Second surface; 2. Light guide mechanism; 201. Light input end; 2011. Insertion part; 2012. Base; 202. Light output end; 203. Connecting part; 3. Surface finish layer; 4. Optical fiber; 5. Fixing part; 501. Neck structure; 6. Flexible foam; 7. Fabric. Detailed Implementation

[0049] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0050] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0051] First, let's explain the two terms mentioned below:

[0052] Molding mold: A mold used to make the ceiling frame;

[0053] Composite mold: A mold that bonds the surface finish and the ceiling frame together. Typically, the ceiling frame is placed on the lower mold, and the surface finish is placed on the ceiling frame or on the upper mold. At least one of the surface finish or the ceiling frame is coated with adhesive. The upper mold is then lowered to bond the surface finish and the ceiling frame together.

[0054] Example 1

[0055] See Figure 1 This embodiment discloses a starry sky ceiling, including a ceiling frame 1, a light guiding mechanism 2, and a surface layer 3. The light guiding mechanism 2 is connected to the ceiling frame 1 and is used to install optical fibers 4 and guide the light emitted by the optical fibers 4 out of the ceiling frame 1. The surface layer 3 is laminated to one side of the ceiling frame 1 to ensure the aesthetics of the starry sky ceiling, and at the same time can block the light guiding mechanism 2 to prevent the light guiding mechanism 2 from protruding from the ceiling frame 1. In this embodiment, the surface layer 3 is light-transmitting.

[0056] The ceiling frame 1 serves as the overall support frame for the starry sky ceiling, and further includes a first surface 101 and a second surface 102. The first surface 101 serves as the outer surface of the ceiling frame 1 and is the surface used for the composite surface layer 3. The second surface 102 serves as the inner surface of the ceiling frame 1 and is the surface facing the sheet metal. The optical engine is usually located between the second surface 102 of the ceiling frame 1 and the sheet metal.

[0057] The light guide mechanism 2 further includes an input end 201, an output end 202, and a connecting portion 203 connecting the input end 201 and the output end 202.

[0058] The light-inlet end 201 is located on the same side as the optical engine, specifically on the second surface 102 of the ceiling frame 1. The light-inlet end 201 is used to connect the optical fiber 4 and includes a connector 2011 and a base 2012 connected to the connector 2011. The connector 2011 has a connector cavity of a predetermined depth, into which the optical fiber 4 is inserted. Preferably, the opening of the connector cavity is flared to facilitate the insertion of the optical fiber 4. The base 2012 is used to connect with the connecting part 203. To ensure the stability of the light-inlet end 201 and the continuity of light guidance, the connector 2011 and the base 2012 are preferably integrally formed and connected. Furthermore, to prevent light leakage and reduce light loss, the base 2012 should smoothly transition to the connecting part 203.

[0059] To reduce the space occupied by the light-incident end 201 between the second surface 102 and the sheet metal of the ceiling frame 1, in this embodiment, the light-incident end 201 is positioned on the second surface 102 along its length, i.e., it is connected to the second surface 102 in a flat state, and the optical fiber 4 is inserted into the insertion cavity in a horizontal direction. In some embodiments, adhesive can also be injected between the optical fiber 4 and the insertion cavity to make the connection of the optical fiber 4 more secure.

[0060] The light-emitting end 202 is set perpendicular to the light-incident end 201. The ceiling frame 1 is provided with a through hole along the vertical direction (thickness direction) that matches the outer diameter of the light-emitting end 202. The light-emitting end 202 is inserted into the through hole. The light-emitting end 202 and the base 2012 are connected by a connecting part 203. In order to facilitate processing and ensure the continuity of the light guide and reduce light loss, the base 2012, the connecting part 203 and the light-emitting end 202 are preferably integrally formed and connected.

