Enhanced diffusive lighting and pattern effects on automotive surface panels

Abstract

The present invention relates to an automotive body panel illumination, the object of which is to obtain a whitest diffusive appearance that maximizes light intensity transmission. An automotive light emitting panel system (200) includes a light emitting unit arrangement as defined by an anti-fog diffusing coating (10) coated onto a light transmissive substrate (30) and a corresponding masked (40) cover lens patterned with opaque gaps (8) configured to convey incident light directly through the patterned optical arrangement, and operates between a hidden mode and a lighting mode of the light emitting unit.

Description

Technical Field

[0001] The present invention relates to diffuse light formulations and light pattern effects for automotive plastic panels. More specifically, the present invention relates to a coated mask arrangement along a surface panel or cover lens of an automotive light unit that applies a "ghosting effect" transition during the hidden-to-lit aspect of road and signal lighting. Background Art

[0002] In the automotive field of vehicle lighting, manufacturers are seeking to improve lighting effects that combine lighting and signaling functions, and additional technical enhancements are desired in order to achieve eye-catching lighting and aesthetic effects. Certain vehicle signaling applications, such as daytime running lights (DRLs), require high-intensity lighting with high uniformity to overcome common problems associated with LED-based lighting, which typically exhibits low uniformity and hot spots.

[0003] Among the enhancement goals, automakers require striking white diffuse lighting, such that the on-state of a light unit is visibly different from the off-state of the unit, and a pattern can appear when the light unit is enabled. Automakers also seek striking diffuse light formulations to appear visibly along the plastic panels between the hidden to lit modes of the automotive light units. To date, manufacturers have achieved this white diffuse appearance by applying particulate additives suspended in a light-transmitting medium. This approach has presented unsatisfactory results, resulting in a grayish "milk jug look" rather than a striking, clear, uniform white appearance.

[0004] Such conventional practices for achieving this diffuse uniform intensity balance present significant drawbacks in vehicle applications requiring high uniformity (e.g., signal lamps) and have led designers to apply diffusion techniques such as films, surface glazing, layered coatings, added optics, added suspensions, or impregnation to light-transmitting media and foreign filters in order to correct or reduce non-uniform intensity and hot spot effects. While such approaches can improve uniformity, these approaches often result in significant light loss due to scattering and other mechanisms that result in loss of light intensity.

[0005] Accordingly, in the automotive field, there is a need for LED-based lighting units that exhibit a high degree of light uniformity, eye-catching light diffusion, opalescent effects, and aesthetic design flexibility to produce a low-cost, luxurious appearance. Unique diffusion arrangements can be deployed through panel and lens cover emission to address and meet the goals sought by industrial and related industries. Summary of the invention

[0006] Accordingly, the present invention has an object to overcome the above-mentioned shortcomings in the prior art. One object of the present disclosure is to provide an enhanced automotive solution to provide eye-catching white diffuse lighting with a "ghosting effect" technique. Another object is to produce highly uniform lighting for signaling applications, including DRL applications that require lighting patterns with high intensity and uniformity.

[0007] An additional objective is to simplify the manufacturing system and process to produce an enhanced and cost effective uniform light emitting unit to produce a striking white light for automotive surface panels and enhanced styling along cover lenses. And a basic objective is to provide a diffuse coating with the highest light transmittance and the whitest unlit appearance on a light-transmissive cover or panel.

[0008] Specifically, the present invention proposes to produce lighting features that have a hazy appearance or "ghosting effect" when the lighting is off and produce an apparent bright white diffuse glow appearance when the lighting is enabled. The present invention also proposes to produce features that appear consistent and remain uniform in light intensity without adding technical complexity or requiring additional processing of the transmissive medium. At the same time, the design of components in production is greatly simplified.

[0009] In the off state of the light emitting unit, the panel lens with the patterned mask formed on the panel lens appears to conceal the visibility outside the range of the panel lens. When the light emitting unit is turned off or on, the superimposed pattern mask with the light-transmitting gap is expected to maintain the same pattern aspect. However, in view of the on or off condition of the light emitting unit, the visible appearance of the panel lens through the light emitting unit maintains the same pattern, but the visibility changes between the on and off states for the observer. Therefore, the on aspect of the light emitting unit is different from its off aspect. And thus, according to the present invention, the light emitting unit produces a so-called "ghosting effect".

[0010] In addition, the light source beam or incident light intensity passing through the gap of the pattern mask can be different from the light source beam or incident light intensity of other sections of the panel lens gap area. Therefore, a uniform or gradient light intensity can be perceived over the entire illuminated area of ​​the panel lens or light-transmitting surface of the light-emitting unit.

[0011] These and other objects of the present disclosure can be achieved by one or more of the following aspects. Accordingly, the present invention proposes:

[0012] A light-emitting panel having light-diffusing properties associated with an automotive lighting or signaling system, the light-emitting panel comprising: a polymer panel made of a light-transmitting medium; a sealing coating on an outer surface of the polymer panel; a light-blocking mask on the sealing coating, wherein the light-blocking mask comprises a pattern formed with a plurality of bleed-gaps produced by a laser ablation process; and an anti-fog diffusing coating on an opposite side of the outer surface.

[0013] The light emitting panel according to the alternative aspect, wherein the sealing coating is pre-coated on the polymer panel or has been designed into the polymer panel when the polymer panel is manufactured.

