Flexible three-dimensional display assembly for electric vehicle

Abstract

A flexible three-dimensional display assembly is provided. A flexible display assembly includes electrically interconnected light emitting elements, a flexible mesh fixture, and a display bezel. The light emitting elements are electrically interconnected by the conductor system. The light emitting elements are coupled to the flexible mesh fixture by an arrangement of structurally interconnected frame units housing pairs of light emitting elements. A flexible mesh fixture is secured to the substrate of the display bezel such that the pair of light emitting elements is held in optical alignment with a corresponding pair of apertures of the display bezel.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 355,339, filed on June 24, 2022, the contents of which are incorporated herein by reference. This application is related to U.S. Application No. 18 / 189,431, filed on March 24, 2023, which claims the benefit of U.S. Provisional Application No. 63 / 323,739, filed on March 25, 2022. Background Art

[0003] A grille may cover an opening in the body of a vehicle to allow air to flow into and out of the opening, thereby circulating cooling air to the vehicle's internal combustion engine to prevent overheating. A grille may also provide a visual design to the front of the car, which may appeal to buyers and allow the buyer to identify the make and model of the vehicle. For an all-electric vehicle with an electric motor, a grille may be outdated and unnecessary. Summary of the invention

[0004] A flexible three-dimensional display assembly is provided. The flexible display assembly includes electrically interconnected light emitting elements, a flexible lattice fixture, and a display bezel. The light emitting elements are electrically interconnected by a conductor system. The light emitting elements are coupled to the flexible lattice fixture by an arrangement of structurally interconnected frame units that accommodate pairs of light emitting elements. The flexible lattice fixture is fastened to a substrate of a display bezel so that the light emitting element pairs are held in optical alignment with corresponding pairs of holes of the display bezel. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] A more detailed understanding may be obtained from the following description, which is given by way of example in conjunction with the accompanying drawings, in which:

[0006] Figure 1 is an exploded perspective view of components of a flexible display assembly;

[0007] Figure 2 It is interconnected Figure 1 A plan view of an electrical conductor system of a light emitting element in a flexible display assembly;

[0008] Figure 3 yes Figure 1 A perspective view of an arrangement of light emitting elements in one example of a flexible display assembly;

[0009] Figure 4 yes Figure 1 A front view of a light emitting element in one example of a flexible display assembly;

[0010] Figure 5 is including Figure 1A perspective view of an example light emitting element disposed on an electrical conductor in one example of a light emitting element of a flexible display assembly shown in FIG.

[0011] Figure 6 yes Figure 5 Perspective views of example light emitting elements viewed from different viewing angles;

[0012] Figure 7 yes Figure 1 a perspective view of a portion of a flexible display assembly;

[0013] Figure 8 is a schematic illustration of another example light emitting element coupled to an electrical conductor;

[0014] Fig. 9 and Fig.10 is a schematic illustration of an example spring clip providing electrical interconnection in embodiments described herein;

[0015] Fig.11 is a schematic illustration of an example light emitting element coupled to an electrical conductor according to embodiments described herein;

[0016] Fig.12 is a schematic illustration of a compressible pin providing an electrical connection according to embodiments described herein;

[0017] Fig.13 is a top view of a light emitting element according to an embodiment described herein;

[0018] Fig.14 is a top view of a pair of light emitting elements according to an embodiment described herein;

[0019] Fig.15 is a block diagram showing a portion of a lead frame assembly according to an embodiment described herein;

[0020] Fig.16 Yes Fig.15 A structural diagram of a frame unit of a lead frame assembly shown in;

[0021] Fig.17 Is set in Fig.15 In the framework unit Fig.14 A top view of a pair of light emitting elements shown in ;

[0022] Fig.18 is a functional diagram illustrating power and control interconnections of an example frame unit of a flexible grid according to embodiments described herein;

[0023] Fig.19 is a functional block diagram showing a light emitting element string arranged according to the embodiments described herein;

[0024] Fig. 20is a functional block diagram showing a light emitting element cluster according to an embodiment described herein;

[0025] Fig.21 is a block diagram illustrating an arrangement for interconnecting a cluster of light emitting elements to a control element according to embodiments described herein; and

[0026] Fig. 22 is a top view of an example frame unit of a flexible grid fixture including a lead frame in embodiments described herein. DETAILED DESCRIPTION

[0027] Examples of different light illumination systems and / or light emitting diode (LED) embodiments will be described more fully below with reference to the accompanying drawings. These examples are not mutually exclusive, and features found in one example can be combined with features found in one or more other examples to achieve additional embodiments. Therefore, it will be understood that the examples shown in the accompanying drawings are provided for illustrative purposes only, and they are not intended to limit the present disclosure in any way. Like numbers always refer to like elements.

[0028] It will be understood that although the terms first, second, third, etc. can be used to describe various elements in this article, these elements should not be limited by these terms. These terms can be used to distinguish an element from another element. For example, the first element can be referred to as the second element and the second element can be referred to as the first element without departing from the scope of the present invention. As used herein, the term "and / or" can include any and all combinations of one or more associated listed items.