[0061] See also Figure 1The connecting portion 203 needs to have a predetermined length and be made of an elastic material so that it can deform to a certain extent without affecting the orientation of the light-incident end 201. In this embodiment, the connecting portion 203 extends from the base 2012, and the base 2012 should transition smoothly to the connecting portion 203. The connecting portion 203 is usually cylindrical, and its diameter is significantly reduced relative to the base 2012 to support its deformation. The cross-sectional diameter of the connecting portion 203 is usually set to 0.5-2.0 mm, preferably 0.75-1.5 mm, and the length of the connecting portion 203 is set to 10-100 times its cross-sectional diameter. A suitable cross-sectional diameter of the connecting portion 203, combined with a suitable length, can support the elastic deformation of the connecting portion 203. In this embodiment, the length of the light-emitting end 202 needs to be slightly greater than the thickness of the ceiling frame 1. The light-emitting end 202 is installed in the through hole of the ceiling frame 1, and in a free state, the light-emitting end 202 protrudes from the first surface 101 of the ceiling frame 1. After the composite surface layer 3, due to the obstruction of the surface layer 3, the light-emitting end 202 cannot protrude from the first surface 101 of the ceiling frame 1, but will be flush with the first surface 101 of the ceiling frame 1, which will cause the connecting part 203 to undergo a certain deformation. This deformation causes stress, so that the light-emitting end 202 and the surface layer 3 form a tight contact, thereby ensuring that clear and bright light spots can be formed on the surface layer 3.

[0062] The light guide mechanism 2 should be made of a material with good light transmission and a certain degree of elasticity to support the deformation of the connecting part 203. It is usually made of organic polymer material, preferably transparent plastic material, such as PMMA, PS, PET, PC, etc.

[0063] The surface layer 3 is connected to the first surface 101 of the ceiling frame 1. The surface layer 3 is a translucent skin with good light transmission, typically between 4-40%, and possesses a certain degree of toughness. The translucent skin is usually made of PVC, PU, ​​or PO material. The surface layer 3 not only allows light from the light-emitting end 202 to pass through clearly, but also provides some shielding for the structure within the surface layer 3, effectively blocking the light-emitting end 202 and preventing a sharp, prickly feel, thus ensuring the aesthetic effect of the starry sky ceiling.

[0064] Example 2

[0065] The difference between this embodiment and Embodiment 1 is that in the starry sky ceiling provided in this embodiment, the surface layer 3 is provided with a hole through which the light-emitting end 202 passes, and the surface layer 3 can be made of ordinary, opaque surface material.

[0066] For details, see Figure 2This embodiment discloses a starry sky ceiling, including a ceiling frame 1, a light guiding mechanism 2, and a surface layer 3. The light guiding mechanism 2 is connected to the ceiling frame 1 and is used to install optical fibers 4 and guide the light emitted by the optical fibers 4 out of the ceiling frame 1. The surface layer 3 is laminated to one side of the ceiling frame 1 to ensure the aesthetics of the starry sky ceiling.

[0067] The ceiling frame 1 serves as the overall support frame for the starry sky ceiling, and further includes a first surface 101 and a second surface 102. The first surface 101 is the outer surface of the ceiling frame 1, facing the occupants, and the second surface 102 is the inner surface of the ceiling frame 1, facing the sheet metal. The optical engine is usually located between the second surface 102 of the ceiling frame 1 and the sheet metal.

[0068] The light guide mechanism 2 further includes an input end 201, an output end 202, and a connecting portion 203 connecting the input end 201 and the output end 202.

[0069] The light-inlet end 201 is located on the same side as the optical engine, specifically on the second surface 102 of the ceiling frame 1. The light-inlet end 201 is used to connect the optical fiber 4 and includes a connector 2011 and a base 2012 connected to the connector 2011. The connector 2011 has a connector cavity of a predetermined depth, into which the optical fiber 4 is inserted. Preferably, the opening of the connector cavity is flared to facilitate the insertion of the optical fiber 4. The base 2012 is used to connect with the connecting part 203. To ensure the stability of the light-inlet end 201 and the continuity of light guidance, the connector 2011 and the base 2012 are preferably integrally formed and connected. Furthermore, to prevent light leakage and reduce light loss, the base 2012 should smoothly transition to the connecting part 203.

[0070] To reduce the space occupied by the light-incident end 201 between the second surface 102 and the sheet metal of the ceiling frame 1, in this embodiment, the light-incident end 201 is positioned on the second surface 102 along its length, i.e., it is connected to the second surface 102 in a flat state, and the optical fiber 4 is inserted into the insertion cavity in a horizontal direction. In some embodiments, adhesive can also be injected between the optical fiber 4 and the insertion cavity to make the connection of the optical fiber 4 more secure.

