Miniature LED for vehicle interior lamp

Abstract

The invention discloses a vehicle interior lamp based on micro LEDs. The micro-LEDs may be arranged in the panel at a density to produce light of the same or similar intensity as existing interior lamp designs or to comply with legal requirements. These micro LED interior lamps may allow for cheaper, more energy efficient, smaller, and / or more customizable interior lamps.

Description

[0001] Background Art and Technical Field

[0002] The present disclosure generally relates to micro LEDs and their use in automotive applications.

[0003] Vehicle interior lighting is typically very simple, where one or two light sources illuminate the entire vehicle, which can be distracting to the driver and pose a danger.

[0004] Vehicle interior lights cannot convey complex information. If the glove box light is on, the driver may be able to tell that the glove box is open, but cannot provide more information without a complex blinking code that the driver has to remember.

[0005] Due to the driver's dashboard display, the driver can easily obtain interior lighting information, but passengers may have to rely on the driver to tell them which door is ajar or which seat belt is not fastened.

[0006] When looking for new vehicle lighting applications, there is still much room for improvement in traditional lighting. For example, it is difficult to create a light-enhanced music system when the light has only one color and one intensity. Summary of the Invention

[0007] The present invention relates to a method of using micro LEDs in vehicle interior lights, the method comprising: having a micro LED panel that includes one or more micro LED dies of micro LEDs; having a substrate to which the micro LED dies are bonded; and having a connector that allows the electronics of the micro LED panel to be integrated with the vehicle, wherein the micro LED panel performs the function of a vehicle interior light. Brief Description of the Drawings

[0008] Figure 1: Illustrates the integration of a transfer microdevice and an electro-optic thin film device in a hybrid structure according to one embodiment.

[0009] Figure 2: Illustrates a micro LED panel of an interior light according to one embodiment.

[0010] Figure 3: Illustrates a micro LED panel of an interior light according to one embodiment, the micro LED panel being colored and / or textured based on the vehicle component to which it is attached.

[0011] Figure 4 : Illustrates micro LEDs embedded in an interior component of a vehicle according to one embodiment, where the color can be adjusted based on the situation (dim light for night driving, bright light for night reading, colored light for aesthetics, etc.).

[0012] Figure 5: Illustrates a mirror with embedded micro LEDs according to one embodiment.

[0013] Figure 6 : A micro-LED panel of an internal lamp combined with a non-micro-LED light source is illustrated according to an embodiment.

[0014] FIG. 7: A micro-LED panel of an internal lamp integrated into a fabric is illustrated according to an embodiment. DETAILED DESCRIPTION

[0015] Embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings, in which like reference numerals refer to like elements throughout the several views, and in which exemplary embodiments are shown. However, the embodiments of the claims may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples. The present disclosure discloses structures, systems, and methods related to micro-LEDs in the external or internal aspects of vehicle lamps.

[0016] Figure 1AShows an example of integrating a transfer microdevice 106 with an electro-optic thin film device 112 in a hybrid structure. This is an example of an integrated micro-LED chip, which is later picked up and placed into a chip array. For those skilled in the art, it is obvious that there are many ways to create micro-LED chips and integrate them in a chip array, such as in accordance with US20160218143A1—Microdevice integration into system substrate. In multiple hybrid structure embodiments, a receptor substrate 102 and contact pads 104, an array of microdevices 106 are transferred onto these contact pads, and the thin film electro-optic device is integrated into these contact pads. The microdevice 106 can be transferred and bonded to the bonding pads 104 of the receptor substrate 100. In one case, a dielectric layer 108 is formed above the substrate 102 to cover the exposed electrodes and conductive layers. Lithography and etching can be used to pattern the dielectric layer 108. Then a conductive layer 110 is deposited and patterned to form the bottom electrode of the thin film electro-optic device 112. If there is no risk of unwanted coupling between the bottom electrode 110 and other conductive layers in the receptor substrate, the dielectric layer 108 can be eliminated. However, this dielectric layer can also be used as a planarization layer to provide better fabrication of the electro-optic device 112. A dam layer 114 is deposited on the substrate 102 to cover the edges of the electrodes 110 and the microdevices 106. Then the thin film electro-optic device 112 is formed above this structure. An organic LED (OLED) device is an example of a thin film electro-optic device, which can be formed using different techniques, such as but not limited to shadow masking, lithography, and printing patterning. Finally, the top electrode 118 of the electro-optic thin film device 112 is deposited and, if necessary, patterned. In an embodiment where the thickness of the microdevice 106 is significantly high, cracks or other structural problems may occur in the bottom electrode 110. In these embodiments, a planarization layer can be used in combination with or without the dielectric layer 108 to solve this problem. In another embodiment, the microdevice 106 can have a device electrode 116. This electrode can be shared among other microdevices 106 in the system substrate. In this case, a planarization layer (if present) and / or a dam structure 114 cover the electrode 116 to avoid any short circuit between the electro-optic device 112 and the device electrode 116.