[0029] It will be understood that when an element such as a layer, region, or substrate is referred to as being "on" or "extending to" another element, it may be directly on or directly extending to another element, or there may also be intermediate elements. In contrast, when an element is referred to as being "directly on" or "directly extending to" another element, there may be no presence of intermediate elements. It will also be understood that when an element is referred to as being "connected" or "coupled" to another element, it may be directly connected or coupled to another element and / or connected or coupled to another element via one or more intermediate elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there is no presence of intermediate elements between the element and the other element. It will be understood that these terms are intended to cover different orientations of elements in addition to any orientation depicted in the figures.

[0030] Relative terms such as "below," "above," "upper," "lower," "horizontal," or "vertical" may be used herein to describe the relationship of one element, layer, or region to another element, layer, or region illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.

[0031] Figure 1 is an exploded view of a flexible three-dimensional (3D) display assembly 800. Figure 1 In the example shown in , the flexible display assembly 800 includes a flexible grid fixture 600 , an arrangement 400 of electrically interconnected light emitting elements 100 , and a display bezel 500 .

[0032] The flexible grid fixture 600 may include a plurality of structurally interconnected frame units 602. Each respective frame unit 602 may define a respective corresponding opening 601 formed to accommodate a respective corresponding pair of light emitting elements 100a, 100b. The light emitting elements 100 may be attached to the flexible grid fixture 600 by any suitable fixing technique, including, for example, laser welding, heat staking, and / or a clamping system, thereby forming a subassembly 850 in which the structurally interconnected frame units 602 comprising the flexible grid fixture 600 may mechanically support the electrically interconnected light emitting elements 100 in the arrangement 400.

[0033] Figure 1 The example flexible grid fixture 600 shown in FIG. 1 includes nine frame units 602 that define nine corresponding openings 601. Figure 1 In the example shown in FIG. 6 , the flexible grid fixture 600 arranges nine pairs of light emitting elements 100 or 18 individual light emitting elements 100 into three rows and three columns. Figure 1 The arrangement and number of frame units 602 and lighting elements 100 in the example are selected only for ease of illustration and discussion. In practical embodiments, the flexible grid fixture 600 may include any desired number of frame units 602 to define a variety of arrangements 400 of lighting elements 100.

[0034] The display bezel 500 may include a substrate 502 that defines an arrangement of pairs of holes 501 (example pairs indicated at 501a, 501b). The arrangement of the pairs of holes of the display bezel 500 may correspond to the arrangement 400 of the light emitting elements 100, because each pair of light emitting elements 100a, 100b supported by the frame unit 602 may have a corresponding pair of holes 501a, 501b in the display bezel 500. The display bezel 500 may be constructed of plastic, metal, or layers of these materials, and the holes 501 may be formed by molding the display bezel substrate 502. As long as the orientation of the pairs of holes 501a and 501b corresponds to the orientation of the pairs of light emitting elements 100a and 100b on the flexible grid fixture 600, the pairs of holes 501a, 501b may be arranged in any desired orientation, such as side by side along the horizontal axis of the display bezel 500 or from top to bottom along the longitudinal axis of the display bezel 400.

[0035] The electrically interconnected light emitting elements 400 can be securely coupled to the flexible grid fixture 600 to form a subassembly 850. The subassembly 850 can then be attached to the substrate 502 of the display frame 500 to form a flexible 3D display assembly 800. The flexible 3D display assembly 800 can include pairs 100a, 100b of electrically interconnected light emitting elements 100, each respective pair of light emitting elements being optically aligned with a corresponding pair of holes 501a, 501b. In some embodiments, portions of the inner surface of the substrate 502 of the display frame 500 proximate to the light emitting elements 100 can be white to reflect any stray light emitted by the light emitting elements 100 that may illuminate the substrate 502. Such reflection can increase the intensity of the emitted light and improve the optical efficiency of the light emitting elements 100.

[0036] exist Figure 1 In the example shown in FIG. 6 , the frame units 602 of the flexible grid fixture 600 define back-to-back triangular openings corresponding to the triangular light-emitting elements 100. However, the grid fixture 600 can be configured such that the frame units 602 define openings 601 having other shapes, such as square, circular, rectangular, or any other desired shape. In those examples, the light-emitting elements 100 can have corresponding shapes so that one or more light-emitting elements 100 can be securely disposed in the corresponding openings 601 defined by the frame units 602.

[0037] In an example embodiment, the flexible grid fixture 600 is formed to include mechanical fixing elements (such as heat stacks, mechanical click systems, or screws) for fixing the subassembly 850 to the substrate 502 of the display bezel 500. In other words, the flexible grid fixture 600 can provide a fixing system that mechanically couples the individual light emitting elements 100 to the display bezel 500 at the locations of the corresponding holes 501 on the substrate 502 of the display bezel 500. Therefore, the arrangement of the holes 501 on the substrate 502 of the display bezel 500 can be predefined by the arrangement 400 of the frame units 602 of the flexible grid fixture 600. The flexible grid fixture 600 can provide a secure mechanical attachment of the subassembly 850 to the display bezel 500, such that the corresponding pairs 100a, 100b of the light emitting elements 100 disposed in the corresponding corresponding grid openings 601 of the frame units 602 are maintained in a stable optical alignment with the corresponding corresponding pairs 501a, 501b of the holes 501 of the display bezel 500.

[0038] Subassembly 850 may include a sufficient number of mechanical support structures (not shown) to maintain a constant pressure of subassembly 850 against display structure 500 when subassembly 850 is secured to display structure 500. The result is that a flexible 3D display assembly can be mounted to a curved structure (such as the grille of an automobile) while maintaining optical alignment of its optical components.