[0071] The light-emitting end 202 is set perpendicular to the light-input end 201. The ceiling frame 1 is provided with a through hole along the vertical direction (thickness direction) that matches the outer diameter of the light-emitting end 202. The light-emitting end 202 is inserted into the through hole. The light-emitting end 202 and the base 2012 are connected by a connecting part 203. In order to facilitate processing and ensure the continuity of the light guide and reduce light loss, the base 2012, the connecting part 203 and the light-emitting end 202 are preferably integrally formed and connected.

[0072] The connecting portion 203 needs to have a predetermined length and be made of an elastic material, so that it can deform to a certain extent without affecting the orientation of the light-incident end 201. In this embodiment, the connecting portion 203 extends from the base 2012, is usually cylindrical, and has a smaller diameter than the base 2012 to support its deformation. The cross-sectional diameter of the connecting portion 203 is usually set to 0.5-2.0 mm, preferably 0.75-1.5 mm, and the length of the connecting portion 203 is set to 10-100 times its cross-sectional diameter. A suitable cross-sectional diameter of the connecting portion 203, combined with a suitable length, can support the elastic deformation of the connecting portion 203. In this embodiment, the length of the light-emitting end 202 needs to be greater than the thickness of the ceiling frame 1. The light-emitting end 202 is installed in the through hole of the ceiling frame 1, and one end of the light-emitting end 202 protrudes through the first surface 101 of the ceiling frame 1. Furthermore, the surface layer 3 is provided with a hole that matches the outer diameter of the light-emitting end 202. One end of the light-emitting end 202 passes through the hole and is slightly exposed in the surface layer 3, which makes the light emission effect better.

[0073] The portion of the light-emitting end 202 that exposes the surface finish layer 3 needs to be rounded off, which can be achieved through injection molding or shaping to prevent occupants from scratching it when they touch it.

[0074] The light guide mechanism 2 should be made of a material with good light transmission and a certain degree of elasticity to support the deformation of the connecting part 203. It is usually made of organic polymer material, preferably transparent plastic material, such as PMMA, PS, PET, PC, etc.

[0075] In this embodiment, since the light-emitting end 202 is exposed on the surface layer 3, the light emission effect is better and the light spot is clearer and brighter. At the same time, since the surface of the exposed light-emitting end 202 is smooth, the occupant will not be scratched when touching it with their hands, and the light-emitting end 202 can retract and automatically reset to prevent a sharp touch.

[0076] Example 3

[0077] See also Figure 1 or Figure 2 In this embodiment, the starry sky canopy also includes a fixing part 5, which is used to fix the light-incident end 201 to the second surface 102 of the canopy frame 1. Specifically, the fixing part 5 is connected to the bottom end of the insertion part 2011 and is configured with a pointed bottom end structure. The pointed bottom end structure allows the fixing part 5 to be inserted into the canopy frame 1, thus initially fixing the relative position of the light-incident end 201 and the canopy frame 1. At the same time, through the two-point cooperation of the fixing part 5 and the light-emitting end 202, the orientation of the light guiding mechanism 2 on the canopy frame 1 can be defined.

[0078] The number of fixing parts 5 is set to at least one, or can be set to multiple, to ensure sufficient connection stability.

[0079] In some embodiments, to ensure the stability of the connection between the fixing part 5 and the ceiling frame 1, a necking structure 501 is provided at the root of the fixing part 5, i.e., the connection position with the ceiling frame 1. This necking structure 501 is in a circumferentially retracted state. Since the second surface 102 of the ceiling frame 1 is also made of elastic material, after the fixing part 5 is inserted into the ceiling frame 1, the corresponding position of the second surface 102 of the ceiling frame 1 springs back and engages with the necking structure 501, making the fixing part 5 and the ceiling frame 1 tightly connected and preventing easy disengagement. Preferably, adhesive can also be injected between the fixing part 5 and the ceiling frame 1 to further enhance the strength of the connection between the fixing part 5 and the ceiling frame 1.

[0080] In some embodiments, to make the injection molding of the light guide mechanism 2 easier, the fixing part 5 can be detachably connected to the bottom end of the plug-in part 2011, such as by snap-fit ​​connection. The detachable connection method enables the light guide mechanism 2 to be assembled onto the ceiling frame 1 with a certain stress.

