Heat dissipation for light bar assembly of steering wheel

Abstract

A lightbar assembly (100) configured to be mounted at a rim of a steering wheel (100) of a vehicle is disclosed. The lightbar assembly (100) can include components of a driver monitoring system. The lightbar assembly includes a PCB strip (139) having a plurality of visible light LEDs and infrared LEDs (172, 173) and LED drivers (131). The PCB strip (139) is coupled to a support plate (127) of a housing (120) that surrounds the PCB strip. The support plate (127) transfers heat generated by the LEDs and LED (172, 173) drivers away from the PCB strip (139).

Description

Technical Field

[0001] This disclosure relates generally to the field of steering wheels. More specifically, this disclosure relates to heat dissipation of light bar assemblies for steering wheels, and in some embodiments to heat dissipation of light bar assemblies for driver monitoring systems mounted on steering wheels. Background Technology

[0002] The steering wheel is a major component of a vehicle. Positioned in front of the driver (or operator occupant) for easy and clear access, the steering wheel has historically been quite simple and clean, its single purpose being to allow the driver to guide the vehicle, although recently the number of buttons and switches on the steering wheel for providing driver input to vehicle systems has increased. Even recently, the steering wheel has been identified as a close and prominent feature for monitoring the driver and / or communicating with the driver. For example, illuminated and tactile features can provide information and / or feedback to the driver from the vehicle. The steering wheel can also be well-positioned for mounting sensors and monitoring devices to monitor the driver.

[0003] A driver monitoring system (DMS) mounted on the steering wheel monitors the driver while the vehicle is in motion. The DMS can detect signs of driver distraction, drowsiness, etc., which could lead to vehicle accidents, resulting in injury or death to the vehicle's occupants. The DMS can detect the direction of the driver's head and / or eyes as signs of distraction and drowsiness. Additionally, the DMS can detect blinking frequency as a sign of distraction and drowsiness. The DMS can also monitor the driver when the vehicle's autonomous or semi-autonomous control system is activated. The DMS can provide visual, auditory, and / or physical alerts, warnings, or automatically deactivate the semi-autonomous control system if driver distraction or drowsiness is detected. Some steering wheel-mounted DMS systems have one or more drawbacks or may perform poorly in one or more aspects. Certain embodiments disclosed herein address one or more of these problems. Attached Figure Description

[0004] Embodiments of the invention will become more apparent from the following description taken in conjunction with the accompanying drawings and the appended claims. It should be understood that the drawings depict only typical embodiments and are therefore not intended to limit the scope of this disclosure; the embodiments will be described and illustrated in detail with reference to the drawings.

[0005] Figure 1 This is a front view of a light bar assembly installed on a steering wheel according to one embodiment of the present disclosure.

[0006] Figure 2 yes Figure 1 The front view of the light strip component.

[0007] Figure 3 yes Figure 1 An exploded view of some components of the light strip assembly.

[0008] Figure 4 yes Figure 1 A perspective view of the housing of the light strip assembly.

[0009] Figure 5 yes Figure 1 A cross-sectional view of the light strip assembly. Detailed Implementation

[0010] It is readily understood that the components of the embodiments generally described and illustrated in the accompanying drawings can be arranged and designed in a variety of different configurations. Therefore, as shown in the drawings, the following more detailed description of various embodiments is not intended to limit the scope of this disclosure protected by the claims, but merely represents various embodiments. Although various aspects of the embodiments are presented in the drawings, they are not necessarily drawn to scale unless specifically indicated.

[0011] The steering wheel is a primary component of a vehicle, positioned in front of the driver for easy access to operate the vehicle and, more specifically, to control its direction. While typically simple, its sole purpose is to provide the driver with a means of guiding the vehicle, although recently buttons and switches have begun to appear on steering wheels to provide driver input to the vehicle (e.g., to audio or video systems, cruise control, Bluetooth-connected phones or other devices, and the vehicle's dashboard display). Even recently, the steering wheel has been identified and used as a crucial and prominent feature for signaling to the driver or otherwise communicating with the driver, as well as for monitoring the driver. For example, lighting and tactile features have been combined to provide information and / or feedback from the vehicle to the driver. The steering wheel can also be well-positioned for mounting sensors and monitoring devices to monitor the driver.

[0012] Driver monitoring systems (DMS) are used to reduce or minimize vehicle accidents caused by drowsy or distracted driving. DMS are installed in various locations within a vehicle, including but not limited to the steering wheel, instrument panel, and / or dashboard, or overhead. In the following disclosure, "DMS" generally refers to a driver monitoring system typically mounted to the steering wheel, although the principles discussed may apply to other types of driver monitoring systems installed in other locations within a vehicle. A DMS may include a light bar assembly. Alternatively or additionally, the light bar assembly may include components of the DMS.