[0039] Figure 2 3 is a plan view of a conductor system 300. The system 300 may include a plurality of interconnected individual conductive segments 1800. Each conductive segment 1800 may extend from one light emitting element 100 to another light emitting element, or from one pair of light emitting elements to another pair of light emitting elements. Alternatively, each conductive segment 1800 may extend along a string of light emitting elements 100.

[0040] The various conductive segments 1800 are interconnected to form light emitting element clusters 400, 450, to which the conductive segments 1800 deliver power, data, and control signals. In the example shown, the cluster 400 includes three strings 211, 213, 215 of lighting elements 100, wherein each string includes three pairs of lighting elements 100 (one pair is indicated at 100a, 100b) electrically connected by corresponding conductive segments 1800. Each cluster may include a total of 18 light emitting elements, with each string including 6 elements 100. Similarly, the second cluster 450 may include three strings of light emitting elements 100.

[0041] Clusters 400 and 450 themselves may be interconnected by conductive segments 1800 arranged to provide a common bus that transmits power, data, and control signals to each string of light emitting elements in the corresponding cluster. Individual conductor elements 1800 may include wires or cables as described below. In some embodiments, conductor elements 1800 may be disposed within a structural element of flexible grid fixture 600. In those embodiments, flexible grid fixture 600 itself may include conductor system 300.

[0042] For example, in some embodiments, electronic components can be disposed within portions of the flexible grid fixture to contact individual ones of the light emitting elements 100 via contacts on corresponding PCBs 170. In some examples, electrical contact elements, such as lead frames or spring contacts, can be formed as part of an injection molding process by which the flexible grid fixture 600 is formed or constructed. In other examples, the electrical contact elements can be placed after injection molding on corresponding receptacles formed in the flexible grid fixture 600 during injection molding. For example, after injection molding of the flexible grid fixture 600, the electrical contact elements can be placed or clipped into or onto portions of the flexible grid fixture 600. In some examples, electrical contact elements and / or electrical or electronic components, such as a controller chip, can be disposed within the light emitting element 100 when the light emitting element 100 is formed.

[0043] Figure 3 4 is a perspective view of clusters 400, 450 of electrically interconnected light emitting elements 100 according to one example of a 3D flexible display assembly 800. Each cluster may include multiple strings of light emitting elements 100. For example, cluster 400 includes strings 211, 213, and 215 of light emitting elements 100. In the illustrated example, each string includes six light emitting elements, or three pairs (e.g., 100a, 100b) of light emitting elements 100. A second cluster 450 may include three strings 210, 212, and 214 of light emitting elements 100, each string including six light emitting elements 100 (or three pairs 100a, 100b) of light emitting elements 100.

[0044] exist Figure 3In the example shown in , the light emitting elements 100 in each string are electrically connected by conductor segments (1800) comprising one or more flexible printed circuit boards 180. The strings comprising each cluster can themselves be interconnected by one or more conductive segments comprising the flexible printed circuit board 180. Each string can be driven by at least an integrated circuit (IC) 190 implementing a driver. Each driver IC 190 can electrically drive and control each surface emitter 100 of the string 100 individually, or can drive and control the string 200 collectively.

[0045] Figure 4 is a front view of an example light emitting element 100, the example light emitting element 100 comprising Figure 1 The arrangement of electrically interconnected light emitting elements 100 is shown in FIG. Figure 2 The configuration shown in Figure 1 One of several light emitting element 100 configurations of electrically interconnected light emitting elements 100 is shown in FIG.

[0046] like Figure 4 As shown in FIG. 1 , the light emitting element 100 includes a mixing box 110, and a light source 130 is disposed in the mixing box 110. In some examples, the mixing box 110 is substantially filled with TiO 2 The light source 130 may include one or more light emitting diodes (LEDs), each LED having an anode and a cathode (in Figure 2 ), to deliver power to the light source 130, thereby causing light to be emitted therefrom.

[0047] The light emitting element 100 may further include a printed circuit board 170 coupled to the mixing box 110. The printed circuit board 170 may be a rigid printed circuit board including an anode terminal 35 and a cathode terminal 25. The anode and cathode of the light source 130 may be electrically coupled to the anode terminal 35 and the cathode terminal 25 of the first printed circuit board 170, respectively.

[0048] The transparent layer 140 can be disposed in the mixing box 110 adjacent to the light source 130. In some embodiments, the transparent layer 140 includes a transparent silicone material layer. The transparent layer 140 can be molded (e.g., vacuum molded) in the mixing box 110 so that the light source 130 is in optical contact with the transparent layer 140 without an air gap between the light source 130 and the transparent layer 140.

[0049] In some embodiments, the light emitting element 110 further includes a partially transparent scattering or diffusing layer 150 disposed in the mixing box 110 adjacent to the transparent layer 140. The diffusing layer 150 can form a light emitting surface at the open end of the mixing box 110. The diffusing layer 150 can be configured to define a desired lateral brightness distribution of light emitted by the light source 130. In some embodiments, the light diffusing layer 150 can be molded or cast to shape the diffusing layer 150 before the diffusing layer 150 is disposed in the mixing box 110. In some embodiments, the layers 140, 150 can be configured in terms of color, transparency, scattering particles, shape, thickness, and position to produce a substantially Lambertian emission and provide a substantially uniform appearance.