[0014] In the light emitting panel according to the alternative aspect, the composition of the polymer panel is formed of a polycarbonate (PC) or polymethyl methacrylate (PMMA) based material.

[0015]

[0013] The light emitting panel of the alternative aspect, wherein the composition of the light blocking mask has a coverage thickness (T) of about 12 micrometers to 15 micrometers (0.012 mm to 0.015 mm).

[0016] In the light emitting panel of the alternative aspect, a plurality of light-leaking gaps are formed on the light blocking mask by an ablation process.

[0017]

[0013] The light emitting panel of the alternative aspect, wherein the anti-fog diffuse coating has a measured thickness (T) or layer depth of about 8 microns to 15 microns (0.008 mm to 0.015 mm).

[0018]

[0013] The light emitting panel of an alternative aspect wherein the light emitting panel having light diffusing properties is incorporated as part of an automotive component or lighting unit.

[0019] The light emitting panel of the alternative aspect, wherein the sealing coating covers the light blocking mask and the plurality of light-leaking gaps along the polymer panel.

[0020]

[0013] The light emitting panel of the alternative aspect, wherein the seal coating is a polyurethane based material along the outside of the polymer substrate.

[0021] The light emitting panel of the alternative aspect is configured to generate incident light without hot spots and with substantial uniformity along the pattern formed with the plurality of light-leaking gaps when activated by the plurality of light sources of the associated light emitting units.

[0022] A light emitting panel as described in an alternative aspect, wherein the light emitting panel is configured to produce a "ghosting effect" feature to an observer to show a visible visual impression when the associated light emitting unit is turned on and to show a different visual effect when the associated light emitting unit is turned off.

[0023] A light-emitting panel of an automobile lighting system, the light-emitting panel comprising:

[0024] A polymer panel made of a light-transmitting substrate; a sealing coating on an outer side of the polymer panel; a light-diffusing coating formulation on the same or opposite side of the outer side; a mask coating with light-changing properties overlying the sealing coating, wherein the mask coating includes a pattern formed with a plurality of light-leaking gaps produced by an ablation process; and a plurality of light sources configured to transmit light between the inner side and the outer side through the plurality of light-leaking gaps after propagating through the light-diffusing coating formulation, the polymer panel, and the plurality of light-leaking gaps.

[0025] A light-emitting panel, comprising:

[0026] A light-transmissive polymer substrate; an anti-fog diffusion coating formulation along the inner side of the polymer substrate, the anti-fog diffusion coating formulation having both anti-fog and light-smoothing functions within an integrated layer, the integrated layer being configured to provide an observer with a predetermined value of anti-fog diffusion and a predetermined value of light diffusion of luminous intensity; a mask coating of a light-changing composition coated along the outer side or the inner side of the polymer substrate, the outer side being opposite to the inner side; a plurality of light-leaking gaps within the mask coating, the plurality of light-leaking gaps being configured to receive a plurality of diffuse light beams passing through the anti-fog diffusion coating formulation having moisture-hiding properties and light-diffusing properties; the plurality of light-leaking gaps being formed on the mask coating by a laser ablation method; the diffuse light being configured to be altered or blocked during transmission through the mask coating and the polymer substrate; the diffuse light being suitable for passing through a plurality of light-leaking gaps or unobstructed areas of a light-emitting panel.

[0027]

[0013] The light emitting panel of an alternative aspect wherein the anti-fog diffuse coating on the inside of the polymer substrate measures about 8 to 15 microns (0.008 to 0.015 mm) thick.

[0028]

[0013] The light emitting panel of the alternative aspect, wherein the composition of the light blocking mask has a coverage thickness (T) of about 12 micrometers to 15 micrometers (0.012 mm to 0.015 mm).

[0029] A method for manufacturing a light emitting panel, the method comprising:

[0030] A polymer panel made of a light-transmitting substrate is presented; a sealing coating is applied on the outer side of the polymer panel; a light-diffusing coating formulation is applied on the same or opposite side of the outer side; a mask coating with light-changing capabilities is applied on the sealing coating or on one side of the polymer panel; a plurality of light-leaking gaps constituting a pattern are formed in the mask coating with light-changing capabilities by an ablation process; and a plurality of light sources are provided, which transmit light through the plurality of light-leaking gaps; and the plurality of light sources are propagated, and the plurality of light sources are configured to transmit light between the inner side and the outer side through the light-diffusing coating formulation, the polymer panel and the plurality of light-leaking gaps.

[0031] A method for manufacturing a light emitting panel, the method comprising:

[0032] A polymer panel is presented that is made of a light-transmissive substrate coated with a sealing coating; a light-diffusing coating formulation is applied on the same or opposite side of the outer side; a mask coating having light-changing properties is applied, the mask coating covering along the inner side or the outer side; a plurality of light-leaking gaps forming a pattern are formed by an ablation process in the mask coating having light-changing properties; and a plurality of light-leaking gaps are provided that are suitable for transmitting ambient light or transmitted light between the outer side and the inner side through the light-diffusing coating formulation and the polymer panel.

[0033] Certain expressions contained herein refer to components that are "configured to" or "adapted to" function in a particular manner. In this regard, such components are "configured to" or "adapted to" embody particular characteristics or function in a particular manner, wherein such expressions are structural expressions, rather than expressions of intended use. More specifically, references herein to the manner in which a component is "configured to" or "adapted to" refer to the existing physical condition of the component, and thus should be considered as express expressions of the structural characteristics of the component.