[0081] Comparative Example 1

[0082] See Figure 3 This comparative example discloses a starry sky ceiling. First, a ceiling frame 1 is fabricated. The first surface 101 of the ceiling frame 1 is laminated with a fabric 7 containing soft foam 6. The soft foam 6 gives the ceiling a soft touch, and the fabric 7 gives the ceiling a delicate appearance. The fabric 7 can be made of suede. Then, a transparent optical fiber mounting hole is drilled in the ceiling frame 1. The light-inlet end 201 of the optical fiber 4 is connected to the optical engine, and the light-outlet end 202 of the optical fiber 4 passes through the optical fiber mounting hole in the ceiling frame 1 and is exposed. The optical fiber 4 is pulled taut from the first surface 101 of the ceiling frame 1, and the excess optical fiber 4 remains on the first surface 101 of the ceiling frame 1. Glue is applied to the optical fiber mounting hole on the second surface 102 of the ceiling frame 1 to fix the optical fiber 4 to the ceiling frame 1. After the glue cures, the excess optical fiber 4 on the first surface 101 of the ceiling frame 1 is cut off, so that the light-outlet end 202 of the optical fiber 4 is flush with the surface of the suede fabric on the first surface 101 of the ceiling frame 1.

[0083] The adhesive used to secure the fiber optic cables at the mounting holes prevents the fiber optic cables 4 from retracting. Therefore, when pressure is applied to the first surface 101 of the ceiling frame 1, the suede fabric, containing the soft foam 6, will sink, while the fiber optic cables 4 will not retract. This results in the fiber optic cables 4 feeling prickly to the touch; the soft feel of the soft foam 6 is the root cause of this problem. Simultaneously, the damage to the suede fabric caused by the fiber optic mounting holes affects the appearance of the starry sky ceiling to some extent.

[0084] Comparative Example 2

[0085] See Figure 4This comparative example discloses a starry sky ceiling. First, a ceiling frame 1 is fabricated. The first surface 101 of the ceiling frame 1 is connected to a fabric 7, which is a single layer of suede (or a single layer of knitted fabric, which will not be described in detail later). Then, a transparent optical fiber mounting hole is drilled in the ceiling frame 1. The light-inlet end 201 of the optical fiber 4 is connected to the optical engine, and the light-outlet end 202 of the optical fiber 4 passes through the optical fiber mounting hole in the ceiling frame 1 and is exposed. The optical fiber 4 is pulled taut from the first surface 101 of the ceiling frame 1, and the excess optical fiber 4 remains on the first surface 101 of the ceiling frame 1. Glue is applied to the optical fiber mounting hole on the second surface 102 of the ceiling frame 1 to fix the optical fiber 4 to the ceiling frame 1. After the glue cures, the excess optical fiber 4 on the first surface 101 of the ceiling frame 1 is cut off, so that the light-outlet end 202 of the optical fiber 4 is flush with the surface of the suede fabric on the first surface 101 of the ceiling frame 1.

[0086] When the first surface 101 of the ceiling frame 1 is pressed, the single-layer suede fabric will not sink significantly due to the absence of soft foam 6. Although the optical fiber 4 is held in place by adhesive and will not shrink, the compression of the single-layer suede fabric is limited, so there is no issue of the optical fiber 4 being prickly to the touch. However, because the suede fabric is single-layered and lacks soft foam 6, it lacks a soft feel. At the same time, the damage to the suede fabric caused by the optical fiber mounting holes affects the appearance of the starry sky ceiling to some extent.

[0087] Comparative Example 3

[0088] See Figure 5 This comparative example discloses a starry sky ceiling. First, a ceiling frame 1 is fabricated. The first surface 101 of the ceiling frame 1 is made of a fabric 7 with soft foam 6, such as suede fabric with soft foam 6. The suede fabric has holes arranged in a pattern. These holes need to be set before being laminated to the ceiling frame 1, and are arranged in multiple neat groups. The hole diameter is set to be more than twice the diameter of the optical fiber 4. Then, optical fiber mounting holes are drilled at the positions where the light spot pattern is set on the ceiling frame 1, ensuring that the optical fiber mounting holes fall into the holes already existing on the suede fabric. The optical fiber 4 passes through the optical fiber mounting holes on the ceiling frame 1. On the second surface 102, the optical fiber 4 is connected to the optomechanical system. On the first surface 101, the optical fiber 4 protrudes from the holes on the surface of the suede fabric. Glue is applied to the point where the optical fiber 4 passes through the second surface 102 of the ceiling frame 1 to fix the optical fiber 4 to the second surface 102 of the ceiling frame 1. The optical fiber 4 on the first surface 101 of the ceiling frame 1 is trimmed flat, and the optical fiber 4 is trimmed so that it is slightly lower than the surface of the fabric.

