Laser light engine with optical fiber integration in decorative parts

Abstract

A lighting trim component and method of manufacturing the same includes a flexible optical fiber assembly configured to receive and transmit a light beam generated by a light engine through the flexible optical fiber assembly to illuminate the flexible optical fiber assembly; and a trim component in which the flexible fiber optic assembly is integrated such that when illuminated by the light beam, the flexible fiber optic assembly produces a light embellishment on the trim component.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of Spanish patent application No. P202230544, filed on June 20, 2022, the disclosure of which is hereby incorporated by reference in its entirety. Background Art

[0003] Related fields

[0004] The present application relates generally to trim parts such as automotive trim parts, and more particularly to systems and methods for providing a light engine with fiber optic integration in a trim part. Background Art

[0006] In today's decorative parts, such as automotive decorative parts, it is often desirable to incorporate light embellishments. One conventional solution for incorporating light embellishments is to utilize relatively inexpensive and low-power light sources in conjunction with light guide structures that direct / guide the light generated by the light sources to create visible light patterns. However, these conventional solutions are somewhat limited by relatively low brightness (e.g., δ ~ 2500 candelas per square meter or cd / m 2 ) and any structural limitations of the light guide (e.g., limitations of plastic moldings, packaging space, etc.). Therefore, while conventional light-embellished decorative components and methods of making the same do achieve their most basic intended purposes, improvements in the relevant field are still desired.

[0007] The purpose of the background description provided herein is to generally present the context of the present disclosure. The work of the presently named inventors is neither explicitly nor implicitly admitted to be prior art against the present disclosure to the extent described in this background section and to the description of various aspects that may not otherwise be regarded as prior art at the time of filing. Summary of the invention

[0008] According to one aspect of various embodiments of the present disclosure, a lighting decorative component is presented. In an exemplary implementation, the lighting decorative component includes: a flexible fiber optic component configured to receive and reflectively transmit a light beam generated by a light engine through the flexible fiber optic component to illuminate the flexible fiber optic component; and a decorative component, the flexible fiber optic component being integrated in the decorative component so that when illuminated by the light beam, the flexible fiber optic component generates a light embellishment on the decorative component.

[0009] In some exemplary embodiments, the lighting decorative component may also include a multi-layer co-extruded profile structure having a flexible optical fiber assembly therein and defining a first set of fixing features for aligning and assembling the multi-layer co-extruded profile structure. In other exemplary embodiments, the decorative component may also include a decorative shell defining a complementary second set of fixing features for aligning and assembling the multi-layer co-extruded profile structure in the decorative shell. In still other exemplary embodiments, the multi-layer co-extruded profile structure may be a closed structure, such as a closed structure in which a flexible optical fiber assembly is integrated. In still other exemplary embodiments, the multi-layer extruded profile structure may be an open structure so that a flexible optical fiber assembly can be integrated therein separately and / or independently.

[0010] In certain exemplary implementations, the light engine is a laser light engine configured to generate a laser beam; however, it should be understood that the light engine may have other light source configurations (e.g., multiple LEDs). In other exemplary implementations, the multilayer co-extruded profile structure includes a glass fiber structure for preventing elongation or mitigating elongation. In yet other implementations, the light engine and the flexible optical fiber assembly are configured to generate a brightness greater than the brightness of a lighting decorative component based on a conventional light emitting diode (LED) and a light guide. In these and still other implementations, the brightness generated by the lighting decorative component is three to four times the brightness of a lighting decorative component based on a conventional LED and a light guide. In at least some exemplary implementations, the brightness generated by the lighting decorative component is approximately 7000 candelas (cd / m 2 ), and the light intensity generated by the lighting decoration component based on conventional LED and light guide is about 2500cd / m 2 In certain other exemplary implementations, the brightness generated by the lighting decoration component may be less than the light intensity generated by a conventional configuration, the lighting decoration component providing about 1400 cd / m 2 brightness level; or provide about 800cd / m 2 Up to 2000cd / m 2 Brightness levels within the range.

[0011] According to another aspect of various embodiments of the present disclosure, a method for manufacturing a lighting decorative component is presented. In at least one exemplary implementation, the method includes: providing a decorative component; forming a flexible fiber optic component configured to receive and transmit a light beam generated by a light engine through the flexible fiber optic component to illuminate the flexible fiber optic component; and forming the lighting decorative component by integrating the flexible fiber optic component into the decorative component so that when illuminated by the light beam, the flexible fiber optic component generates a light embellishment on the decorative component.