[0034] The above structures may be changed and modified without departing from the concept of the present invention. And it should be understood that the embodiments and examples cited above are non-limiting, as there are other embodiment variations in the present invention, as shown and described herein. In addition, unless these claims are otherwise clearly stated by their language, such concepts are intended to be covered by the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate different embodiments to explain these embodiments together with the specification. Therefore, the drawings are not necessarily drawn to scale. Any value dimensions shown in the accompanying tables and drawings are for illustration purposes only, and these value dimensions may or may not represent actual or preferred values ​​or dimensions. Where applicable, some or all features may not be shown to assist in the description of potential features. In the drawings:

[0036] Figure 1 are embodiments of light emitting panels and cross sections according to the present invention.

[0037] Figure 2 is an example of a cross section of a light emitting panel depicting an alternative configuration of a laminate stack according to the present invention.

[0038] Figure 3A is a sample embodiment of a light emitting panel according to the present invention, which demonstrates a "ghost effect" stereogram in a hidden or unlit mode.

[0039] Figure 3Bis a sample embodiment of a light emitting panel according to the present invention, which demonstrates a "ghost effect" stereogram in a visible or lit mode.

[0040] Figure 4 is an example of a cross section of a light emitting panel depicting an alternative configuration of a laminate stack according to the present invention.

[0041] Figure 5 is a non-limiting illustrated embodiment of an ablation mask pattern applied to a light emitting panel according to the present invention.

[0042] Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 and Fig.12 is a non-limiting example of an ablation mask pattern that may be applied to a light emitting panel according to the present invention.

[0043] Fig.13 , Fig.14 and Fig.15 are non-limiting examples of different forms and optical features that may be embedded in a substrate and applied on a light emitting panel according to the present invention.

[0044] Fig.16 An illustrative flow chart method of manufacturing a light diffuser panel system in accordance with the present invention is depicted.

[0045] Fig.17 An alternative embodiment of an illustrative flow chart method of manufacturing a light diffuser panel system in accordance with the present invention is depicted. DETAILED DESCRIPTION

[0046] The description set forth below in conjunction with the accompanying drawings is intended to be a description of different embodiments of the disclosed subject matter, and is not necessarily intended to represent any one selected embodiment. In some cases, for the purpose of providing an understanding of the disclosed embodiment, this specification may include specific details. However, it will be clear to those skilled in the art that the disclosed embodiment may be put into practice without these specific details. In some cases, known structures and components may be shown in block diagram form to avoid blurring the conception or design changes of the disclosed subject matter.

[0047] It should be understood that terms such as "front", "rear", etc. that may be used herein only describe reference points and do not necessarily limit the embodiments of the present disclosure to any particular orientation or configuration. In addition, terms such as "first", "second", "third", etc. only identify one of the multiple parts, components and / or reference points disclosed herein, and likewise do not necessarily limit the embodiments of the present disclosure to any particular configuration or orientation.

[0048] Furthermore, the terms “about,” “approximately,” “approximately,” “substantial,” and similar terms generally refer to ranges of the identified values ​​or any values ​​therebetween, including within a margin of 20%, 10%, or preferably 5%, in certain embodiments.

[0049] In the automotive field of vehicle lighting, automobile manufacturers seek to improve lighting effects that combine lighting and signaling functions and desire additional technical enhancements to achieve eye-catching lighting and aesthetic effects that both satisfy vehicle consumers and improve design satisfaction ratings, thereby enhancing the manufacturer's brand in a cost-effective manner.

[0050] A common problem with light emitting diodes (LEDs) is that the light they emit tends to be very directional, resulting in low uniformity and hot spots. Because certain vehicle signaling applications, such as daytime running lights (DRLs), require high intensity and high uniformity, a common problem associated with LEDs is that the light they emit tends to be very directional, resulting in low uniformity and hot spots.

[0051] Among the enhancement goals, automobile manufacturers and customers require eye-catching white diffuse lighting with "ghosting effect" technology. The "ghosting effect" technology enables a visible visual effect to be presented when the light-emitting unit is turned on or an unexpectedly different visual effect when the light-emitting unit is turned off. For example, when turned off, the light-emitting unit can have a normal bright black aspect appearance or a dark background appearance, hiding the view of the observer or providing a different visual effect than when the lighting device is turned on, so that when turned on, the visual effect of the emitted light can be uniform. In addition, when the light-emitting unit is enabled, a light pattern can appear. Such a light pattern can be purely decorative, can include a manufacturer logo, or can even perform a signaling function, such as a night position light. Although there may be different competing solutions in the relevant field that allow the "ghosting effect" to be produced, there is still a need for continuous improvement or enhancement of further solutions.

[0052] Another specific enhancement required by automakers is the characteristic of bright, uniform white illumination. Automakers require an eye-catching diffuse light formulation that hides the "ghosting effect" of the light-emitting unit until it becomes visible along the car's plastic panels between lighting modes. Typically, to achieve this white diffuse appearance, manufacturers resort to embedding or suspending particulate additives in a light-transmitting medium, but the results are less than ideal, presenting a grayish "milk jug look" rather than an eye-catching, clear, uniform white appearance.