[0050] Figure 5 It is shown Figure 4 100 is a perspective view of the light emitting top surface 120 of the mixing box 100 of the light emitting element 100 shown in FIG. Figure 4 As described above, the mixing box 100 is formed by the side 111 ( Figure 5 ), an open end 120 including a light emitting surface, and an opposite closed end 160. The mixing box 110 can be coupled to a first printed circuit board (PCB) 170 at the closed end 160, which can be a rigid printed circuit board. Figure 5 In the example shown in , ( Figure 2 The conductor element 1850 shown in FIG. 1 includes a flexible printed circuit board (FPCB) 180. The first PCB 170 may be composed of ( Figure 5 and Figure 6 The conductive portion (not shown) is configured to couple the electrodes of the light source 130 to the corresponding conductive portions of the FPCB 180 when the PCB 170 is coupled to the mixing box 110 and the FPCB 180.

[0051] As mentioned above about Figure 4 As described above, the light 2 from the light source 130 propagates through the transparent layer 140 and the light diffusion layer 150 of the mixing box 110. The light 2 can leave the mixing box 110 through the exit surface 120 of the light diffusion layer 150. When the flexible frame fixture 600 is fixed to the display frame 500, the light 2 leaving the mixing box 110 can propagate through the corresponding holes 501 in the display frame 500 (at the exit surface 120 of the light diffusion layer 150). Figure 1 ). In some embodiments, the surface portions of the display bezel 500 are configured to reflect emitted light back toward one or more of the surface portions of the mixing box 110. In this way, the display bezel can recycle stray emitted light, thereby increasing the optical efficiency of the light emitting element and contributing to the intensity of light propagating from the display bezel 500.

[0052] Figure 6 is a perspective view of the mixing box 110, which shows Figure 5 The bottom surface 160 of the mixing box 110 is shown in FIG. The mixing box 110 may include a top edge (at Figure 5 and Figure 6 The top edge is formed as a lip 126 that defines a perimeter around the open end 120 of the mixing box 110, with the light reflecting side 111 (not visible in the figure), and the lip 126 extends outwardly from the side 111 and is substantially perpendicular to the side 111.

[0053] Figure 7 is a perspective view of a portion of the flexible display assembly 800. Figure 7 As shown in , each frame unit 602 may include a side 611. Figure 7 As shown in , when the pair 110a, 110b of the light-emitting elements 100 are arranged in the corresponding openings 601 of the frame unit 602 and the flexible grid fixing device 600 is fixed to the display frame 500, the edge of the frame unit 602 can engage the inner surface of the flange 126 to press the outer surface of the flange 126 against the inner surface 507 of the display frame substrate 502.

[0054] Each frame unit 602 can be formed to define a space that can accommodate ( Figure 2 ) corresponding openings 66 for conductors 1800, such as wires, cables, or FPCB 180, extending between the light emitting elements 100 to electrically interconnect the light emitting elements 100 in strings and / or clusters (in Figure 1 and Figure 3 ). Thus, the flexible grid fixture 600 can structurally support the conductor system 300, which can interconnect a plurality of electrically interconnected light emitting elements, while structurally supporting the light emitting elements themselves in the arrangement defined by the frame unit 602.

[0055] In some examples, the frame unit structural portions and other structural portions of the flexible grid fixture 600 can be formed to integrate a power supply, an IC for implementing a driver, a controller, and other electronic components that cooperate to control the light source 130 to produce various lighting patterns on the display bezel 500 when the flexible display assembly 800 is mounted to a structure (such as a grille surface portion of an electric vehicle).

[0056] The resulting flexible display assembly 800 can provide lighting elements, electrical interconnects, and control components in a form ready for attachment to a surface of a structure that will carry the display assembly, such as a grille area of ​​an electric vehicle. The flexible display assembly 800 can form visually distinct display lighting patterns when mounted on a surface of a structure and powered. Advantageously, the flexible display assembly 800 can be bent to conform itself to a curved surface, such as a curved surface in a grille area of ​​an electric vehicle body.

[0057] Figure 8 A light emitting element 100 is shown, which includes a light source 130 disposed in a mixing box 110 and includes Figure 4 The PCB 170. The light source 130 may include an anode terminal and a cathode terminal (at Figure 8 ), which are respectively connected to corresponding terminal pads (in Figure 5 ).

[0058] In some embodiments, an integrated circuit (IC) implementing a driver and / or a controller may be disposed within the mixing box 110 and coupled to the light emitting element 130 to control the light emitted therefrom. In some embodiments, such an IC may be disposed on a surface of the PCB 170 and coupled to the light source 130 via contacts disposed on the surface of the mixing box 110.

[0059] In these embodiments, the bottom surface 126 or other surface (not shown) of the mixing box 110 can provide electrical contact pads connected to the pins of the integrated circuit. The additional contact pads can transmit data and / or control signals to the integrated circuit, which in turn can control the power delivered to the light source 130 accordingly. In this case, in addition to the anode terminal 35 and the cathode terminal 25, the PCB 170 can include data and / or control terminals (not shown).