[0013] As used herein, the terms “dashboard” and “instrument panel” refer to the prominent area of ​​a motor vehicle that is in front of the occupants, which typically includes a glove box in its passenger-facing portion and may include instruments (e.g., a radio and / or climate controls) in its more central area, although such instruments are not required to be present.

[0014] The phrase “connected to” is broad enough to refer to any suitable connection or other form of interaction between two or more entities, including mechanical, fluid, and thermal interactions. Thus, two components can be connected to each other even if they are not in direct contact. The phrase “attached to” or “directly attached to” refers to an interaction between two or more entities that are in direct contact with each other and / or separated only by any suitable kind of fastener (e.g., mounting hardware or adhesive).

[0015] The disclosed light bar assembly typically uses a housing with two mating shells mounted to a portion of the steering wheel rim. A cover or covering covers the outer surface of the shell. A lens is positioned within a slit between the two portions of the cover, such that the lens abuts the cover to prevent light leakage between the lens and the cover. The light bar assembly facilitates illumination of the driver's face with infrared (IR) light from an IR light-emitting diode (LED), allowing a camera to detect the driver's face and eyes. The light bar assembly can also transmit visible light from a visible LED to provide an indication of the DMS status.

[0016] In other embodiments, the light bar assembly may be integrated into the rim of the steering wheel to provide feedback and / or convey information to the driver of the vehicle. The light bar assembly may emit light colors and / or patterns to display or convey status and / or other information about the vehicle and / or its surroundings.

[0017] Figures 1 to 5 Different views of light strip assemblies and related components according to various embodiments of this disclosure are shown. In some views, each device may be coupled to an additional component not included in each view, or shown as having that additional component. Furthermore, in some views, only selected components are shown to provide detail of the component relationships. Some components may be shown in multiple views, but are not discussed in conjunction with each view. The disclosure provided in conjunction with any of the accompanying drawings relates to and applies to the disclosure provided in conjunction with any other accompanying drawings or embodiments.

[0018] Figures 1 to 5 A light strip assembly 100 according to one embodiment of the present disclosure is depicted. Figure 1 This is a front view of a light bar assembly 100 installed on a steering wheel 190 according to one embodiment of the present disclosure. Figure 2 yes Figure 1 Front view of the light strip assembly 100. Figure 3 yes Figure 1 Exploded view of certain components of the light strip assembly 100. Figure 4 yes Figure 1 A cross-sectional view of the light strip assembly 100. Figure 5 yes Figure 1A perspective view of the housing of the light strip assembly 100.

[0019] exist Figure 1 In the illustrated embodiment, the light bar assembly 100 is coupled to the steering wheel 190 such that the light bar assembly 100 partially forms part of the steering wheel 190. The light bar assembly 100 is mounted to the upper portion of the steering wheel 190. In other embodiments, the light bar assembly 100 may be positioned at any suitable location on the steering wheel 190. For example, the light bar assembly 100 may be positioned on a side portion 193 or a bottom portion 194 of the steering wheel 190. In another embodiment, the light bar assembly 100 may define the entire circumference of the steering wheel 190.

[0020] like Figure 2 As depicted, the light strip assembly 100 may include a body 101, a first or inner housing 110, a second or outer housing 120, a printed circuit board (PCB) assembly 130, a lens 134, a cover or enclosure 140, a padding member 160, a visible light LED harness 170, and an IR LED harness 171. The body 101 is... Figure 2 The diagram shows a steering wheel with an elongated, arcuate shape extending between tuck grooves 103. The arcuate shape may include an arc length of approximately 20 mm to approximately 300 mm. In some embodiments, the body 101 may have any suitable elongated shape, such as a straight shape, an angled shape, etc., to accommodate a steering wheel having a D-shape, a rectangle, a yoke, etc. Figure 2 As shown, lens 134 includes an elongated, arched shape similar to that of body 101. Lens 134 is disposed within light bar assembly 100 such that it is directed toward the driver of the vehicle.

[0021] Package 140 Figure 2 The package is depicted as covering the body 101 between the side portions 193 of the steering wheel 190, except where the lens 134 is located within the light bar assembly 100. In some embodiments, the package is adhered or attached to the outer surfaces of the inner shell member 110 and the outer shell member 120. The package 140 may be rolled into a roll-in recess 103 adjacent to each end of the body 101. The roll-in recess 103 may conceal the ends of the package 140 to create an aesthetically pleasing appearance and prevent the ends from getting caught in the driver's hands as the steering wheel 190 is turned. The package 140 may include a single strip, two strips, three strips, or more strips, as will be discussed below. Figure 2 The package 140 of the illustrated embodiment may include leather material. In other embodiments, the package 140 may be formed of any suitable invisible light-transmitting material, such as natural leather, vinyl, synthetic leather, microfiber synthetic leather, polystyrene, etc.