[0053] Therefore, conventional limitations and practices present significant disadvantages for vehicle applications requiring high uniformity (e.g., signal lamps). These limitations have led designers to apply diffusion techniques such as films, surface glazing, layered coatings, added optics, added suspensions, etc. to light-transmitting media and external filters in order to correct or reduce non-uniform intensity and hot spot effects. These conventional approaches often result in significant light loss due to scattering and other mechanisms that easily lead to loss of light intensity.

[0054] Accordingly, in the automotive field, there is a need for LED-based lighting units that exhibit a high degree of light intensity and consistent uniformity, eye-catching light diffusion, opalescent effects, and aesthetic design flexibility to produce a low-cost, luxurious appearance. Therefore, embodiments of the present invention achieve the following objectives: Provide uniform illumination with bright or eye-catching white lighting for enhanced styling along cover lenses and automotive surface panels by achieving lighting effects through an enhanced and cost-effective method.

[0055] For some additional background on the simplest abstract concept of lighting products, a light emitting unit typically includes a housing frame, a lens body or cover lens and a light source within the housing. The manufacture of automotive light units involves securing the cover lens to the light emitting unit housing. The lens body is placed over the mouth of the housing frame to enclose and form the housing of the light emitting unit. Typically, when power is applied, the emitted light shines through the cover lens or lens body. The diffuse arrangement can be adapted to address the objectives sought by different embodiments of the present invention by light emission through the panel or lens cover.

[0056] An automotive light unit is intended to indiscriminately mean a vehicle rear light or a vehicle front light, or may also be interchangeably referred to as a headlamp or headlight. As is known, an automotive light unit may serve as a vehicle exterior light having a lighting or signaling function directed toward the exterior of the vehicle. For example, a light unit may potentially serve as a position light, a direction or turn indicator light, a daytime running light (DRL), a brake light, a fog light, a reversing light, a low beam light, a high beam light, or some combination thereof.

[0057] LED signal assemblies are used today to great practical effect. In the automotive industry, many motor vehicles now use LED-based lighting assemblies. A large amount of engineering work associated with these vehicle lighting assemblies is focused on reducing their overall size. In addition, LED-based vehicle assemblies typically rely on multiple LED light sources, each of which inherently produces high light intensity and has a small beam angle. As a result, many LED-based lighting assemblies produce "hot spots" of discrete light associated with each LED light source (including "low-profile" assemblies). The present invention addresses the purpose of how to configure and design LED-based vehicle lighting units and assemblies to produce highly uniform illumination for signal applications, including DRL applications that require lighting patterns with high intensity and uniformity.

[0058] exist Figure 1 In the present invention, light source 1 represents a luminous source of electromagnetic radiation or a source of visually perceived radiant energy (including "visible" light of the electromagnetic spectrum), but may include a wide range or combination of electromagnetic energy or radiant energy, including X-ray energy, ultraviolet energy and infrared energy, microwave spectrum and radio wave spectrum. Light source 1 may include every conventional and suitable lighting element source, such as filament-based lamps or incandescent lamps, fluorescent lamps, arc or gas discharge type lamps, light emitting diodes (LEDs) or other suitable conventional sources. Light source 1 may include one element or multiple (more than one) lighting elements.

[0059] Highly uniform light is particularly beneficial for a number of vehicle signaling applications (e.g., brake lights, tail lights, daytime running lights (DRLs), turn signals, reverse lights, etc.). In certain vehicle signaling applications, a lighting assembly that can produce an output lighting pattern having a combination of high uniformity and high intensity is particularly advantageous. For example, certain federal regulations require DRLs to produce high intensity lighting patterns, and customers often require that such patterns be produced with high uniformity.

[0060] exist Figure 1 , a cross section of a light emitting panel 100 is shown. The light emitting panel 100 may include a cover lens or a lens body and become part of an automotive component or a lighting device. The light emitting panel 100 includes a light transmissive medium 30 (hereinafter referred to as a "substrate"), on which an anti-fog diffusion coating 10 and a sealing coating 20 are provided. The sealing coating 20 may include a separate layer formed on the substrate 30, or may be an integral part of the light transmissive medium 30 during manufacture. The light transmissive medium 30 includes a polymer or glass-like composition having light transmissive properties, thereby allowing the light beam 11 from the light source 1 to allow incident light to pass through the substrate 30.

[0061] In one embodiment, the light-transmitting medium 30 may include a polycarbonate (PC) or polymethyl methacrylate (PMMA) material. The light-transmitting medium 30 may include a hard coating or a sealing coating or a protective layer in a constituent layer or outer layer of the substrate 30. The anti-fog diffusion coating 10 includes a unique formulation that performs both light-leveling functional characteristics and anti-fog functional characteristics, which is applied on one side of the light-transmitting medium 30 to form an important component of the light-emitting panel 100. The coating means of the anti-fog diffusion coating 10 may include, for example, spraying, manual or mechanical coating or dipping as a non-limiting example. In one embodiment, the coating thickness (T) of the anti-fog diffusion coating 10 is about 12 microns to 15 microns (0.012mm to 0.015mm). In an alternative embodiment, the coating thickness (T) value of the anti-fog diffusion coating 10 can also obtain acceptable results in the range of 8 microns to 12 microns (0.008mm to 0.012mm).