[0012] In certain exemplary embodiments, the method further comprises co-extruding the flexible fiber optic assembly to form a multi-layer co-extruded profile structure, the flexible fiber optic assembly being integrated into the multi-layer co-extruded profile structure, and the multi-layer co-extruded profile structure defining a first set of fixing features for aligning and assembling the multi-layer co-extruded profile structure. In another exemplary embodiment, the decorative component further comprises a decorative shell defining a complementary second set of fixing features, and wherein forming the lighting decorative component further comprises aligning and assembling the multi-layer co-extruded profile structure therein using the first set of fixing features and the complementary second set of fixing features. In some additional exemplary embodiments, the multi-layer co-extruded profile structure is a closed structure in which the flexible fiber optic assembly is integrated. In a further exemplary embodiment, the multi-layer extruded profile structure is an open structure so that the flexible fiber optic assembly can be integrated therein.

[0013] In various exemplary implementations, the light engine is a laser light engine configured to generate a laser beam; however, it should be understood that the light engine may have other light source configurations (e.g., multiple LEDs). In certain exemplary implementations, forming the fiber optic assembly includes forming a glass fiber structure to prevent elongation or reduce elongation. In additional exemplary implementations, the light engine and the flexible fiber optic assembly are configured to generate a brightness greater than the brightness of a lighting decorative component based on conventional LEDs and light guides. In these and still other exemplary implementations, the brightness generated by the lighting decorative component is three to four times the brightness of a lighting decorative component based on conventional LEDs and light guides. In at least some exemplary implementations, the light intensity generated by the lighting decorative component is approximately 7000 cd / m 2 , and the light intensity generated by the lighting decoration component based on conventional LED and light guide is about 2500cd / m 2 In certain other exemplary implementations, the brightness generated by the lighting decoration component may be less than the light intensity generated by a conventional configuration, the lighting decoration component providing about 1400 cd / m 2 brightness level; or provide about 800cd / m 2 Up to 2000cd / m 2 Brightness levels within the range.

[0014] Other areas of applicability of the teachings of the present disclosure will become apparent from the detailed description, claims, and drawings provided below, wherein similar reference numerals refer to similar features throughout the several views of the drawings. It should be understood that the detailed description, including the disclosed embodiments and drawings cited therein, are merely exemplary in nature, for illustrative purposes only, and are not intended to limit the scope of the present disclosure, its application, or use. Therefore, variations that do not depart from the examples of the present disclosure are intended to be within the scope of the present disclosure. Combinations of the various exemplary implementations listed are also intended to be within the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1A to Figure 1B is a functional block diagram of an example illuminated trim component and an example system for its manufacture according to various example embodiments of the present disclosure;

[0016] FIG. 2A to FIG. 2B is a side view of a first example lighting decoration component according to various exemplary embodiments of the present disclosure;

[0017] FIG. 3A to FIG. 3C is a side view of a second example lighting trim component according to various example implementations of the present disclosure; and

[0018] Figure 4 is a flow chart of an example method of manufacturing a lighting trim component according to various example implementations of the present disclosure. DETAILED DESCRIPTION

[0019] As previously discussed, in certain conventional trim components such as automotive trim components (e.g., front grille assemblies, headlight and / or taillight trim, decklid trim, door handles, etc.), it is desirable to incorporate light accents. One exemplary solution for incorporating light accents is to utilize a relatively inexpensive light source (such as a single or low-power light emitting diode (LED)) in conjunction with a light guide structure that guides and / or directs (i.e., directs) the light generated by the LED to create a visible light pattern. However, these conventional solutions are somewhat limited by the relatively low brightness of the LED (e.g., ~2500 candelas per square meter or cd / m 2 ) and any structural limitations of the light guides to which they are associated (e.g., limitations of molded parts). Therefore, while conventional light-embellished decorative components and methods of making the same generally achieve their basic intended purposes, improved structure, manufacturing, and operability are still desired.

[0020] Thus, improved lighting decorative components and methods of making the same are presented herein. According to various embodiments, these lighting decorative components incorporate a flexible fiber optic assembly that receives and transmits a light beam generated by a light engine (e.g., a laser light engine) through the flexible fiber optic assembly to generate a large brightness level (e.g., ~7500 cd / m 2 ) and more flexible structural designs. Non-limiting examples of these lighting decorative components include automotive exterior components (such as grille assemblies, headlights / taillights, door handles, trunk lid trim) and automotive interior components (such as door handles, infotainment systems and roof linings). It should be understood that the systems and methods of the present disclosure may also be applied outside the automotive field, such as in other passenger transportation (rail, aviation, etc.) and consumer products (furniture, appliances, etc.), which are listed only as non-limiting examples of the intended uses of the configurations of the present invention.