[0022] like Figure 2 As shown, the visible light LED harness 170 and the IR LED harness 171 are shown extending from the end of the body 101. Within the body 101, the visible light LED harness 170 and the infrared (IR) LED harness 171 are connected to the PCB assembly 130. Figure 3 (As shown in the diagram). Externally to the body 101, visible light LED harness 170 and IR LED harness 171 enter the steering wheel 190 and are connected to a processor (not shown), which is located remotely from the PCB assembly 130 and connected to the electronic control unit (ECU). The processor can be configured to control the activation of the visible light LED 172 and IR LED 173 connected to the PCB assembly 130. For example, the processor can receive data from the ECU and transmit signals to the visible light LED 172 to illuminate a desired color. The processor can also receive data from the ECU and transmit signals to the IR LED to illuminate the driver's face. The processor is located remotely from the PCB assembly to reduce heat generated by the PCB assembly.

[0023] Figure 3 This is an exploded view of certain components of the light bar assembly 100, depicting an inner housing 110 disposed at the inner circumference of the body 101 and an outer housing 120 disposed at the outer circumference of the body 101. When assembled, the inner housing 110 and outer housing 120 may surround a portion of the rim 191 of the armature 192 of the steering wheel 190 and may be mounted to the rim 191. In some embodiments, the light bar assembly 100 is configured to be coupled at each end of the light bar assembly 100 to the armature 192 of the steering wheel 190 to fill a gap in the rim 191 of the steering wheel 190. The inner housing 110 and outer housing 120 may be joined together using any suitable technique to define a support structure for the light bar assembly 100 and at least partially define a portion of the outer circumference of the steering wheel 190. For example, the inner housing 110 and outer housing 120 may be joined using fasteners, thermal welding, ultrasonic welding, vibration welding, thermal riveting, bonding, etc. Figure 3 In the illustrated embodiment, the inner shell 110 and the outer shell 120 may be connected or attached by fasteners 115 (e.g., screws). The inner shell 110 and the outer shell 120 may be formed of any suitable material, such as polycarbonate, acrylonitrile-butadiene-styrene (ABS), polyamide, polyethylene terephthalate, aluminum, magnesium, PC / ABS, polybutylene terephthalate, etc.

[0024] The inner shell 110 may include an elongated arcuate shape and a semi-circular cross-sectional shape. The inner shell 110 may include a slot edge 111 and an adjacent edge 117 disposed opposite to the slot edge 111. The outer shell 120 may include an elongated arcuate shape and a semi-circular cross-sectional shape, such as... Figure 4 As shown. The housing 120 may include a slot edge 121 and an adjacent edge 126 disposed opposite to the slot edge 121. During assembly, as... Figure 4 As shown, the slot edge 111 of the inner housing 110 can be configured to align with the slot edge 121 of the outer housing 120, and can define a slot 104 disposed between the slot edges 111 and 121. The slot 104 can be disposed on the rear-facing surface of the light bar assembly 100. The width of the slot 104 can range from about 2 mm to about half the circumference of the body 101. In addition, during assembly, the adjacent edges 117 and 126 can be configured such that they are adjacent to or in contact with each other.

[0025] PCB assembly 130 may be at least partially disposed within the assembled inner housing 110 and outer housing 120, and may extend along the length of the inner housing 110 and outer housing 120. PCB assembly 130 may include: a PCB strip 139; an LED driver 131 mounted to the PCB strip 139 and configured to drive visible light LEDs 172 and / or IR LEDs 173 mounted to the PCB strip 139; a light guide 132; a diffuser or intermediate lens 133; a lens 134; and a housing 136. PCB strip 139 may have a precise shape consistent with the shape of housing 110. In other words, the LEDs are not disposed within slot 104. LED driver 131 may be any suitable automotive-grade multichannel LED driver. For example, LED driver 131 may be a Texas Instruments TPS929120 12-channel 40-V high-side LED driver or any other suitable LED driver.

[0026] The visible light LED 172 can be of any suitable type. For example, the visible light LED 172 may include an RGB chip configured to emit red (625nm), green (528nm), and blue (465nm) light. The tunable RGB chip allows the visible light LED 172 to emit one or more of a variety of colors by mixing red, green, and blue light. The number of visible light LEDs 172 can range from two to sixteen or more.