[0062] The light beam 11 emitted from the light source 1 undergoes a light leveling process while propagating the incident light through the anti-fog diffuse coating formulation 10 to provide a uniform intensity result, thereby meeting the balanced uniform-eye-catching intensity objectives of the present invention. The uniform light intensity value is consistent within a 10% variation range as measured by known prior art methods along the light output of the light emitting panel. The light intensity values ​​can be measured from multiple reference positions along the outside of the light emitting panel to determine the uniformity measurement value.

[0063] The anti-fog function is used to prevent fogging or vision-obstructing moisture from accumulating along the surface of the anti-fog diffuse coating 10 by hiding water droplets so that they are not visible. The key factor in the formulation that enables the anti-fog function of the anti-fog diffuse coating 10 is the concealment of moisture. The anti-fog diffuse coating 10 promotes water shedding performance through the polyurethane-based resin formulation, but is mainly used to hide and conceal water droplets, rather than working by absorbing, dispersing or causing moisture to be sucked away. The hybrid formulation coating can perform dual functions, including a light-leveling component and an anti-fog component, which can be combined with each other to represent the anti-fog diffuse coating 10. Alternatively, a separate coating formulation with a light-leveling component and a secondary coating formulation with an anti-fog component can also be used to achieve equivalent results through the process of different coatings.

[0064] The light leveling function is used to diffuse penetrating light and eliminate hot spots, while also enhancing white light conspicuity. The anti-fog diffuse coating formulation 10 includes a silica-based matting agent or matting particles, added at a concentration between 5% and 9% by volume, to reduce gloss and perform a light leveling function. In one embodiment, a silica-based matting agent or matting particles having a size of 4 to 12 microns (0.004 to 0.012 mm) can be stirred in to obtain acceptable results. However, in other embodiments, a silica-based matting agent or matting particles having a size of 6 to 9.5 microns (0.006 to 0.0095 mm) can be stirred in to obtain more favorable results.

[0065] In one embodiment, the coating thickness T of the anti-fog diffuse coating 10 can be in the range of 8 micrometers to 15 micrometers (0.008 mm to 0.015 mm). In another embodiment, the coating thickness T of the anti-fog diffuse coating 10 is typically 12 micrometers to 15 micrometers (0.012 mm to 0.015 mm) to achieve a more desired strength level required by customers.

[0066] When the appropriate model is applied for each corresponding medium (transparent clear, opaque, milky, granular transparent and granular reflective media), consistent and repeatable intensity levels can be achieved through measurable characteristics using modeling techniques known in the practice of the optical field (Lambertian, specular reflection, Gegenbauer scattering model phase, Gaussian or other medium material related models). It should be noted that the intensity results generally vary with the wavelength of the light source, the incident angle measurement from the light source, the measurement of the peripheral span along each incident angle, and the thickness of the transparent medium. The uniform light intensity value is consistent within a 10% variation range as measured by known existing methods along the light output of the light emitting panel. The light intensity values ​​can be measured from multiple reference positions along the outside of the light emitting panel to determine the uniformity measurement value.

[0067] The seal coating 20 represents a protective top coating to prevent weathering, contamination and degradation. The seal coating 20 is preferably a polyurethane-based material, but may also be another sealing material. The seal coating 20 is applied directly or indirectly along one side of the light-transmitting medium 30, and other intermediate components (i.e., mask pattern layers) may be covered thereon. The seal coating 20 may be applied by any means, such as, by way of non-limiting example, spraying, manual or mechanical application, or by dipping.

[0068] The anti-fog diffuse coating 10 includes a chemical formulation that provides an anti-fog function (moisture concealing material) and a light-leveling function (light-leveling technology) through an integrated coating material. Some of its details have been previously disclosed in this article and shared above. The anti-fog diffuse coating 10 includes a composition formed by a polyurethane-based resin and a leveling additive [preferably finely ground silica or glass-based particles of 6 microns to 9.5 microns (0.006mm to 0.0095mm) suspended in a white wavelength pigment], which combines light-leveling properties to promote diffusion and remove gloss. In an alternative embodiment, a matting agent or matting particles may include a wax based on polyethylene, polypropylene, PTFE, carnauba wax or amide in a coating or pigment included in the anti-fog diffuse coating 10. Alternatively, a leveling additive may include talc or corn starch to achieve similar performance effects, but it is not recommended due to the lack of durability due to the softness of such constituent materials.

[0069] like Figure 1 , Figure 2 and Figure 4 As shown, the LED light source 1 transmits the light beam 11 directly through the anti-fog diffuse coating 10 and the corresponding light-emitting panel embodiment, so that the observer P sees a uniform light pattern effect, which is consistent with the intensity measurement characteristics that can be measured and derived by the above-mentioned known applied modeling technology.

[0070] Figure 2A cross section of a light emitting panel 200 is depicted, the light emitting panel comprising Figure 1 The light emitting panel 200 may be incorporated into a cover lens or a lens body and may become part of an automotive component or a lighting device. Figure 2 A mask coating 40 is included, and a light seepage gap 8 is formed in the surface pattern area of ​​the mask coating 40 after the mask coating 40 is subjected to an ablation process. The mask coating 40 can be applied to the light-transmitting medium 30 by any means, such as, as a non-limiting example, spraying, manually, by mechanical coating or dipping process. In one embodiment, the coating thickness (T) value of the mask coating 40 can be about 12 microns to 15 microns (0.012mm to 0.015mm) to obtain the best results. For alternative embodiments, the coating thickness (T) value of the mask coating 40 can be set based on other laser ablation resolutions adjusted with time performance results. Through development testing, the criticality of this coating thickness of the mask coating 40 is crucial to effectively block the light seepage through the light-transmitting medium 30 and avoid the appearance of gray shades or undesirable blurred tones that make the appearance unclear when observed.