[0060] Anode terminal 35 and cathode terminal 25, as well as data and control terminals (if any) may be formed on top surface 171 of PCB 170. Figure 8 In the embodiment shown in FIG, the anode terminal and the cathode terminal on the bottom surface 160 of the light box 110 can be connected to the anode terminal 35 and the cathode terminal 25 of the PCB 170 respectively by means of corresponding conductive spring clips 1300. Each spring clip 1300 can extend between a terminal pad on the bottom surface 126 of the light box 110 and a corresponding terminal on the top surface 171 of the PCB 170.

[0061] The proximal end 1301 of the spring clip 1300 can make electrical contact with the corresponding terminal pads on the bottom surface 126 of the light box 110, while the distal end 1302 can make electrical contact with the corresponding terminals (25 or 35) on the top surface 171 of the PCB 170. In some applications, the proximal portion 1303 of the spring clip 1300 can be disposed between the bottom surface 160 of the light box 110 and a support structure (such as a heat sink 1306 disposed between the light source 130 and the PCB 170).

[0062] Fig. 9 is a perspective view of spring clip 1300 . Fig.10 is a front view of spring clip 1300. Spring clip 1300 may include a flexible middle portion 1303 that may bend in response to an applied compressive force, such as when pressure is applied to light box 110 to press light box 110 onto PCB 1700. Spring clip 1300 may be disposed relative to terminal 25 or 35 of PCB 170 such that in response to bending of middle portion 1303, terminal end 1302 slidably engages terminal 25 or 35 without interrupting electrical contact.

[0063] PCB 170 can be formed to extend the conductive portions of anode terminal 25, cathode terminal 35, and additional terminals (if any) formed on top surface 171 of PCB 170 to bottom surface 172, for example, via pins 1305 extending from bottom surface 172 of PCB 170. In such an embodiment, wire or cable 1307 may include conductive element 1800 (at Figure 2 ). Wire 1307 may be coupled to pin 1305 via connector 1309.

[0064] Fig.11 Shows Figure 8 An alternative embodiment of the light emitting element shown in Fig.11 In the example shown in , PCB 170 is configured to include spring pins 1405 that extend from terminals formed on top surface 171 of PCB 170 through PCB 170 and bottom surface 172 of PCB 170. In such an embodiment, wire 1407 includes conductive segment 1800 of conductor system 300. Fig.12 An example of a suitable spring pin 1405 is shown.

[0065] Fig.13 is a top view looking down at the illuminated top surface 120 of the mixing box 100, which includes a mixing box suitable for implementing Figure 1 800 of the display assembly 800 depicted in FIG. The light emitting element 100 may include a light source 130 disposed within a mixing box 110 (also in FIG. Figure 5). Fig.13 In some embodiments, light source 130 includes one or more LEDs 101 provided as a lead frame package 102. In some embodiments, lead frame package 102 provides a single LED 101. In other embodiments, lead frame package 102 can provide multiple LEDs 101, such as red, green, and blue LEDs. Package 102 can include an LED configured to emit light of any color or combination of colors, or can provide an LED configured to emit monochromatic light or white light.

[0066] In the example shown, the leadframe package 102 includes an integrated circuit (IC) 103, which can be a driver IC and / or a controller IC. In some arrangements, the IC 103 is coupled to the anode or cathode of the LED 101 to provide power according to a power control signal that pulses the LED on and off according to a pulse width modulation (PWM) scheme, where the length of the "on" time relative to the "off" time determines the brightness of the LED. In some embodiments, the LED package 102 can include more than one driver or controller IC, such as one driver IC for each LED 101 that includes the package 102. In other embodiments, the LED package 102 does not include a driver or controller IC.

[0067] In some embodiments, each lead frame package 102 provides leads 24, 26, 28, and 30 for electrically connecting the light emitting element 100 to components external to the mixing box 110. For example, in Fig.13 In the embodiment shown in FIG. 1 , the leads 24, 26, 28 and 30 are connected to corresponding leads provided by the flexible grid fixture 600 to connect the lead frame package 102 to an operating power source and a driver and / or controller IC 103. The leads 24, 26, 28 and 30 of the lead frame 105 do not need to be connected to the corresponding leads provided by the flexible grid fixture 600. Fig.13 The arrangement of the lead frame 105 is provided in the same arrangement as shown in the example of FIG. A person of ordinary skill in the art will appreciate after reading this specification that various suitable configurations of LED package 102 and lead frame 105 structures and arrangements may be suitable for implementing the embodiments described herein. These may include arrangements in which leads 24, 26, 28, and 30 are configured to connect to corresponding leads outside the mixing box 110 via connections formed on one or more outer surfaces of the mixing box 110. In some embodiments, the lead frame 105 may provide only two leads, one being a power lead and the other being a return lead.

[0068] Fig.14 Shows two Fig.13 Each light emitting element 100 shown in FIG. 1 is provided with a pair of light emitting elements 100a, 100b (also Figure 1). The light emitting elements 100a and 100b are shown arranged as they would appear when arranged in the frame unit 602 of the flexible grid fixture 600 ( Figure 1 Each light emitting element 100 may include a lead frame package 102 that provides a lead frame 105 including a set of leads 24 , 26 , 28 , and 30 .