[0027] The IR LED 173 can be configured to emit IR light in the range of approximately 800 nm to approximately 2500 nm, and may be approximately 940 nm. Other suitable wavelengths can be used. The number of IR LEDs 173 can range from two to six or more. The IR LEDs 173 can be positioned at opposite ends of the PCB strip 139, spaced approximately 20 mm to 300 mm apart. In addition to generating visible and IR light, the visible LEDs 172 and IR LEDs 173 can also generate heat. If heat is retained by the visible LEDs 172 and IR LEDs 173, the heat may cause changes in the illumination properties of the visible LEDs 172 and IR LEDs 173. For example, elevated ambient temperature may reduce the illumination output from the visible LEDs 172 and IR LEDs 173. Additionally, elevated ambient temperature may reduce the lifespan of the visible LEDs 172 and IR LEDs 173.

[0028] PCB strip 139 can be thermally connected to and supported by PCB support plate 127, such as... Figure 3 As shown. The PCB support plate 127 provides multiple functions, such as supporting the PCB strip 139 and dissipating heat generated by the PCB strip 139. The PCB support plate 127 may include multiple recesses to form spaces for various components of the PCB strip 139. In the illustrated embodiment, the PCB support plate 127 includes recesses 127A at opposite ends of the PCB support plate 127. Recesses 127A allow plugs 170A and 171A for the visible light LED harness 170 and the IR LED harness 171 to protrude through the PCB support plate 127. Therefore, when supported by the PCB support plate 127, the visible light LED harness 170 and the IR LED harness 171 can be inserted into the PCB board 139.

[0029] The PCB support plate 127 may also include another recess 127B. In the illustrated embodiment, the recess 127B is located near the center of the PCB support plate 127. The recess 127B allows the LED driver 131 to protrude through the support plate 127.

[0030] Figure 4A detailed view of the housing 120, including a PCB support plate 127 supporting the PCB strip 139, is depicted. The PCB support plate 127 dissipates heat generated by the visible light LEDs 172 and IR LEDs 173, allowing the visible light LEDs 172 and IR LEDs 173 to be maintained at a relatively constant operating temperature. The PCB strip 139 may be coupled to or thermally coupled to the PCB support plate 127. In other words, the support plate 127 may act as a heat sink configured to transfer heat away from the visible light LEDs 172 and IR LEDs 173 to the housing 120 and dissipate it to the external environment. In other embodiments, the support plate 127 may be associated with an inner housing 110 (not shown).

[0031] like Figure 4 As shown, the support plate 127 extends radially inward from the inner surface 129 of the housing 120 and includes an elongated arcuate shape. The PCB strip 139 may be thermally bonded to the support plate 127 or otherwise disposed on the support plate, such that heat generated by the visible light LEDs 172 and IR LEDs 173 is transferred to the support plate 127 and dissipated throughout the light strip assembly 100 and / or dissipated to the external environment. The PCB support plate 127 may be shaped to correspond to the PCB strip 139 and may extend co-linearly with the length of the PCB strip 139. In some embodiments, the PCB strip 139 and the PCB support plate 127 include an arcuate shape. Figure 4 In the depicted embodiments, the support plate 127 may be formed as an integral part of the housing 120 using an injection molding method. In other embodiments, the support plate 127 may be formed as a separate part and attached to or attached to the housing 120 using any suitable technique, such as bonding, welding, friction fitting, snap-fit, etc.

[0032] In some embodiments, the support plate 127 is formed of the same material as the housing 120. In some embodiments, the support plate 127 and the housing 120 may be integral, and in other embodiments, the support plate 127 may be coupled to the housing 120. In other embodiments, the support plate 127 is formed of a material with high thermal conductivity. For example, the support plate 127 may be formed of aluminum, copper, etc. In some embodiments, a thermal pad, grease, or paste 128 may be disposed between the PCB strip 139 and the support plate 127 to facilitate heat transfer. The thermal pad 128 may be formed of any suitable material with high thermal conductivity (such as aluminum, copper, siloxane elastomers, non-siloxane elastomers, etc.). The thermal paste or grease 128 may be formed of any suitable material with high thermal conductivity (such as epoxy resin, siloxane, polyurethane, acrylate, etc., filled with alumina, boron nitride, zinc oxide, aluminum nitride, siloxane, etc.).