[0021] Fiber optic technology has traditionally been used in communications to transport light (i.e., information) over long distances with minimal distortion. However, by controlling the operation of a fiber optic assembly (e.g., one or more fiber optic cables) and an associated light engine, it is possible to cause the fiber optic assembly to emit light in a controlled manner. In this regard, the basic operation of optical fiber generally involves two concepts: refraction of light (when passing between different mediums) and internal reflection (total internal reflection, or "TIR"). In order to overcome the unintentional escape of light from the optical fiber core of a fiber optic assembly, a coating or "cladding" with a lower reflectivity ("RI") is added to the core of the fiber optic assembly. Another coating with a lower RI than the cladding is typically applied to the cladding to ensure that any stray light that escapes the cladding is reflected back into the core. The fiber optic assembly is then typically coated or wrapped in a solid covering (e.g., ) and thick cable jacket for environmental protection.

[0022] In certain configurations, a fiber optic assembly can also include multiple cables or different cores. A technique for manufacturing fiber optic cables / assemblies is extrusion, in which one or more layers (as described above) are formed by extruding the corresponding materials through a tool or mold. The fiber optic core is typically made of plastic fiber or glass fiber. In contrast to plastic fibers (e.g., acrylic / polymethyl methacrylate ("PMMA") or polycarbonate ("PC") cores with silicone resin cladding), glass fibers are typically composed of a pure glass (silicon dioxide or "SiCH") core with a less pure glass or plastic cladding. Although glass fibers are somewhat brittle and easily broken, they allow additional light to enter the system, can send a wider spectrum of light wavelengths, exhibit less loss, and can better handle extreme environments (temperature, moisture, corrosion, etc.) compared to plastic fibers.

[0023] Reference Figure 1A to Figure 1B , illustrates a functional block diagram of an exemplary lighting decoration component 100 and an exemplary system 150 for its manufacture according to some embodiments of the present disclosure. The lighting decoration component 100 generally includes a decoration component 104 having a multi-layer extruded profile structure 108 therein. The decoration component 104 can be formed, for example, using one or more injection molding machines 154 and a desired material, such as a thermoplastic (PC, PMMA, etc.). The multi-layer extruded profile structure 108 can be formed, for example, using one or more extruders 158. Both separate extrusion processes and co-extrusion processes are possible, as discussed in more detail below. The last general manufacturing step according to various processes is to use one or more assemblers 162 (robots, people, or a combination of the two) to integrate the extruded profile structure 108 with the decoration component 104 to obtain the final lighting decoration component 100. This may include, for example, using one or more sets of fixing features 124 (e.g., interlocking tabs, complementary threaded holes / screws, etc.) to align and assemble the components to each other.

[0024] As shown, the extruded profile structure 108 generally includes a fiber optic assembly 116, which may include one or more fiber optic cables 120 integrated into the structure 108. Each fiber optic cable 120 may be formed by forming a glass fiber structure, and thereby or actively prevent or mitigate elongation of the fiber optic cable 120 (e.g., to prevent breakage / damage). As discussed in more detail above, the glass fiber structure may be integrated into other materials (thus, a "multi-layer" structure). The light engine 112 is configured to generate a light beam that is reflected and sent through the fiber optic cables 120 of the fiber optic assembly 116. The light beam may be any desired color / wavelength. In an exemplary implementation, the light engine 112 is one or more laser light engines configured to generate a laser beam, but it should be understood that the light engine 112 may have other light source configurations (e.g., multiple LEDs). The human eye is sensitive to light with wavelengths in the range of approximately 400 nanometers (nm) to 700 nm (ranging from blue / violet to red). For transmission through fiber optic cable 120 (e.g., before illumination for display / human perception), light in the infrared region (having longer wavelengths than visible light, typically about 850nm, 1300nm, and 1550nm) can be utilized because optical fiber has much less attenuation at those wavelengths.

[0025] Reference FIG. 2A to FIG. 2B as well as FIG. 3A to FIG. 3C , respectively illustrate side views of a first exemplary lighting decoration component 200 and a second exemplary lighting decoration component 300 according to some embodiments of the present disclosure. FIG. 2A to FIG. 2BIn the embodiment of the present invention, as previously described herein, coextrusion is performed. Coextrusion can allow, for example, fewer processing steps and more efficient integration of optical fiber components therein. In one step, a coextrusion process is performed to form a multilayer coextrusion profile structure 208 having a flexible optical fiber component and a set of fixing features 212, for alignment and assembly of the multilayer coextrusion profile structure 208 in the decorative component 204 in another step (e.g., using corresponding fixing features as shown in the figure) to form a final lighting decorative component 200. Therefore, in certain embodiments as shown in the figure, the multilayer coextrusion profile structure 208 can be a closed structure that allows the flexible optical fiber component to be easily integrated therein.