[0017] Figure 1BIllustrates the structure of sharing the device among several pixels (or sub-pixels) after post-processing to deposit the common electrode and the color conversion layer. Here, the micro-device 106 is not fully patterned, but the horizontal conditions are engineered such that the contacts 104 define the regions assigned to each pixel. A system substrate 102 with contact pads 104 and a donor substrate with the micro-device 106. After transferring the micro-device 106 to the system substrate 102, post-processing can be performed, such as depositing the common electrode 120, the color conversion layer 122, the color filter, etc. However, the methods described in this disclosure and other possible methods can be used. After forming the active region, the described color conversion layer can be added to the pixel (or sub-pixel) active region. If the active region of the pixel (or sub-pixel) is covered by a reflective layer, this can provide a higher fill factor and higher performance and avoid color leakage from the side pixels (or sub-pixels). In another embodiment, the micro-device 106 is grown on a buffer / sacrificial layer.

[0018] Figure 2A Shows a micro-LED panel with an internal light. Figure 2B Shows Figure 2A The cross-section of the micro-LED panel along line A-A'. Figure 2C Shows Figure 2A The possible location of the micro-LED panel inside a vehicle. Element 201 can be a micro-LED panel, which can include one or more sheets containing multiple micro-LEDs. Multiple small micro-LED sheets can be integrated together into a larger flat panel. The panel can include a certain density of micro-LEDs to produce the same light as existing internal lights. The panel can use RGB micro-LEDs. The intensity and color of the light from the micro-LED panel can be programmable and change based on the input. Element 202 can be an adhesive tape, which can allow the micro-LED panel to adhere or otherwise connect to the vehicle. Element 204 can be a substrate to which the micro-LED sheets can be bonded. The substrate can be silicon, glass, sapphire, any other substrate known in the art, any material to which the micro-LED sheets can be bonded, or any combination of these materials. The substrate can also house or bond to the electronics connected to the micro-LEDs. These electronics can be housed within the substrate, tunnel through the substrate to reach the micro-LEDs, or use the substrate as part of the circuit. Element 206 can be an adhesive tape, which can allow the micro-LED panel to adhere or otherwise connect to the vehicle. Element 208 can be a protective layer. The protective layer can protect against environmental and / or vibration damage. The protective layer can be made of glass, epoxy resin, plastic, metal, other protective materials, or any combination of protective materials. The protective layer can be hermetically sealed. Element 210 can be located on the vehicle dashboard Figure 2AA micro-LED panel. The micro-LED panel in this position can display information, project information onto the windshield, provide lighting, or contribute to the atmosphere inside the vehicle. Component 211 can be a Figure 2A A micro-LED panel. The micro-LED panel in this position can display information, allow the driver or passenger of the vehicle to select functions such as GPS or music, otherwise serve as a user interface for the vehicle's computer, provide lighting, or contribute to the atmosphere inside the vehicle. Component 212 can be a Figure 2A A micro-LED panel. The micro-LED panel in this position can provide lighting or contribute to the atmosphere inside the vehicle. Component 214 can be a Figure 2A A micro-LED panel. The micro-LED panel in this position can provide lighting or contribute to the atmosphere inside the vehicle. The micro-LED panel in this position can be configured not to interfere with the passenger-side airbag. Component 214 can be a Figure 2A A micro-LED panel. The micro-LED panel in this position can provide lighting or contribute to the atmosphere inside the vehicle. Component 215 can be a Figure 2A A micro-LED panel. The micro-LED panel in this position can display information to the driver, provide lighting, or contribute to the atmosphere inside the vehicle. The micro-LED panel in this position can be configured not to interfere with the driver's airbag. Component 217 can be a Figure 2A A micro-LED panel. The micro-LED panel in this position can display information, serve as a user interface for the passenger, provide lighting, or contribute to the atmosphere inside the vehicle. Component 217 can be a Figure 2A A micro-LED panel. The micro-LED panel in this position can provide lighting or contribute to the atmosphere inside the vehicle. The micro-LED panel can be located inside the glove box and be activated when the glove box is opened. The micro-LED panel can be smaller than a typical interior bulb, thus reducing the space required for interior lighting. Although the initial cost of the micro-LED interior light may be higher than that of a traditional interior light, cost savings can be achieved in other aspects, such as replacement and energy costs. Micro-LEDs are more efficient than traditional interior lights, generating less heat and wasting less energy. Due to the reduced volume required, the micro-LED interior light may be lighter than its traditional counterpart. Due to the smaller size of the micro-LED panel, the replacement cost of the micro-LED interior light may be lower than that of other interior lights, which means that the replacement may be less invasive and can be done easily enough without vehicle maintenance expertise.