[0033] In some embodiments, the light strip assembly 100 may include multiple support plates. For example, as discussed above, the housing 120 may include a first PCB support plate 127 extending radially inward from the inner surface of the housing 120 and configured to support the PCB strip 139 and dissipate heat generated by the visible light LEDs 172 and IR LEDs 173, such that the visible light LEDs 172 and IR LEDs 173 can be maintained at a relatively constant operating temperature. The inner housing 110 may include a second PCB support plate extending radially inward from the inner surface of the inner housing 110. The second PCB support plate may be configured to support the PCB strip 139 and dissipate heat generated by the visible light LEDs 172 and IR LEDs 173, such that the visible light LEDs 172 and IR LEDs 173 can be maintained at a relatively constant operating temperature. In other words, both the first PCB support plate 127 and the second PCB support plate may support the PCB strip 139, absorb heat from the PCB strip 139, and dissipate heat. The first and second support plates sandwich the PCB strip 139 in the middle, wherein one of the support plates extends co-existing with the PCB strip 139, and the other support plate sandwiches the PCB strip 139 in a position where the visible light LED 172 and IR LED 173 are not located. Both the first and second support plates can be stacked (or overlapped) or adjacent (edge-to-edge, where each support plate is adjacent to a portion of the PCB strip 139) on the same side of the PCB strip 139. In these embodiments, the heat generated by the visible light LED 172 and IR LED 173 can be transferred away from the LEDs 172 and 173 to the inner housing 110 and outer housing 120 for dissipation to the external environment. In this way, the heat generated by the LEDs 172 and 173 is dissipated on a surface area twice the size of the surface area of ​​an embodiment having a single support plate 127 connected to the outer housing 120 (e.g., the surface area of ​​the inner housing 110 and outer housing 120). The second PCB support plate may be formed of a material similar to the first PCB support plate 127, and may also include thermal pads, grease or paste that may be disposed between the PCB strip 139 and the support plate 127 to facilitate heat transfer.

[0034] Figure 5 A cross-sectional view of the light strip assembly 100 is shown. The cross-sectional view of the light strip assembly 100 provides background on how the light strip assembly 100 is assembled. The light guide 132 may have, for example... Figure 3 The slender, arched shape shown and such Figure 5The rectangular cross-sectional shape is shown. The light guide 132 may be disposed adjacent to the visible light LED 172 to guide the visible and IR light emitted by the visible light LED 172 and the IR LED 173 toward the diffuser 133. The light guide 132 may be formed of any suitable transparent material. For example, the light guide 132 may be formed of poly(methyl methacrylate) (PMMA), polycarbonate, glass, etc. The refractive index of the light guide 132 may be in the range of about 1.4 to about 1.6, and may be about 1.492.

[0035] A diffuser 133 can be disposed between the light guide 132 and the lens 134. The diffuser can have, for example, Figure 3 The slender, arched shape shown and such Figure 5 The square cross-sectional shape is shown. The light diffuser 133 can be configured to uniformly distribute or diffuse visible and / or IR light received from the light guide 132 before it is transmitted to the lens 134. The diffuser 133 can be formed of any suitable transparent material, such as PMMA, polycarbonate, polyamide, etc. The diffuser 133 can be textured on its top and / or bottom surfaces to promote uniform light diffusion along the length of the diffuser 133. The texture can be any suitable level to promote uniform light diffusion. In other embodiments, the top surface of the diffuser 133 can be configured as a Fresnel lens with curved and inclined surfaces.

[0036] Lens 134 may be disposed adjacent to diffuser 133 and may include, for example, Figure 3 The depicted shape is an elongated, arched form. Lens 134 can be configured to receive diffused light from diffuser 133 and transmit the light toward the driver of the vehicle, such that visible light is noticeable to the driver and IR light illuminates the driver's face. Lens 134 can be formed of PMMA, polycarbonate, or any other suitable material. The refractive index of lens 134 can be in the range of about 1.4 to about 1.6, and can be about 1.586. Figure 5 As shown, the cross-sectional profile of lens 134 may include a mushroom shape having a head portion 138, the width of which is greater than the width of the stem portion 153. The width of the head portion 138 may range from about 2 mm to about half the circumference of the body 101. In other embodiments, lens 134 may be any suitable shape, such as dome-shaped, polygonal, etc. The head portion 138 may be covered with a film 152 to provide a scratch-resistant and chemically resistant surface for lens 134. In some embodiments, film 152 is formed from a polycarbonate substrate having a UV-curable hard coating. In other embodiments, film 152 may include a sprayed or dip-coated hard coating. The bottom surface of lens 134 may be textured in a manner similar to the textured surface of diffuser 133.

[0037] like Figure 2 and Figure 3 As depicted, lens 134 may include a visible light transmission portion 155 and an IR light transmission portion 156. Figure 2 and Figure 3 In the depicted embodiment, lens 134 has two IR light transmitting portions 156 disposed at either end of lens 134. A visible light transmitting portion 155 is disposed between the IR light transmitting portions 156. In other embodiments, lens 134 may include more than two IR light transmitting portions 156 disposed at different locations along the length of lens 134. For example, lens 134 may include three IR light transmitting portions 156, with two IR light transmitting portions 156 disposed at either end of lens 134 and a third IR light transmitting portion 156 disposed approximately at the middle of the length of lens 134. The distance between two IR light transmitting portions 156 may be in the range of about 20 mm to about 300 mm. Visible light transmitting portions 155 may be disposed above visible light LED 172 such that visible light is transmitted through visible light transmitting portions 155. IR light transmitting portions 156 of lens 134 may be disposed above IR LED 173 such that IR light is transmitted through IR light transmitting portions 156.