[0089] Because the holes on the suede fabric are more than twice the diameter of optical fiber 4, optical fiber 4 is slightly lower than the surface of the suede fabric and still has a certain viewing angle.

[0090] Because the optical fiber 4 is held in place by the adhesive, it will not shrink back. Although the fabric 7 contains soft foam 6 which will cause some shrinkage, the end face of the optical fiber 4 is lower than the plane of the suede fabric, so the problem of the optical fiber 4 being prickly to the touch is greatly alleviated.

[0091] Because the suede fabric of the ceiling frame 1 has many holes, the damage caused by the perforation to the ceiling frame 1 is not visible from the first side 101. However, the number of holes on the suede fabric must be sufficient and the diameter must be large enough. The number of holes must be so large that all light spots can find suitable holes that already exist on the fabric 7. The diameter of the holes must be larger than the thickest optical fiber 4 used.

[0092] Because the holes in the suede fabric are relatively large, the optical fiber 4 can be trimmed slightly below the surface of the fabric 7. Therefore, when the optical fiber 4 is not lit, what you see are the holes that existed on the fabric 7 before the ceiling frame 1 was made. The light spots will only appear after the optical fiber 4 is lit.

[0093] Because the suede fabric has too many and too large holes, the fabric 7 has too little coverage of the skeleton, which easily leads to appearance defects.

[0094] In addition, the trimming length of the fiber optic cable 4 end face is difficult to control. If it is too long, it will still cause a problem of being pricked. If it is too short, it will be easily blocked by the fabric 7, resulting in a smaller side viewing angle.

[0095] Comparative Example 4

[0096] See Figure 6 This comparative example discloses a starry sky canopy. First, a canopy frame 1 is made, and through holes are drilled in the canopy frame 1 as optical fiber assembly holes. Then, a light-transmitting skin is attached to the first surface 101. The light-emitting end 202 of the optical fiber 4 is inserted into the optical fiber assembly hole on the canopy frame 1, and the light-emitting end 202 of the optical fiber 4 is fixed to the second surface 102 of the canopy frame 1. The light-incoming end 201 of the optical fiber 4 is bundled and connected to an optical engine.

[0097] By taking advantage of the light-transmitting property of the light-transmitting skin, the optical fiber 4 does not pass through the light-transmitting skin. In this comparative example, the surface of the light-transmitting skin is intact, which solves the problem of the optical fiber 4 being prickly to the touch.

[0098] Drilling holes for fiber optic mounting after the translucent outer layer has been laminated is risky as it easily damages the outer layer, and the resulting debris is difficult to clean. Drilling holes in the ceiling frame 1 before laminating the translucent outer layer avoids damage and makes cleaning easier if debris is generated. However, the fiber optic mounting holes after laminating the translucent outer layer become blind holes. While it's easy for fiber optic cable 4 to enter the mounting hole, achieving a tight seal with the translucent outer layer is difficult. Applying too much force will cause the translucent outer layer to bulge, and the force from fiber optic cable 4 is hard to maintain. During adhesive curing, it's difficult to maintain this force consistently; even when applying adhesive with this force, the force decreases or disappears after curing and the pressure is released.

[0099] The inconsistent contact between fiber 4 and the transparent skin affects the light spot effect. When the contact is tight, the light spot is a clear and bright spot corresponding to the diameter of fiber 4. When the fiber 4 and the transparent skin are not in tight contact, the light spot is a blurry spot with a larger diameter.

[0100] Regarding the starry sky ceiling provided in Embodiment 1, the present invention also discloses a method for manufacturing a starry sky ceiling, comprising the following steps:

[0101] Make the ceiling frame 1, and drill through holes along the thickness direction of the ceiling frame 1.

[0102] The first surface 101 of the ceiling frame 1 is a composite surface layer 3, which is a translucent skin;

[0103] A light guide mechanism 2 is installed on the second surface 102 of the ceiling frame 1. The light output end 202 of the light guide mechanism 2 is inserted into the through hole. The fixing part 5 is inserted into the ceiling frame 1 so that the insertion part 2011 of the light input end 201 lies flat on the second surface 102 of the ceiling frame 1.