[0026] exist FIG. 3A to FIG. 3C In the embodiment of the present invention, a separate extrusion or forming process is performed as previously described herein. As shown, the decorative component also includes a decorative shell, which defines a first set of fixing features, and wherein forming the lighting decorative component also includes aligning and assembling the multilayer extruded profile structure with the decorative shell using the first set of fixing features. In one step, an extrusion process is performed to form an optical fiber assembly 316. In another step, another extrusion process is performed to form a multilayer extruded profile structure 308 having a first set of fixing features 312, for aligning and assembling the optical fiber assembly 316 in the multilayer extruded profile structure in another step. Therefore, the multilayer extruded profile structure 308 can be an open structure so that the optical fiber assembly 316 can be integrated therein. In another step, the decorative component 304 (e.g., having a corresponding complementary second fixing feature or a part of the decorative component, such as a grille component / component, integrated as shown) receives and aligns the multilayer extruded profile structure 308 with the integrated optical fiber assembly 316 in the decorative component to form the final lighting decorative component 300.

[0027] With reference to the fiber optic assemblies described above, it will be further understood that the exemplary advantages thereof are size-related. This is due in part to the structure of the assembly (also described above), but is also intended to overcome the problems of conventional solutions. Plastic moldings and / or packaging space limitations require smaller and smaller components. In order to provide an attractive solution not only in terms of brightness but also in terms of size, various embodiments of the fiber optic assembly have a diameter that is less than three millimeters in size. In certain embodiments, the diameter may be about three millimeters; in other embodiments, the diameter may be between 1 millimeter and 2 millimeters; in still other embodiments, the diameter may be less than two millimeters or even less than one millimeter.

[0028] Reference Figure 4, a flow chart of an exemplary method 400 for manufacturing lighting decorative components according to some specific implementations of the present disclosure is illustrated. Although the components previously described and illustrated herein may be used as part of method 400, it should be understood that method 400 may be applicable to forming any suitable lighting decorative components. At 404, a decorative component is formed / provided (e.g., using injection molding). At 408, light engines each configured to generate and emit a light beam are provided. As a non-limiting example, a laser light engine configured to generate a laser beam (i.e., a laser + fiber-based configuration) may be used. In additional embodiments, the light engine may be LED-based (i.e., an LED + fiber-based configuration). Of course, other light engines or combinations of light engine types may be combined and utilized as needed.

[0029] At 412, the flexible fiber optic assembly is configured to receive and transmit a light beam through the flexible fiber optic assembly to illuminate the flexible fiber optic assembly. As previously discussed, the manufacturing process 400 may involve a co-extrusion or separate extrusion / forming process and a subsequent alignment / assembly process. At 416, an illuminated decorative component is formed by integrating at least the flexible fiber optic assembly within the decorative component so that when illuminated by the light beam, the flexible fiber optic assembly produces a light embellishment on the decorative component. The method 400 then ends or returns to 404 for one or more additional manufacturing cycles.

[0030] Although the first, second, third and other terms can be used to describe various elements, components, regions, layers and / or parts in this article, these elements, components, regions, layers and / or parts should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or part from another region, layer or part. Unless the context clearly indicates, terms such as "first", "second" and other numerical terms do not imply order or sequence when used herein. Therefore, without departing from the teaching content of the example embodiment, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or part.

[0031] It should also be understood that the mixing and matching of features, elements, methods and / or functions between the various examples may be expressly contemplated herein, such that a person skilled in the art will recognize from the present teachings that the features, elements and / or functions of one example may be combined into another example as appropriate, unless otherwise described above.

Claims

1. A lighting decoration component, comprising: a flexible fiber optic assembly configured to receive the light beam generated by the light engine and pass the light beam through the flexible fiber optic assembly so as to illuminate the flexible fiber optic assembly; and A decorative component having the flexible fiber optic assembly integrated therein such that the flexible fiber optic assembly produces a light accent on the decorative component when illuminated by the light beam.

2. The lighting decorative component according to claim 1, further comprising a multi-layer co-extruded profile structure having the flexible optical fiber assembly integrated therein, and the multi-layer co-extruded profile structure having a first set of fixing features for aligning and assembling the multi-layer co-extruded profile structure with the flexible optical fiber assembly.

3. The lighting trim component of claim 2, wherein the trim component further comprises a trim housing having a complementary second set of securing features for aligning and assembling the multi-layer coextruded profile structure in the trim housing.