[0038] The IR transmission portion 156 may be opaque, making it transmissive to visible light. In other words, the IR transmission portion 156 may transmit IR light but not visible light. The IR transmission portion 156 may create a dead front effect of the lens 134, where the visible light transmission portion 155 may be illuminated by the visible light LED 172, and the IR transmission portion 156 may not be illuminated by the visible light LED 172. In other words, the visible light transmission portion 155 may appear illuminated, while the IR transmission portion may appear dark or unilluminated. The IR transmission portion 156 may include a material that absorbs or blocks visible light from being transmitted from the IR transmission portion 156 of the lens 134. This material may be any suitable material, such as COVESTRO PC AX 2675ST978001. In some embodiments, the material may be dispersed as a filler throughout the IR transmission portion 156. In other embodiments, the material may be a film covering at least one surface of the IR transmission portion 156.

[0039] The IR-transmitting portion 156 can be joined to the visible light-transmitting portion 155 using any suitable technique. For example, in one embodiment, the light-transmitting portion 155 is injection molded as a first injection molding and the IR-transmitting portion 156 is injection molded as a second injection molding to form a continuous or integral lens 134. In another embodiment, the light-transmitting portion 155 and the IR-transmitting portion 156 can be injection molded separately and then joined together using any suitable technique (such as welding, thermal bonding, adhesion, etc.).

[0040] The lens housing 136 can be attached to the PCB strip 139. The lens housing 136 can be formed of any suitable material that transmits IR light but does not transmit visible light. Figure 5 The rod portion 153 of the lens 134 is shown to be disposed within the lens housing 136, such that it holds the rod portion 153 and the head portion 138 extends beyond the lens housing 136. The diffuser 133, the light guide 132, the visible light LED 172, and the IRLED 173 are disposed within the lens housing 136.

[0041] The light strip assembly 100 can be arranged around the rim 191, such as Figure 5 As shown, the inner shell 110 and the outer shell 120 are joined together such that they surround the rim 191. The inner shell 110 and the outer shell 120 can be joined together using any suitable technique, such as fastening, thermal welding, ultrasonic welding, vibration welding, thermal riveting, bonding, etc. For example, Figure 5 The depicted embodiment shows an inner housing 110 and an outer housing 120 joined together using fasteners 115 (e.g., screws). The head of the screw 115 is disposed in a screw receiver 125 of the outer housing 120, and the threads of the screw 115 are screwed into a thread receiver 116 of the inner housing 110.

[0042] exist Figure 5In one embodiment, the first elongated strip 141 of the wrap 140 includes a first edge portion 144. The first edge portion 144 wraps around the slot edge 111 and is disposed or rolled into the slot 104. The second elongated strip 142 includes a second edge portion 145, which wraps around the slot edge 121 and is disposed or rolled into the slot 104. The first edge portion 144 and the second edge portion 145 define a slit 105 disposed between the first edge portion 144 and the second edge portion 145. The width of the slit 105 may range from about 0.5 mm to about half the circumference of the body 101. The thickness of the first edge portion 144 and the second edge portion 145 may range from about 0.7 mm to about 1.5 mm. In some embodiments, the second elongated strip 142 may be an integral part of the wrap 154 ​​for wrapping the steering wheel 190 around the light bar assembly 100. In other embodiments, the first elongated strip 141 and the second elongated strip 142 may be separate strips that are joined together (e.g., sewn together) and attached to the package 154.

[0043] like Figure 5 As shown, at least a portion of the lens 134 is disposed within the slit 105 and faces the vehicle's driver toward the rear of the vehicle. The first edge portion 144 and the second edge portion 145 may clamp or abut against the opposite sides of the head portion 138 of the lens 134 to prevent visible light transmitted by the visible light LED 172 from leaking around the lens 134, while allowing visible light to pass through the lens 134. In other words, the first edge portion 144 and the second edge portion 145 contact the sides of the head portion 138 of the lens 134 to form a light shield that prevents visible light from passing between the lens 134 and the first edge portion 144 and the second edge portion 145. Clamping may occur when the inner housing 110 and the outer housing 120 are joined together, and thereby the slot edge 111 of the inner housing 110 and the slot edge 121 of the outer housing 120 provide sufficient force to clamp the first edge portion 144 and the second edge portion 145 against the opposite sides of the lens 134.