[0104] Insert the optical fiber 4 dispersed by the optical fiber 4 bundler into the jacking cavity;

[0105] Inject adhesive into the insertion position of the insertion cavity and / or the fixing part 5.

[0106] In this invention, by taking advantage of the light-transmitting properties of the surface layer 3, the optical fiber 4 and the light guiding mechanism 2 do not need to pass through the surface layer 3, so the surface of the surface layer 3 is intact, fundamentally solving the problem of being prickly to the touch.

[0107] It is understandable that when the light spot size needs to be consistent, a light guide mechanism 2 with the same diameter of the light output end 202 can be used. When the light spot size needs to be inconsistent, the light spot size can be controlled by using a light guide mechanism 2 with a different diameter of the light output end 202, and the brightness of the light spot can be controlled by using a suitable optical fiber 4.

[0108] The illuminance on the optical engine is to be as uniform as possible. Using a larger diameter optical fiber 4 will result in more light flux, thus achieving greater brightness of the light spot. If a large and bright light spot is required, the output end 202 of the light guide mechanism 2 needs to have a larger diameter, and the input end 201 needs to have a larger inner diameter to accommodate two or more optical fibers 4, thereby achieving greater light flux with the limited diameter of the optical fiber 4.

[0109] The manufacturing method of the starry sky canopy will be further described in detail below with reference to embodiments. It should also be understood that the following embodiments are only used to further illustrate the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-essential improvements and adjustments made by those skilled in the art based on the above content of the present invention are within the scope of protection of the present invention.

[0110] Example 4

[0111] In this embodiment, the method for manufacturing the starry sky ceiling provided in Embodiment 1 includes the following steps:

[0112] Step 1: Make the ceiling frame 1 and drill through holes in the ceiling frame 1 along the thickness direction.

[0113] Step 2: Apply a composite finish layer 3 to the first surface 101 of the ceiling frame 1. This finish layer 3 is a translucent skin.

[0114] Step 3: Install the light guide mechanism 2 on the second surface 102 of the ceiling frame 1, insert the light-emitting end 202 of the light guide mechanism 2 into the through hole, insert the fixing part 5 into the ceiling frame 1, so that the insertion part 2011 of the light-inlet end 201 lies flat on the second surface 102 of the ceiling frame 1. At this time, the connecting part 203 undergoes a certain deformation, which can continuously maintain a slight pressure on the surface layer 3.

[0115] Step 4: Insert the optical fiber 4 dispersed by the optical fiber 4 bundler into the jacking cavity.

[0116] Step 5: Inject adhesive into the insertion position of the insertion cavity and the fixing part 5 to increase the strength of the connection and enable the fixing part 5 to withstand greater force.

[0117] After the fixing part 5 is inserted into the ceiling frame 1, the light guiding mechanism 2 is fixed to the second surface 102 of the ceiling frame 1. Before the adhesive is injected at the insertion position of the fixing part 5, the mechanical connection structure between the fixing part 5 and the ceiling frame 1 can maintain their relative position. After the adhesive is injected, it can withstand greater force. At the same time, because the connecting part 203 undergoes a certain deformation, it can maintain a slight pressure on the surface layer 3.

[0118] Example 5

[0119] In this embodiment, the method for manufacturing the starry sky ceiling provided in Embodiment 1 includes the following steps:

[0120] Step 1: Make the ceiling frame 1 and drill through holes in the ceiling frame 1 along the thickness direction.

[0121] Step 2: Install the light guide mechanism 2 on the second side 102 of the ceiling frame 1, insert the light-emitting end 202 of the light guide mechanism 2 into the through hole and expose it from the first side 101 of the ceiling frame 1, insert the fixing part 5 into the ceiling frame 1, and the insertion part 2011 of the light-inlet end 201 lies flat on the second side 102 of the ceiling frame 1. At this time, the connecting part 203 hardly deforms.

[0122] Step 3: Inject adhesive into the insertion position of the fixing part 5 to firmly connect the light guide mechanism 2 to the ceiling frame 1;

[0123] Step 4: Apply a composite finish layer 3 to the first surface 101 of the ceiling frame 1. This finish layer 3 is a translucent skin.

[0124] Step 5: Insert the optical fiber 4 dispersed by the optical fiber 4 bundler into the jacking cavity;

[0125] Step six: Inject adhesive into the jacking cavity to increase the strength of the fiber optic 4 connection.