[0071] The LED light source 1 transmits the light beam 11 directly through the anti-fog diffuse coating 10 and the substrate 30, so that the observer P sees the lighting effects produced by the formed light leakage gap 8, which are consistent with the intensity measurements that can be obtained according to the known applied modeling techniques as described earlier in this document. The uniform light intensity value is consistent within a 10% variation range as measured by known methods along the light output of the light emitting panel. The light intensity values ​​can be measured from multiple reference positions along the outside of the light emitting panel to determine the uniformity measurement value.

[0072] The ablation process refers to the material removal of the deposit or layer of the mask coating 40 by an excitation wavelength or high intensity beam process such as, as a non-limiting example, a laser (light amplification by stimulated emission of radiation). The ablation process is not limited to laser-based material removal means, but can also refer to other processes of material destructive removal, such as mechanical grinding, sonic, thermal, UV wavelength or vibration processes. In one embodiment, ablation uses a pattern removal resolution of about 0.3 mm with a spacing of 0.3 mm. In alternative embodiments, laser ablation can use fine or coarse resolution pattern removal, which patterns are obtainable based on the applied laser wavelength.

[0073] Figure 3A and Figure 3B The embodiments shown are respectively provided for hiding until lighting. Figure 2 Product samples showing the contents are depicted where the unlit ( Figure 3A ), the observer P can see the light-emitting panel 200, and when the light-emitting panel 200 is actively illuminated ( Figure 3B), an observer can see the pattern emerge through the light-leaking gaps 8 of the mask coating 40 at the associated light-leaking regions 88. The light-leaking regions 88 can represent sections of multiple light-leaking gaps 8, which can represent different pattern arrangements.

[0074] Figure 3A It is described how the light emitting panel 200 appears to the observer P in an unlit condition, wherein the masking sections 77 along the panel surface covertly conceal the formed pattern and the light-bleeding gaps 8, which are indistinguishably hidden within the masking coating 40 when left unlit. Figure 3B An illuminated state of the light emitting panel 200 is depicted having a pattern of light bleeding regions 88 and light bleeding gaps 8 that reveal pattern features from a hidden ghost state and are distinguishable from the mask coating 40 when illuminated to an observer P. Although the mask coating 40 preferably represents a light blocking composition, in various embodiments, the mask coating 40 is not limited to light blocking properties and may also be opaque or may include iridescent materials to enhance lighting effects or adjust light transmission as desired.

[0075] Figure 4 A cross section of a light emitting panel 400 is depicted, showing a structure similar to Figure 2 elements; however, Figure 4 The embodiment of the present invention can be varied in that the layer positions of the mask coating 40 and the sealing coating 20 can be interchanged. The light emitting panel 400 can be incorporated into a cover lens or a lens body and can become part of an automotive component or a light emitting unit 70. Figure 4 In the embodiment of the present invention, the sealing coating 20 covers the mask coating 40 .

[0076] Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 and Fig.12 Depicted are different embodiments of the differentiated pattern 42 of the light seepage gap 8 produced after applying laser ablation in the mask coating 40. As shown in different illustrative embodiments, actual graphic examples of fine gradients, dots, geometric shapes or superimposed patterns 42 can be depicted using the ablation process so that a variety of non-limiting pattern effects can provide additional style for eye-catching diffusion, some decorative interest features or lighting effects. The resolution of the pattern 42 produced can vary between embodiments, but one embodiment can produce a light seepage gap 8 pattern and light seepage areas 88 at a resolution of 0.3 mm (with a spacing of 0.3 mm). Fig.12The alternative embodiment of FIG. 1 depicts a non-limiting example in which the laser ablation pattern includes a combined effect with a smoke-colored light-transmitting medium 30 and a mask coating 40 to produce a sample on the surface panel 200. Other examples of the pixelated pattern 42 that can be produced along the surface panel 200 can be observed in an unlit and observable back-lit state, respectively, as shown in FIG. Fig.10 and Fig.11 As displayed.

[0077] The previously described light intensity measurements and aspects of achievable intensity effects that are proportionally related to specific variables and factors (as a function of light source wavelength, incident angle measurements from the light source, measurements along the perimeter span at each incident angle, and thickness of the light transmissive medium and the following types: transparent clear, opaque, opalescent, granular transparent, and granular reflective media) can change the light diffusivity and white light intensity balance. Some of the listed factors are based on the type of light transmissive medium 30 (e.g., transparent, opaque, opalescent, granular transparent, granular reflective) at different media thicknesses with the application of special treatments or within the listed wavelength ranges or at measured refractive incident angles or at measured operating temperatures under methods formulated by Gaussian, specular reflectance, Lambert, Geigenbauer models.