[0069] Fig.15 is a top view of a portion of an example second leadframe assembly 112. Unlike the first leadframe 105 of the leadframe package 102, the second leadframe assembly 112 is external to the light emitting element 100 and the leadframe package 102. The second leadframe assembly 112 may include one or more physically separate and electrically isolated electrical conductors that extend substantially in parallel and are formed as a unitary structure that generally corresponds in shape and size to the shape and size of the flexible grid fixture 600. In some embodiments, the leadframe assembly may include more than one part so that the parts may be coupled to those portions of the flexible grid fixture 600 where leadframe connections are desired. In some embodiments, the leadframe assembly 112 may be formed as an integral part of the flexible grid 600 during molding of the flexible grid 600.

[0070] The second lead frame assembly 112 can be configured to couple with the flexible grid fixture 600 to provide electrical connections between the light emitting elements 100 disposed within the frame units 602 and to external components such as a power supply 1010 and a controller 1020 to distribute power and control signals to the light emitting elements in the structural arrangement defined by the flexible grid fixture 600. For example, the second lead frame assembly 112 can provide terminal end portions or leads 1024, 1026, 1028, and 1030 around each frame unit 602. When the light emitting elements 100 are disposed in each frame unit, the leads provided by the first lead frame 105 can be connected to corresponding leads 1024, 1026, 1028, and 1030 provided by the second lead frame 112 to electrically interconnect the light emitting elements 100 disposed in the flexible grid fixture 600 when the flexible grid fixture 600 is coupled to the display bezel 500 to form the display assembly 800.

[0071] Fig.16 The frame unit 602 of the flexible grid fixture 600 is shown, in which a Fig.15 , for example, by molding the lead frame assembly 112 into the flexible grid fixture 600 when manufacturing the flexible grid fixture 600. In alternative embodiments, the lead frame assembly 112 may be coupled to the flexible grid fixture 600 after the flexible grid fixture 600 is formed. Fig.17 Shows Fig.15 The frame unit 602 shown in FIG. 1 has a pair of light emitting elements 100 a and 100 b disposed therein.

[0072] Fig.18 1 is a functional diagram showing power and control interconnections between a controller IC 1020 and a power source 1010 and a pair of light emitting elements 100a, 100b via leadframe interconnections. Each of the light emitting elements 100a, 100b may include an LED package 102 disposed on a rigid printed circuit board 170. In the example shown, the leadframe 112 is configured so that the leads correspond to the leads or connectors provided on the rigid printed circuit board 170, and the corresponding conductors comprising the leadframe 112 are coupled to the controller IC 1020 and the power source IC 1010 via first and second ports 1020 and 1011 formed on or attached to the leadframe assembly 112 (not visible), which may be coupled to the flexible grid fixture 600 or embedded within the flexible grid fixture 600 and distributed to the frame unit 602.

[0073] In some embodiments, either or both of ICs 1020 and 1010 may be disposed within flexible grid fixture 600, or formed during molding within flexible grid fixture 600. In other embodiments, IC 1020 and / or IC 1010 may be disposed within flexible grid fixture 600 and coupled to an external power source, such as a vehicle battery, and / or coupled to a user interface through which a user may configure controller 1020 to control LEDs 101 of light emitting element 100 according to user preferences.

[0074] Fig.19 1 is a block diagram of a string 1080 of a light emitting element 100 according to an example embodiment. In this example, the string 1080 may include a first half 1060a and a second half 1060b. Each half string may include three pairs (e.g., each pair includes Figure 1 100a, 100b) light emitting elements 100 shown in the string 1080, there are a total of six light emitting elements 100 in the string 1080. For example, the half string 1060a may include three adjacent light emitting elements 100a. Each light emitting element 100a may include at least one corresponding LED 101a disposed in a corresponding mixing box 110a. Each light emitting element 100a may further include a corresponding driver IC 1049a coupled to an anode and / or cathode of the corresponding LED 101a.

[0075] Each driver 1049a can be coupled to the driver 1049a of the adjacent light emitting element 100a by one or more conductors 1050. The conductors 1050 can transmit control signals and / or data between the drivers 1049. The driver 1049 can switch power to the corresponding LED 101 according to the control signal according to a pulse width modulation (PWM) scheme to adjust the brightness of the corresponding LED 101a. The driver 1049a at one end of the half string 1060a can be coupled to receive a control signal from the half string controller 1021a transmitted by one or more conductors 1044a. In some embodiments, each LED comprising the light emitting element 100 can be individually addressable by a signal transmitted by the conductors 1050a, 1050b.

[0076] The power supply 1010, which may be provided as an integrated circuit, may provide an operating voltage and return path to each driver 1049a in the half string 1060a and each driver 1049b in the half string 1060b via conductor 1048. The half string 1060b may include an arrangement of light emitting elements 100b, LEDs 101b, drivers 1049b, and controllers 1021b. In some embodiments, the power supply 101 and / or controller ICs 1021a, 2021b may be embedded in ( Figure 1 ) within or coupled to a portion of the flexible grid fixture 600 (shown in Figure 1 Portion of the flexible grid fixture 600 (shown in ).

[0077] In some embodiments, conductor 1048 may be provided by lead frame subassembly 112 (e.g., in Fig.15 ), the lead frame subassembly 112 may be disposed in a flexible grid fixture 600 (in Fig.16 ), while conductors 1050a and 1050b may be provided as wires (e.g., in Figure 8 ) or via one or more flexible printed circuit boards (in Figure 7 ). In other embodiments, conductor 1048 and conductors 1050a and 1050b may be provided by a wire frame. In still other embodiments, conductors 1048, 1050a, and 1050b may include wires. Display assembly 800 may be implemented by any combination of wires, flexible printed circuit boards, and / or wire frame leads coupled to flexible grid fixture 600.