[0126] The manufacturing method of the starry sky ceiling disclosed in this embodiment sets the installation process of the light guide mechanism 2 before the surface layer 3 is laminated, which avoids the problem that the through hole becomes a blind hole after the light-transmitting skin is laminated, which is not conducive to the installation of the light guide mechanism 2. The light-emitting end 202 of the light guide mechanism 2 is compressed from the state of protruding from the first surface 101 to the state of being flush with the first surface 101.

[0127] However, when the ceiling frame 1 equipped with the light guide mechanism 2 is laminated with the translucent skin, the design of the composite mold presents difficulties. Therefore, it is necessary to ensure that the position and orientation of the light guide mechanism 2 are completely determined, and then reserve a clearance recess for the light guide mechanism 2 on the back layer of the composite mold in advance, so that the ceiling frame 1 can still be laminated with the translucent skin through the mold.

[0128] In a scheme that uses optical fiber 4 directly without light guide mechanism 2, the operation of first installing the light guide element and then laminating the translucent skin is almost impossible to implement because optical fiber 4 is too long, its direction is uncertain, and it is very difficult to avoid obstacles. Using light guide mechanism 2, the size of the light guide element 102 on the second surface of the ceiling frame 1 is greatly reduced when laminating the translucent skin. Thanks to the position of the fixing part 5 and the through hole, the direction of light guide mechanism 2 is also determined. Therefore, it is feasible to set avoidance recesses on the mold.

[0129] This perfectly defined position is determined by the design of the molding die. The molding die is designed with markings for the positions of the through holes forming the light spots and the fixing points corresponding to the pointed structures of the fixing part 5. This ensures accurate positioning and consistent orientation during the installation of the light-emitting end 202 and the fixing part 5. In areas with dense light spots, the correspondence between the light spot positions and the fixing point positions must be clearly defined to avoid confusion. Therefore, the molding die includes protrusions for forming the light spot positions, protrusions for forming the fixing point positions, and a connecting line indicating their correspondence, clearly distinguishing these two protrusions. One approach is to place the protrusion for the light spot positions at the end of the connecting line, while the fixing point position is not at the end of the connecting line, but rather an extension line beyond the fixing point. This connecting line can be a recess corresponding to the light guide mechanism 2, which will also serve as the mounting position for the light guide mechanism 2.

[0130] On the composite mold, it is necessary to set the avoidance recess of the light guide mechanism 2. The recess here corresponds to the forming mold and is deeper and larger.

[0131] The connecting part 203 of the light guide mechanism 2 ensures tight contact between the light-emitting end 202 and the light-transmitting skin. After assembly, adhesive can be applied at the position where the light-emitting end 202 is inserted into the through hole. At this time, the two are no longer elastically connected, but fixedly connected. Because the adhesive used to fix the optical fiber 4 requires a long curing time, the connecting part 203 plays a role during this time to ensure tight contact between the light-emitting end 202 and the light-transmitting skin.

[0132] Example 6

[0133] Regarding the starry sky ceiling provided in Embodiment 2, this invention discloses a method for manufacturing the starry sky ceiling, comprising the following steps:

[0134] Step 1: Construct the ceiling frame 1;

[0135] Step 2: Apply composite finishing layer 3 to the first surface 101 of the ceiling frame 1. This finishing layer 3 can be made of ordinary, opaque finishing material.

[0136] Step 3: Drill through holes along the thickness direction of the ceiling frame 1 at the locations where light is required. These through holes extend to the surface layer 3. Install a light guide mechanism 2 on the second surface 102 of the ceiling frame 1. Insert the light-emitting end 202 of the light guide mechanism 2 into the through hole, and make the light-emitting end 202 slightly protrude from the surface layer 3. Insert the fixing part 5 into the ceiling frame 1, so that the insertion part 2011 of the light-inlet end 201 lies flat on the second surface 102 of the ceiling frame 1.

[0137] Step 4: Insert the optical fiber 4 dispersed by the optical fiber 4 bundler into the jacking cavity;

[0138] Step 5: Inject adhesive into the insertion position of the insertion cavity and the fixing part 5.