[0019] Figure 3 shows a micro-LED panel for an interior light, which is colored and / or textured based on the vehicle component to which it is attached. Element 301 can be the micro-LED panel, which may include one or more sheets containing a plurality of micro-LEDs. A plurality of small micro-LED sheets can be integrated together into a larger flat panel. The panel can include a certain density of micro-LEDs to produce the same light as existing interior lights. The panel can use RGB micro-LEDs. The light intensity from the micro-LED panel can be programmable and change based on an input. Element 302 can be an adhesive tape, which can allow the micro-LED panel to adhere or otherwise connect to the vehicle. Element 304 can be a substrate to which the micro-LED sheets can be bonded. The substrate can be silicon, glass, sapphire, any other substrate known in the art, any material to which the micro-LED sheets can be bonded, or any combination of these materials. The substrate can also house or be bonded to electronics connected to the micro-LEDs. These electronics can be housed within the substrate, tunnel through the substrate to reach the micro-LEDs, or use the substrate as part of a circuit. The substrate can be colored and / or textured to match the color and / or texture of the vehicle component to which it is attached or will be attached. For example, if the micro-LED panel is attached to a white leather interior, the substrate can be textured to look like white leather. Element 306 can be a first type of micro-LED sheet that includes a plurality of micro-LEDs. For example, these micro-LED sheets can be used as brake lights and are colored red. Element 308 can be an interior component of the vehicle to which the micro-LED panel is attached. Examples of interior components include a dashboard, cup holder, door handle, drive shaft, seat, seatbelt, etc. The micro-LED panel can improve the vehicle interior by increasing visibility, providing information to the driver or passenger, or enhancing the overall ambiance of the vehicle interior. The micro-LEDs can provide more information about the component than a conventional LED or bulb would be able to, since each micro-LED has the functionality of a single larger LED. Element 310 can be a cross-sectional material of an interior component of the vehicle, such as a patch of fabric or leather, or a panel of glass or plastic.

[0020] Figure 4Shows micro-LEDs embedded in the interior components of a vehicle, where the color can be adjusted based on the situation (dim light for night driving, bright light for night reading, colored light for aesthetics, etc.). Element 401 can be the vehicle interior with a network of integrated micro-LEDs. The micro-LEDs can be coordinated such that the color, brightness, status, etc. of each micro-LED or group of micro-LEDs is set by a central computer system. For example, the computer can set the network of integrated micro-LEDs to "night mode", which can dim or turn off all micro-LEDs except those that display basic information such as speed, gear, fuel level, etc. The user can select and customize the mode via the user interface inside the vehicle or by, for example, connecting a computer to the vehicle via NFC. The micro-LED network can be configured to synchronize with music played through the vehicle's audio system. Element 402 can be a windshield with embedded micro-LEDs. The micro-LEDs can color, change the color, dim, or otherwise alter the view through the windshield. The micro-LEDs can also display information directly on the windshield. The micro-LEDs can be programmed not to distract the driver while driving and can be activated only when the vehicle is parked. These micro-LEDs can be used for visibility and contribute to the atmosphere inside the vehicle. Element 404 can have accessories with embedded micro-LEDs, such as cup holders, door storage compartments, armrests, etc. These micro-LEDs can be used for visibility and contribute to the atmosphere inside the vehicle. Element 408 can be decorated with embedded micro-LEDs. These micro-LEDs can be used for visibility and contribute to the atmosphere inside the vehicle. Element 406 can be a mirror with embedded micro-LEDs. This can be a rearview mirror and / or a side mirror. The micro-LEDs can color, change the color, dim, or otherwise alter the view through the mirror. The micro-LEDs may be able to display information such as warning signals, temperature, direction, etc. directly on the mirror. The micro-LEDs can display video from a camera. For example, the rearview mirror can include a video view from a rearview camera at the rear of the vehicle. These micro-LEDs can be used for visibility and contribute to the atmosphere inside the vehicle. The micro-LED panel can improve the vehicle interior by increasing visibility, providing information to the driver or passenger, or enhancing the overall atmosphere inside the vehicle. The micro-LEDs can provide more information about the components than conventional LEDs or bulbs would be able to, as each micro-LED has the functionality of a single larger LED. Additionally, bulbs and large LEDs cannot be placed inside transparent components (such as mirrors and windows) without causing some obstruction to the view, but micro-LEDs can be added to transparent materials without significantly increasing opacity.