[0078] Fig. 20 is a structural functional diagram showing a flexible grid fixture 600 comprising three columns 3003, 3006, 3009 of frame units 602, each frame unit 602 being configured to accommodate a corresponding pair of LEDs (in Figure 1100a, 100b in the figure). The flexible grid fixture 600 may include an embedded lead frame assembly 112 that extends through the frame unit 602 and along each column 3003, 3006, 3009 of the flexible grid fixture 600. The lead frame 112 may be formed so as to provide each frame unit 602 with a plurality of leads 3024, 3026, 3028, and 3030 for connecting to the corresponding light emitting element ( Fig. 20 The corresponding leads are provided by the lead frame 115 (not shown).

[0079] When the light emitting element is arranged in the corresponding frame unit 602, Fig. 20 The flexible grid arrangement shown in FIG. 4 may define a cluster 400 of light emitting elements 100. Cluster 400 may include three strings corresponding to columns 3003, 3006, and 3009. Each string may include six light emitting elements 100 ( Fig. 20 (not shown). Fig. 20 In the example shown in FIG, driver IC 3011 is coupled to a lead frame conductor extending along column 3003. IC 3012 may be coupled to a lead frame conductor extending along column 3006, and IC 3013 may be coupled to a lead frame conductor extending along column 3009. A cluster controller 3015 may be coupled to drivers 3011, 3012, and 3013 to coordinate control of light emitting elements 100 across the string.

[0080] exist Fig. 20 In the embodiment shown in FIG. 1 , the lead frame 112 provides two conductors (not separately depicted) for each light emitting element 100, such as one conductor providing an operating voltage and another conductor providing a return path. However, in other embodiments, the lead frame 112 may include more than two conductors, such as four or six separate conductors that are connected to the corresponding LED package 1320 (in FIG. Figure 8 and Fig.11 1 and 2. The lead frame 112 may be formed such that each conductor includes a terminal portion forming a lead (e.g., 3024, 3028) that extends into the opening 601 of each frame unit 603 when the light emitting element 100 is disposed in the corresponding frame unit portion.

[0081] Fig.21 is a functional block diagram of a flexible grid fixture 600 configured to implement three clusters 2002, 2004, 2006 of light emitting elements 100. Each cluster may correspond to Fig. 20 The cluster 400 shown in FIG. Fig.21 As shown in FIG. , each cluster may include three strings (eg, 3003, 3006, 3009), each string including three pairs of LEDs 100 (in Figure 1 100a, 100b in the example pair shown). Each cluster 2002, 2004, 2006 can be controlled by a corresponding corresponding cluster controller IC 1302, 1304, 1306. A master controller 1308 can be coupled to the cluster controllers 1302, 1304, 1306 to coordinate the lighting of the LEDs across the cluster controllers. In some embodiments, the cluster controllers 1302, 1304, 1306 can be configured to control each string 3003, 3006, 3009 individually. In other embodiments, the cluster controllers 1302, 1304, 1306 can be configured to control each LED 100 comprising the display assembly 800 individually. In some embodiments, a user interface 1310, which can be a graphical user interface, can be provided to allow a user to configure various lighting parameters and patterns of the LEDs comprising the display assembly 800.

[0082] Fig. 22 3 is a top view of a string 3000 of light emitting elements 100, the string 3000 comprising three pairs of LEDs 100a, 100b, each pair being arranged in a corresponding corresponding frame unit 602. Fig. 22 As shown in , the cathodes 408 of each pair of LEDs 100a, 100b can be connected together to define a common cathode configuration. In this configuration, each of the six LEDs that make up the string 3000 can be controlled individually. For example, each LED can be individually controlled by a signal that is individually provided to each anode 409 of each of the six LEDs that make up the string 3000.

[0083] Conductor system 1400 can include seven electrically isolated conductors. In certain embodiments, conductor system 1400 can include lead frame. One of seven conductors can be connected to the common cathode in each unit 602, to provide a common cathode power path or loop path. Each of the other six conductors can be connected to the corresponding corresponding anode 409 of the six LEDs that form the string 3000, to provide a separate conductive path for each LED. This configuration can allow each LED to be controlled individually. In other words, each LED in string 3000 can be controlled separately from every other LED in string 3000, such as by interrupting the selected conductive path in each conductive path according to the corresponding PWM scheme of the brightness or intensity level of the light emitted by the corresponding LED. For example, each LED in string 3000 can be controlled individually to have a brightness or intensity level different from the brightness or intensity level of every other LED in string 3000.

Claims

1. A display assembly, comprising: a flexible grid defined by a plurality of structurally interconnected frame units, each frame unit configured to accommodate at least one light emitting element, such that the plurality of frame units distribute the light emitting elements over the flexible grid in a first arrangement of the light emitting elements; and a display bezel providing an arrangement of apertures corresponding to the first arrangement of light emitting elements, The flexible grid and the display bezel are configured to interconnect to maintain the light emitting elements in optical alignment with the apertures when the display assembly is positioned on a curved surface of a vehicle.

2. The display assembly of claim 1, further comprising a conductor system configured to electrically interconnect the light emitting elements.