[0139] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A starry sky ceiling, characterized in that, include: The light guiding mechanism (2) includes an input end (201), a connecting part (203), and an output end (202). The input end (201) includes a plug-in part (2011) which has a plug-in cavity for inserting an optical fiber (4). The output end (202) is perpendicular to the input end (201). The connecting part (203) connects the input end (201) and the output end (202). The length of the connecting part (203) is set to 10-100 times the cross-sectional diameter of the connecting part (203). The connecting part (203) is made of an elastic material. A ceiling frame (1) includes a first surface (101) and a second surface (102). The light-incident end (201) is connected to the second surface (102). The ceiling frame (1) has a through hole along the thickness direction. The light-emitting end (202) is inserted into the through hole. A finishing layer (3) is attached to the first surface (101); The length of the light-emitting end (202) is greater than the thickness of the ceiling frame (1) of the starry sky ceiling, so that the light-emitting end (202) extends from the bottom surface of the ceiling frame (1) in a free state.

2. The starry sky canopy according to claim 1, characterized in that, The cross-sectional diameter of the connecting part (203) is set to 0.5-2.0 mm.

3. The starry sky canopy according to claim 1, characterized in that, The light guide mechanism (2) also includes a fixing part (5) connected to the plug-in part (2011), and the fixing part (5) is configured with a pointed bottom end structure.

4. The light guiding mechanism (2) according to claim 3, characterized in that, The number of the fixing part (5) is set to at least one.

5. The light guiding mechanism (2) according to claim 3, characterized in that, The root of the fixing part (5) is provided as a necking structure (501).

6. The starry sky canopy according to claim 1, characterized in that, The surface layer (3) is a translucent skin.

7. The starry sky canopy according to claim 1, characterized in that, The surface layer (3) has a hole that matches the outer diameter of the light-emitting end (202). The light-emitting end (202) passes through the hole and exposes the surface layer (3). The portion of the light-emitting end (202) exposed in the surface layer (3) is rounded.

8. A method for manufacturing a starry sky ceiling as described in claim 6, characterized in that, Includes the following steps: Make a ceiling frame (1) and drill through holes along the thickness direction of the ceiling frame (1); The first surface (101) of the ceiling frame (1) is composite with a surface finish (3), and the surface finish (3) is a translucent skin; A light guide mechanism (2) is installed on the second side (102) of the ceiling frame (1), the light-emitting end (202) of the light guide mechanism (2) is inserted into the through hole, and the fixing part (5) is inserted into the ceiling frame (1); Insert the optical fiber (4) of the optical engine into the light input end (201) of the light guiding mechanism (2).

9. The method for manufacturing a starry sky canopy according to claim 8, characterized in that, Includes the following steps: Step 1: Make the ceiling frame (1) and drill through holes along the thickness direction of the ceiling frame (1). Step 2: A composite surface layer (3) is applied to the first surface (101) of the ceiling frame (1), wherein the surface layer (3) is a translucent skin; Step 3: Install a light guide mechanism (2) on the second side (102) of the ceiling frame (1), insert the light-emitting end (202) of the light guide mechanism (2) into the through hole, and insert the fixing part (5) into the ceiling frame (1); Step 4: Insert the optical fiber (4) of the optical engine into the light input end (201) of the light guiding mechanism (2).

10. The method for manufacturing a starry sky canopy according to claim 8, characterized in that, Includes the following steps: Step 1: Make the ceiling frame (1) and drill through holes along the thickness direction of the ceiling frame (1). Step 2: Install a light guide mechanism (2) on the second side (102) of the ceiling frame (1), insert the light-emitting end (202) of the light guide mechanism (2) into the through hole and expose it from the first side (101) of the ceiling frame (1), and insert the fixing part (5) into the ceiling frame (1); Step 3: A composite surface layer (3) is applied to the first surface (101) of the ceiling frame (1), wherein the surface layer (3) is a translucent skin; Step 4: Insert the optical fiber (4) of the optical engine into the light input end (201) of the light guiding mechanism (2).

11. A method for manufacturing a starry sky ceiling as described in claim 7, characterized in that, Includes the following steps: Constructing the roof frame (1); A composite surface finish (3) is applied to the first surface (101) of the ceiling frame (1); Along the thickness direction of the ceiling frame (1), through holes are drilled where light needs to be emitted. The through holes extend to the surface layer (3). A light guide mechanism (2) is installed on the second side (102) of the ceiling frame (1). The light-emitting end (202) of the light guide mechanism (2) is inserted into the through hole. The fixing part (5) is inserted into the ceiling frame (1). Insert the optical fiber (4) of the optical engine into the light input end (201) of the light guiding mechanism (2).

Images