[0021] Figure 5A Shows a mirror with embedded micro-LEDs. Figure 5B Shows another embodiment of a mirror with embedded micro-LEDs. Figure 5C Shows as a vehicle side mirrorFigure 5A or Figure 5B The mirror of. Component 501 can be a micro-LED mirror including a micro-LED panel, a one-way reflection layer, and a front glass. The light entering the reflection layer through the front glass is reflected, while the light from the micro-LED panel passes through. The observer can see the content reflected by the mirror and the light from the micro-LED panel. Component 502 can be the front glass that protects the reflection layer while allowing light to pass through. This can be glass, plexiglass, or other protective and transparent materials. Component 504 can be a one-way reflection layer that allows light to pass through from one direction but reflects light from the other direction. If the overall visual effect is the same, the one-way reflection layer does not need to be completely reflective or transparent from either direction, such as a two-way mirror. The one-way reflection layer can be made of a thin and nearly transparent metal layer or some other reflective material to form a mirror surface that reflects some light and is penetrated by the rest of the light. Component 506 can be a micro-LED panel, which can include one or more sheets containing multiple micro-LEDs. Multiple small micro-LED sheets can be integrated together into a larger flat panel. The panel can include a certain density of micro-LEDs to produce the same light as existing interior lights. The panel can use RGB micro-LEDs. The light intensity from the micro-LED panel can be programmable and change based on the input. Component 510 can be a micro-LED mirror in which the micro-LEDs are placed on a reflective substrate, eliminating the need for a one-way reflection layer. Component 512 can be a micro-LED panel including one or more sheets that include multiple micro-LEDs on or in a reflective surface. The micro-LED sheets can be embedded in or integrated with the reflective surface. Multiple small micro-LED sheets can be integrated together into a larger flat panel. The panel can include a certain density of micro-LEDs to produce the same light as existing interior lights. The panel can use RGB micro-LEDs. The light intensity from the micro-LED panel can be programmable and change based on the input. Component 514 can be a support panel that can provide various functions, such as adhering the micro-LED board to the vehicle, accommodating electronic components, connecting to the vehicle's electronic components, etc. Component 516 can be using Figure 5A or Figure 5B The side-view mirror of a vehicle with a micro-LED mirror. Component 518 can be an example of a hazard symbol that can be directly displayed on the side-view mirror via a micro-LED. The micro-LED may be able to display various different symbols to warn or notify the driver. The micro-LED panel may also be able to display a video feed from a camera. For example, the side-view mirror can also include a small window view from a rear-side camera to expand the driver's field of view. The micro-LED mirror can increase the amount of information the driver can see in their side-view mirror or rear-view mirror. This can reduce collisions caused by blind spots in the driver's field of view. The micro-LED mirror can also perform other functions when the vehicle is not moving, such as lighting or creating an atmosphere.

[0022] Figure 6A micro-LED panel of an interior lamp combined with a non-micro-LED light source is shown. Element 601 can be a hybrid lighting system that includes micro-LEDs and non-micro-LED light sources such as LEDs, mini-LEDs, fluorescent bulbs, incandescent bulbs, natural lighting, etc. The micro-LEDs and other light sources can be coordinated by a controller or can be controlled independently of each other. Element 602 can be a micro-LED panel that can include one or more sheets containing a plurality of micro-LEDs. A plurality of small micro-LED sheets can be integrated together into a larger flat panel. The panel can include a certain density of micro-LEDs to produce the same light as existing interior lamps. The panel can use RGB micro-LEDs or phosphor-containing blue micro-LEDs to obtain white light. Element 604 can be an adhesive tape that can allow the micro-LED panel to adhere to or otherwise connect to a vehicle. Element 606 can be a substrate to which the micro-LED sheets can be bonded. The substrate can be silicon, glass, sapphire, any other substrate known in the art, any material to which the micro-LED sheets can be bonded, or any combination of these materials. The substrate can also house or bond to electronics connected to the micro-LEDs. These electronics can be housed within the substrate, tunnel through the substrate to reach the micro-LEDs, or use the substrate as part of a circuit. Element 608 can be a non-micro-LED-based light source such as an LED, mini-LED, fluorescent bulb, incandescent bulb, natural lighting, or some other light source that does not use micro-LED technology. The micro-LEDs can improve the interior of a vehicle by increasing visibility, providing information to a driver or passenger, or enhancing the overall ambiance of the vehicle interior. The micro-LEDs can provide more information about components than conventional LEDs or bulbs would be able to because each micro-LED has the functionality of a single larger LED. Additionally, bulbs and large LEDs cannot be placed inside transparent components (such as mirrors and windows) without causing some obstruction to the field of view, but micro-LEDs can be added to transparent materials without significantly increasing opacity. The combination of micro-LEDs and traditional lighting can take advantage of the benefits of both.