[0078] Figures 13 to 15 Different embodiments and effects that can be obtained in the light-transmitting medium 30 are depicted in a non-limiting manner, including embossing, surface etching, bubbles, cracks, molding additives, tints, smoke, colorants or optical effects. As non-limiting examples, Fig.13 Patterned imprints in substrate 30 are depicted to enhance optical effects or light dispersion. Fig.14 Blisters or textured dispersions or embedded features 16 within substrate 30 are depicted. Fig.15 A corrugation or surface etch pattern 24 in the substrate 30 is depicted to further enhance light transmission.

[0079] Fig.16 An embodiment of the present invention is illustratively depicted, and a process or method 1000 for manufacturing a light diffuser panel system is described. In method 1000, the substrate or light-transmitting medium 30 can form a light-emitting panel embodiment accordingly. For example, in a variable method embodiment, two blocks shown in succession can actually be performed substantially simultaneously, or associated blocks can sometimes be performed in reverse order, depending on the functions involved. It should also be noted that each block of the block diagram or flowchart display and the combination of blocks in the block diagram or flowchart display can be implemented by a manual or automated system that performs a specific function, or by a combination of dedicated hardware and control instructions or by executing these combinations.

[0080] In block 1010, a light-transmitting medium or substrate 30 made of a polymer material is provided. In block 1020, an anti-fog diffuse coating formulation 10 is applied along one side of the light-transmitting medium or substrate 30. In a non-limiting manner, the side may represent the outside, inside, or surface side of the substrate 30. In block 1030, a light-blocking or opaque mask (light-changing mask) 40 may be applied on one side of the hard coating 20 or the light-transmitting medium or substrate 30. In block 1032, an ablation process may be performed on the light-blocking or opaque mask (light-changing mask) 40.

[0081] In block 1034, a light source on the inner side 3 of the light transmissive medium or substrate 30 may be enabled, the light source being configured to transmit the light beam 11 through the light blocking or opaque mask 40 and the plurality of light-leaking gaps 8 to the outer side 5 of the light transmissive medium or substrate 30. In block 1036, the enabled light source 1 may be configured to transmit the light beam 11 through the plurality of light-leaking gaps 8 to be seen at a predetermined diffuseness and light intensity value based on the anti-fog diffuse coating formulation 10 as measured by an observer P at the outer side 5 of the light transmissive medium or substrate 30.

[0082] In block 1038, deactivation of the light source 1 may be configured to conceal visibility at the outer side 5 of the light-transmissive medium or substrate 30 as observably measured by an observer P through a plurality of light-bleeding gaps 8, such that obscured segments 77 are presented to the observer P. The obscured segments 77 may represent a concealed view or different visual effects of the associated light-emitting panel (panel lens or cover panel) between unlit and lit states through observable obscured segments 77 or light-bleeding gaps 8.

[0083] Fig.17 Another embodiment of the present invention is shown, and a process or method 2000 for manufacturing a light diffuser panel system is described. In method 2000, accordingly, the substrate or light-transmitting medium 30 can form a light-emitting panel embodiment. For example, in a variable method embodiment, two blocks shown in succession can actually be executed substantially simultaneously, or the associated blocks can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each block of the block diagram or flowchart display and the combination of blocks in the block diagram or flowchart display can be implemented by a manual or automated system that performs a specific function, or by a combination of dedicated hardware and control instructions or executing these combinations.

[0084] In box 2010, a light-transmitting medium or substrate 30 made of a polymer material is provided. In box 2020, an anti-fog diffuse coating formulation 10 is applied along one side of the light-transmitting medium or substrate 30. In a non-limiting manner, the side may represent the outside, inside, or surface side of the substrate 30. In box 2030, a light-blocking or opaque mask (light-changing mask) 40 may be applied along one side of the light-transmitting medium or substrate 30. In box 2032, an ablation process may be performed to form light-leaking gaps 8 on the light-blocking or opaque mask (light-changing mask) 40.

[0085] In block 2034, the light source 1 may be enabled, the light source being configured to transmit the light beam 11 through the light blocking or opaque mask (light altering mask) 40 and the plurality of light-leaking gaps 8, through the outer side 5 and the inner side 3 of the light-transmissive medium or substrate 30. In block 2036, the enabled light source may be configured to transmit the light beam 11 through the plurality of light-leaking gaps 8 to be seen at a predetermined diffuseness and light intensity value based on the anti-fog diffuse coating formulation 10 as measured by an observer P at the outer side 5 of the light-transmissive medium or substrate 30.

[0086] In block 2038, the deactivation of the light sources and the absence of light transmission through the substrate 30 may be configured to conceal visibility at the outer side 5 of the substrate 30 through the plurality of light-bleeding gaps 8 as observably measured by an observer P, such that obscured segments 77 are presented to the observer P. The obscured segments 77 may represent a concealed view or different visual effects of the associated light emitting panel (panel lens or cover panel) between unlit and lit states through observable obscured segments 77 or light-bleeding gaps 8.

[0087] Methods 1000 and 2000 illustrate sample embodiments of production processes for light diffusing panels that incorporate hidden-until-lit features while providing eye-catching lighting effects and optical enhancements that meet predefined light intensity and diffuse light values ​​or regulatory measurement requirements. Thus, lighting performance is qualified and enhanced while meeting market demands at reduced manufacturing costs.