[0044] In some embodiments, the width of slit 105 may be less than the width of the head portion 138 of lens 134, such that the first edge portion 144 and the second edge portion 145 can be compressed by lens 134, and there is little or no space or gap between lens 134 and the first edge portion 144 and the second edge portion 145. In other words, the distance between lens 134 and adjacent cover 140 is 0 mm. In some embodiments, lens housing 136 is invisible to the driver of the vehicle within slit 105. In other embodiments, a small portion of lens housing 136 on both sides of lens 134 is visible to the driver of the vehicle. For example, the visible portion of lens housing 136 may have a width of approximately 1.1 mm on each side of lens 134.

[0045] Figure 3 and Figure 4 An embodiment of a light strip assembly 100 is shown, which includes a pad or cushioning pad 160 disposed between the cover 140 and the inner shell 110 and the outer shell 120. Figure 3 and Figure 4 As depicted in the embodiments, the pad 160 may surround the inner shell 110 and the outer shell 120. In another embodiment, the pad 160 may cover the outer shell 120. The pad 160 may be formed of a polymer foam (such as polyurethane foam) or a natural material (such as cotton). In some embodiments, the pad 160 may be a heating pad, a hands-free detection (HOD) pad, or a combination of a heating pad and a HOD pad. In other embodiments, the pad 160 may be disposed between the package 140 and the inner shell 110 and the outer shell 120. In some embodiments, the light strip assembly 100 does not include the pad 160.

[0046] A method of assembling a light strip assembly 100 includes wrapping a first edge portion 144 of a first strip 141 around a slot edge 111 of an inner housing 110, and tucking the first edge portion 144 into a slot 104. A second edge portion 145 of a second elongated strip 142 wraps around a slot edge 121 of an outer housing 120 and is tucking into a slot 104. A lens 134 is disposed in a slit 105 such that the lens 134 is clamped by the first edge portion 144 and the second edge portion 145. A diffuser 133, a light guide 132, a reflector 137, and a PCB assembly 130 are disposed within the inner housing 110 and the outer housing 120 such that they are adjacent to the lens 134. The inner housing 110 and the outer housing 120 are disposed around a rim 191 of a steering wheel and are joined together using fasteners 115. The wrapping 140 surrounds the inner shell 110 and the outer shell 120 such that the third edge 146 of the first strip 141 abuts or overlaps the fourth edge 147 of the second strip 142. The third edge 146 and the fourth edge 147 are joined together using a stitch 150. The stitch 150 may be formed of any suitable automotive-grade cord (such as nylon thread). In other embodiments, the third edge 146 and the fourth edge 147 may be joined together using any suitable technique (such as heat sealing, bonding, gluing, etc.). In other embodiments, a seam 151 may be provided at any suitable location around the circumference of the light strip assembly 100. For example, the seam 151 may be provided on the bottom portion of the light strip assembly (e.g., Figure 5 (As shown) (for example, set along the inner periphery of the steering wheel).

[0047] Throughout this specification, the phrase “connected to” refers to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interactions. Two components may be connected to each other even if they are not in direct contact. The terms “adjacent” and “adjacent to” refer to items that are in direct physical contact with each other, but these items do not necessarily have to be attached together.

[0048] The phrase “attached to” or “directly attached” refers to the interaction between two or more entities that are in direct contact with each other and / or separated from each other only by any suitable kind of fastener (e.g., mounting hardware or adhesive).

[0049] The terms "an" and "a" can be used to describe an individual, but are not limited to one. For example, while this disclosure may list a light bar assembly having "one lens," it also envisions a light bar assembly having two or more lenses.

[0050] Unless otherwise specified, all ranges include all numbers between the endpoints.

[0051] As used herein, the term "rearward" is used with reference to the rear of the relevant vehicle. For example, a light bar assembly that transmits light in a rearward direction transmits light toward the rear of the vehicle.

[0052] Throughout this specification, references to "implementation" or "this implementation" mean that a particular feature, structure, or characteristic described in connection with this implementation is included in at least one implementation. Therefore, as described throughout this specification, the cited phrase or variations thereof do not necessarily refer to the same implementation.

[0053] Similarly, it should be understood that in the foregoing description of the embodiments, various features are sometimes grouped together in a single embodiment, drawing, or description therein for the purpose of simplifying this disclosure. However, this approach of the disclosure should not be construed as reflecting an intention that any claim requires more features than those expressly recited in that claim. Rather, as reflected in the appended claims, the inventive aspect lies in a combination of fewer than all features of any single embodiment of the foregoing disclosure. Therefore, the claims appended to this Detailed Description are hereby expressly incorporated into this Detailed Description, wherein each claim is itself a separate embodiment. This disclosure includes all permutations of the independent claims and their dependent claims.

[0054] The use of the term "first" in the claims regarding a feature or element does not necessarily imply the presence of a second or additional such feature or element. It will be apparent to those skilled in the art that modifications can be made to the details of the above embodiments without departing from the fundamental principles of the invention. Embodiments of the invention that claim proprietary attributes or privileges are defined as follows.