[0023] Figure 7A A micro-LED panel of an interior lamp is shown, and Figure 7BDisclosed is a micro - LED panel integrated into a fabric. Element 701 can be a micro - LED panel, which may include one or more sheets containing a plurality of micro - LEDs. Multiple small micro - LED sheets can be integrated together into a larger flat panel. The panel can include a certain density of micro - LEDs to produce the same light as existing interior lights. The panel can use RGB micro - LEDs. The light intensity from the micro - LED panel can be programmable and change based on an input. Element 702 can be an adhesive tape, which can allow the micro - LED panel to adhere to or otherwise connect to a vehicle. Element 704 can be a substrate to which the micro - LED sheets can be bonded. The substrate can be silicon, glass, sapphire, any other substrate known in the art, any material to which the micro - LED sheets can be bonded, or any combination of these materials. The substrate can be a fabric, or bonded to or otherwise adhered to a fabric. The substrate can have a flexibility similar to that of the fabric. The substrate can also house or be bonded to electronics connected to the micro - LEDs. These electronics can be housed within the substrate, tunnel through the substrate to reach the micro - LEDs, or use the substrate as part of a circuit. The substrate can be colored and / or textured to match the color and / or texture of the vehicle component to which it is attached or will be attached. For example, if the micro - LED panel is attached to a white leather interior, the substrate can be textured to look like white leather. Element 706 can be a first type of micro - LED sheet including a plurality of micro - LEDs. For example, these micro - LED sheets can be used as brake lights and are colored red. Element 708 can be a fabric component of the vehicle to which the micro - LED panel is attached. Examples of fabric components are seats, floor mats, fabric interiors, etc. The micro - LED panel can improve the vehicle interior by increasing visibility, providing information to the driver or passenger, or enhancing the overall ambiance of the vehicle interior. The micro - LEDs can provide more information about components than conventional LEDs or bulbs would be able to, because each micro - LED has the functionality of a single larger LED.

[0024] The functions performed in the processes and methods can be implemented in a different order. Additionally, the steps and operations outlined are provided only as examples, and some of the steps and operations can be optional, combined into fewer steps and operations, or extended into additional steps and operations without departing from the essence of the disclosed embodiments.

Claims

1. A method of using a micro-LED in a vehicle interior light, the method comprising: Having a micro-LED panel, the micro-LED panel comprising one or more micro-LED chips of micro-LEDs; Having a substrate, the micro-LED chips being bonded to the substrate; And Having a connector that allows the electronics of the micro-LED panel to be integrated with the vehicle, wherein the micro-LED panel performs the function of a vehicle interior light.

2. The method according to claim 1, wherein a plurality of small micro-LED chips are integrated together into a larger flat panel.

3. The method according to claim 2, wherein the panel comprises a certain density of micro-LEDs such that the same light as conventional LED and non-LED interior lights can be produced.

4. The method according to claim 2, wherein the intensity and color of the light from the micro-LED panel are programmable and change based on an input.

5. The system according to claim 2, wherein the panel uses RGB micro-LEDs.

6. The system according to claim 2, wherein the substrate is one of silicon, glass, sapphire, or any material to which the micro-LED chips are bonded, or any combination of these materials.

7. The system according to claim 2, wherein the substrate further houses or is bonded to electronics connected to the micro-LEDs.

8. The method according to claim 1, wherein the connector allows the electronics of the panel to be connected to the vehicle's electronics system, wherein the electronics are further housed within the substrate, tunnel through the substrate to reach the micro-LEDs, or use the substrate as part of a circuit.

9. The method according to claim 1, wherein there is a protective layer against environmental and / or vibration damage, and wherein the protective layer is further made of glass, epoxy resin, plastic, metal, or any combination of protective materials, and wherein the protective layer is further hermetically sealed.

10. The method according to claim 1, wherein an adhesive tape allows the micro-LED panel to be adhered or otherwise connected to the vehicle.

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