3. A display assembly according to claim 2, wherein the conductor system includes a first lead frame assembly, the first lead frame assembly including a plurality of linearly extending conductors, the first lead frame assembly being configured to conform to the shape of the flexible grid, the conductors providing a plurality of leads extending into each frame unit so as to allow contact with corresponding leads of a second lead frame including an LED package, the LED package including a corresponding at least one light-emitting element.

4. The display assembly of claim 1 , wherein each light emitting element comprises: A hybrid box having at least one light emitting diode (LED) package disposed therein, a layer of light diffusing material defining the light emitting surface of the mixing box, and A layer of transparent material is disposed between the light diffusing layer and the at least one LED package.

5. The display assembly of claim 3 , wherein the LED package is mounted on a rigid printed circuit board and electrically coupled to terminals of the rigid printed circuit board via flexible contact strips extending between leads and terminals of the LED package, the flexible contact strips being configured to slidably engage the terminals in response to a flexing force applied to a middle portion of the flexible contact strips.

6. The display assembly of claim 3, wherein each light emitting element comprises a rigid printed circuit board having a compressible pin mechanically coupled thereto, each compressible pin comprising: a proximal portion extending from the printed circuit board perpendicular to a surface of the printed circuit board to retractably engage a corresponding terminal disposed on an outer surface of the mixing box, extending from the proximal end through a mid-portion of the printed circuit board, and A distal end is configured to receive a conductor provided by the flexible mesh.

7. The flexible display assembly of claim 3 , wherein the mixing box comprises a light reflecting side having a top edge, the top edge defining a flange extending around at least a portion of a perimeter of a light emitting surface, the flange extending outwardly from the light emitting surface perpendicular to the reflective side to form an inner flange portion, wherein when the flexible grid is coupled to the display bezel, the inner flange portion abuts a top edge of a corresponding frame unit.

8. The flexible display assembly of claim 2, wherein the conductor system comprises an arrangement of flexible printed circuit boards extending between the light emitting elements.

9. The flexible display assembly of claim 2, wherein the conductors comprise cables or wires extending between the light emitting elements.

10. The flexible display assembly of claim 4, wherein the first lead frame assembly is disposed within the flexible grid.

11. The flexible display assembly of claim 4, wherein the first leadframe assembly is mechanically coupled to the flexible mesh.

12. The flexible display assembly of claim 2, wherein the conductors of the conductor system are arranged to electrically interconnect the light emitting elements to form clusters of electrically interconnected light emitting elements, each cluster comprising three strings of electrically interconnected light emitting elements, each string comprising six light emitting elements.

13. The flexible display device of claim 12, further comprising a cluster controller connected to the conductors of the conductor system and configured to coordinate control of the light emitting elements across each of the three strings of electrically interconnected light emitting elements.

14. The flexible display device of claim 2, wherein the mixing box further comprises an integrated circuit coupled to the light emitting diode.

15. A method of forming a flexible display suitable for being disposed on a curved surface of a vehicle, the method comprising: forming a flexible grid fixture comprising an arrangement of structurally interconnected frame units, each frame unit comprising a wall defining opposing first and second edges, each of the first edges defining a recessed portion; disposing at least one light emitting element of the plurality of electrically interconnected light emitting elements within each of the plurality of structurally interconnected frame units; coupling the arrangement of light emitting elements to the flexible mesh structure to form a lighting subassembly; and Portions of the conductors that electrically interconnect the light emitting elements are disposed into the recessed portions of the corresponding frame units.

16. The method according to claim 15, further comprising: forming a display bezel including a substrate defined by an arrangement of holes corresponding to the arrangement of the frame units; and The illumination subassembly is coupled to the display bezel so as to optically align each respective light emitting element with a corresponding respective aperture.

17. The method of claim 16, wherein coupling the illumination subassembly to a display bezel substrate comprises applying pressure on a first edge of the frame unit to press a flange of the light emitting element against a display bezel substrate.

18. The method of claim 15, further comprising coupling terminals of respective light emitting elements to corresponding terminals of corresponding respective printed circuit boards.

19. A lighting fixture for mounting on a curved exterior surface of a vehicle, the lighting fixture comprising: a flexible grid support frame comprising a plurality of structurally interconnected frame units, each frame unit defining an opening for receiving at least one light emitting element; and a plurality of light emitting elements electrically interconnected by a plurality of conductors, each light emitting element being disposed within a corresponding one of the frame units, Each light emitting element is configured with a flange portion which, when the light emitting element is disposed in the frame unit, engages an edge on one side of the corresponding frame unit so that when the edge on the opposite side of the corresponding frame unit rests on a curved surface of the vehicle, the light emitting element is held in optical alignment with the corresponding hole of the display bezel.

20. A method of forming a flexible grid lighting fixture, comprising: molding a flexible grid structure comprising a plurality of structurally interconnected frame units, each frame unit comprising a wall defining opposing first and second edges, each of the first edges defining a recessed portion; forming a lead frame defining linearly extending conductors having a shape generally conforming to the shape of the flexible mesh structure; and coupling the lead frame to the flexible grid structure such that leads of the linearly extending conductors contact light emitting elements disposed within corresponding frame units such that the conductors comprising the lead frame distribute power to a plurality of structurally interconnected frame units, A terminal end portion is included that extends into each frame unit to contact a terminal of the light emitting element when the light emitting element is coupled to the frame unit.

Images