[0055] Any method disclosed herein includes one or more steps or actions for performing the described method. Method steps and / or actions may be interchanged with each other. In other words, the order and / or use of specific steps and / or actions may be modified unless the correct operation of the implementation requires a specific order of steps or actions.

[0056] Throughout this specification, approximate values ​​are referred to by means of the term "about". For each such reference, it should be understood that in some embodiments, values, features, or characteristics may be specified without approximation.

[0057] Similarly, in the foregoing description of the embodiments, various features are sometimes grouped together in a single embodiment, drawing, or description therein for the purpose of simplifying this disclosure. However, this approach of the disclosure should not be construed as reflecting an intention that any claim requires more features than those expressly recited in that claim. Rather, as reflected in the appended claims, the inventive aspect lies in a combination of fewer than all features of any single embodiment of the foregoing disclosure.

[0058] The claims appended to this written disclosure are hereby expressly incorporated herein, each claim being an independent embodiment in itself. This disclosure includes all permutations of the independent claims and their dependent claims. Furthermore, additional embodiments that can be derived from the appended independent and dependent claims are also expressly incorporated herein.

[0059] Without further detailed description, it is believed that those skilled in the art can utilize the device to its fullest extent using the foregoing description. The claims and embodiments disclosed herein should be interpreted as merely illustrative and exemplary, and do not limit the scope of this disclosure in any way. It will be apparent to those skilled in the art that modifications can be made to the details of the above embodiments using this disclosure without departing from the basic principles disclosed herein. In other words, various modifications and improvements to the embodiments specifically disclosed in the foregoing description are within the scope of the appended claims. Furthermore, those skilled in the art can change the order of steps or actions of the methods disclosed herein without departing from the scope of this disclosure. In other words, the order or use of specific steps or actions can be modified unless the correct operation of the embodiments requires a specific order of steps or actions. Therefore, the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A lightbar assembly (100) for a steering wheel (190), the lightbar assembly comprising: an outer shell (120) including a first PCB strip support plate (127) disposed on an inner surface (129) of the outer shell (120); and an inner shell (110) including a second PCB strip support plate, the inner shell (110) coupled with the outer shell (120); a PCB strip (139) including visible light LEDs (172) and IR LEDs (173), wherein opposite sides of the PCB strip (139) are coupled to the first and second PCB strip support plates (127, 128), respectively, and characterized in that the first and second PCB strip support plates (127, 128) are configured to dissipate heat from the visible light and IR LEDs (172, 173) to the outer shell (120) and the inner shell (110); wherein an outer surface of the outer shell (120) and an outer surface of the inner shell (110) at least partially define a portion of an outer circumference of a steering wheel (190).

2. The lightbar assembly (100) of claim 1, wherein the outer shell (120) and the first PCB strip support plate (127) are unitary.

3. The lightbar assembly (100) of any one of claims 1-2, wherein the first PCB strip support plate (127) is coextensive with a length of the PCB strip (139).

4. The lightbar assembly (100) of any one of claims 1-3, wherein the first PCB strip support plate (127) extends inwardly from the inner surface (129) of the outer shell (120).

5. The lightbar assembly (100) of any one of claims 1-4, wherein the first PCB strip support plate (127) comprises any one of polycarbonate, acrylonitrile butadiene styrene, aluminum, copper, and any combination thereof.

6. The lightbar assembly (100) of any one of claims 1-5, further comprising a thermally conductive gasket (128) disposed between the PCB strip (139) and the first PCB strip support plate (127).

7. The lightbar assembly (100) of claim 6, wherein the thermally conductive gasket (128) comprises any one of aluminum, copper, and any combination thereof.

8. The lightbar assembly (100) of any one of claims 1-5, further comprising a thermally conductive grease (128) disposed between the PCB strip (139) and the first PCB strip support plate (127).

9. The lightbar assembly (100) of claim 8, wherein the thermally conductive grease (128) comprises any one of epoxy, silicone, polyurethane, acrylate, and any combination thereof.

10. The lightbar assembly (100) of claim 8, wherein the thermally conductive grease (128) includes a thermally conductive filler.

11. The lightbar assembly (100) of claim 10, wherein the filler comprises any of aluminum oxide, boron nitride, zinc oxide, aluminum nitride, and any combination thereof.

12. The lightbar assembly (100) of any of claims 1-11, wherein the PCB strip (139) further comprises a plurality of visible light LEDs (172) and a plurality of IR LEDs (173) disposed on the PCB strip (139).

13. The lightbar assembly (100) of any of claims 1-12, wherein the PCB strip (139) further comprises an LED driver (131) disposed on the PCB strip (139).

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