4. The lighting decoration component according to claim 3, wherein the multi-layer co-extruded profile structure is a closed structure having the flexible optical fiber assembly integrated therein. 5 . The lighting decoration component according to claim 3 , wherein the multi-layer extrusion profile structure is an open structure, so that the flexible optical fiber assembly is separated from the multi-layer extrusion profile structure but can still be integrated into the multi-layer extrusion profile structure.

6. The lighting decoration component according to any one of claims 2 to 5, wherein the multi-layer co-extruded profile structure includes a glass fiber structure for at least one of preventing elongation or mitigating elongation.

7. An illuminated trim component according to any one of the preceding claims, wherein the light engine is a laser light engine configured to generate a laser beam.

8. An illuminated decorative component according to any one of the preceding claims, wherein the light engine is a plurality of light emitting diodes (LEDs).

9. The lighting trim component of any one of the preceding claims, wherein the light engine and the flexible fiber optic assembly are configured to generate a light intensity of 800 cd / m 2 Up to 2000cd / m 2 The brightness within the range.

10. The lighting decorative component of claim 9, wherein the generated brightness is about 1400 cd / m 2 .

11. The lighting trim component of any one of the preceding claims, wherein the light engine and the flexible fiber optic assembly are configured to generate greater than about 2500 cd / m 2 brightness level.

12. The lighting trim component of claim 11, wherein the light engine and the flexible fiber optic assembly are configured to generate 2500 cd / m 2 Three to four times the brightness level of the 13. The lighting decoration component of any one of the preceding claims, wherein the brightness level generated by the lighting decoration component is about 7000 candelas per square meter (cd / m 2 ).

14. An illuminated decorative component according to any one of the preceding claims, wherein the optical fibre assembly comprises optical fibres having a diameter of less than three millimetres.

15. A method for manufacturing a lighting decoration component, the method comprising the following steps: Provide decorative parts; forming a flexible fiber optic assembly configured to receive a light beam generated by the light engine and pass the light beam through the flexible fiber optic assembly so as to illuminate the flexible fiber optic assembly; as well as The illuminated decorative component is formed by integrating the flexible fiber optic assembly within the decorative component, such that the flexible fiber optic assembly produces a light accent on the decorative component when illuminated by the light beam.

16. The method according to claim 15 further includes co-extruding the flexible optical fiber assembly to form a multi-layer co-extruded profile structure, wherein the multi-layer co-extruded profile structure has the flexible optical fiber assembly integrated in the multi-layer co-extruded profile structure and defines a first set of fixing features for aligning and assembling the multi-layer co-extruded profile structure.

17. The method of claim 16, wherein the decorative component further comprises a decorative shell defining a complementary second set of fixing features, and wherein forming the lighting decorative component further comprises aligning and assembling the multilayer co-extruded profile structure in the decorative shell using the first set of fixing features and the complementary second set of fixing features.

18. The method of claim 17, wherein the multi-layer co-extruded profile structure is a closed structure having the flexible optical fiber assembly integrated therein.

19. The method of claim 17, wherein the multi-layer extrusion profile structure is an open structure such that the flexible optical fiber assembly is separate from the multi-layer extrusion profile structure but can be integrated into the multi-layer extrusion profile structure.

20. The method of any one of claims 16 to 19, wherein forming the multi-layer coextruded profile comprises forming a glass fiber structure for at least one of preventing elongation or mitigating elongation.

21. The method of any one of claims 15 to 20, wherein the light engine is a laser light engine configured to generate a laser beam.

22. The method of any one of claims 15 to 20, wherein the light engine is a plurality of light emitting diodes (LEDs).

23. The method of any one of claims 15 to 22, wherein the light engine and the flexible fiber optic assembly are configured to generate a wavelength of 800 cd / m 2 Up to 2000cd / m 2 The brightness within the range.

24. The method of claim 23, wherein the generated brightness is about 1400 cd / m 2 .

25. The method of any one of claims 15 to 22, wherein the light engine and the flexible fiber optic assembly are configured to generate greater than about 2500 cd / m 2 brightness level.

26. The method of claim 25, wherein the light engine and the flexible fiber optic assembly are configured to generate 2500 cd / m 2 Three to four times the brightness level of the 27. The method of any one of claims 15 to 22, wherein the brightness level generated by the illuminated decorative component is about 7000 candelas per square meter (cd / m 2 ).

28. An illuminated decorative component according to any one of claims 15 to 27, wherein the optical fibre assembly comprises optical fibres having a diameter of less than three millimetres.

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