[0088] It should be understood that the aspects and examples cited above are non-limiting, as there are other aspects and examples in the present invention as shown and described herein. Unless otherwise stated, the sizes and geometries of the various structures depicted herein are not meant to limit the present invention, so that other sizes or geometries are also possible. Multiple structural components can be provided by a single monolithic structure. Alternatively, a single monolithic structure can be divided into independent multiple components.

[0089] In addition, although features of the present invention may be described in the context of only one of the embodiments shown, such features may be combined with one or more other features of other embodiments for any particular application. It can also be understood from the above that the manufacture of the unique structures herein and their operation also constitute methods according to the present invention.

[0090] List of Reference Numerals

[0091] Light emitting panel 100 200 400LED light source 1

[0092] Internal position 3

[0093] External location 5

[0094] Beam 11

[0095] Anti-fog light diffusion coating 10

[0096] Sealing coating composition 20

[0097] Substrate - light-transmitting medium 30

[0098] Mask coating 40

[0099] The resulting pattern 42

[0100] Embedded optical features 15

[0101] Surface optical features 22

[0102] Etched pattern optical device 24

[0103] Surface 38

[0104] Internal Embedded Features 16

[0105] Light penetration gap 8

[0106] Light seepage area 88

[0107] Shielding section 77

[0108] Light emitting lighting device unit 70

[0109] Method of manufacturing a light emitting diffuser panel system 1000 2000

Claims

1. A light emitting panel having light diffusing properties associated with an automotive lighting or signaling system, the light emitting panel comprising: A polymer panel made of a light-transmitting medium; a sealing coating pre-applied on or already integrated with the polymer panel; a mask coating on the sealing coating, wherein the mask coating comprises a pattern formed with a plurality of light-leaking gaps configured to transmit light through the light-leaking gaps; as well as An anti-fog diffuse coating formulation on the polymer panel.

2. The light emitting panel according to claim 1, wherein: The polymer panel includes polycarbonate (PC) or polymethyl methacrylate (PMMA).

3. The light emitting panel according to claim 1, wherein: The thickness of the mask coating is about 12 microns to 15 microns.

4. The light emitting panel according to claim 1, wherein: A light seepage area is defined by the plurality of light seepage gaps, and the light seepage gaps are configured to form a plurality of patterns through an ablation process.

5. The light emitting panel according to claim 1, wherein: The anti-fog diffuse coating formulation measured a thickness of about 8 to 15 microns.

6. The light emitting panel according to claim 1, wherein: Another sealing coating overlies the mask coating and the plurality of light-bleeding gaps along the polymer panel.

7. The light emitting panel according to claim 1, wherein: The sealing coating overlies the polymer panel below the mask coating and the plurality of light-bleeding gaps.

8. The light emitting panel according to claim 1, wherein: The sealing coating is a polyurethane based material.

9. The light emitting panel according to claim 1, wherein: The light emitting panel is configured to produce uniform light along the pattern without discernible hot spots in the eye of an observer when activated by the light source.

10. The light emitting panel according to claim 1, wherein: The pattern includes a ghosting effect feature, wherein the ghosting effect feature is configured to appear as a light-leaking area feature to show a visible visual effect to a viewer when an associated light emitting unit is turned on, and to show a different visual effect when the associated light emitting unit is turned off.

11. The light emitting panel according to claim 1, wherein: The emitted light passing through the light emitting panel is configured to undergo a light leveling process after the incident light is propagated through the anti-fog diffuse coating formulation.

12. The light emitting panel according to claim 1, wherein: The anti-fog diffuse coating formulation includes a silica-based matting agent or matting particles at a concentration between 5% and 9% by volume.

13. The light emitting panel of claim 1, further comprising a composition configured to diffuse penetrating light and eliminate hot spots.

14. The light emitting panel according to claim 1, wherein: A lens body is shown as part of the automotive system.

15. The light emitting panel according to claim 1, wherein: The striking white diffuse lighting is configured to produce a light output value that is uniform within a 10% variation along the perimeter span of the light emitting panel as measured by known methods.

16. The light emitting panel according to claim 1, wherein: The striking white diffuse lighting is configured to appear to an observer when light enable is applied to the light emitting panel from a "ghosting effect" condition.

17. A motor vehicle using a light emitting panel, the light emitting panel comprising: A light-transmitting polymer substrate; a hybrid coating on the polymer substrate, the hybrid coating combining an anti-fog function and a light-flattening function in an integrated layer, the integrated layer being configured to provide a predefined value of luminous intensity and a predefined value of light diffusion to an observer; a mask coating of a light blocking composition coated on the polymer substrate on an outer side opposite to the inner side; A plurality of light-seeping gaps are formed in the mask coating by laser ablation, and the plurality of light-seeping gaps are configured to receive a plurality of diffuse light beams passing through the hybrid coating.

18. A motor vehicle as claimed in claim 17, wherein: The hybrid coating on the polymer substrate measured a thickness of about 0.008 mm to 0.015 mm.

19. The motor vehicle of claim 17, wherein: The thickness of the mask coating composition is about 0.012 mm to 0.015 mm.

20. A method for manufacturing a light emitting panel for an automobile, the method comprising: Providing a polymer panel made of a light-transmitting substrate; applying an anti-fog diffuse coating on the polymer panel; applying a mask coating over the seal coating on the polymer panel; as well as The mask coating is ablated by a laser means process to form a plurality of light-seeping gaps in a pattern.

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