Thick appearance lens using reflective surface

Abstract

Aspects of the present disclosure include relatively thin lenses that utilize reflective surfaces to provide a thick lens appearance and methods of making the same. An example vehicle includes a component having a lens. The lens includes a light pipe configured such that opposing sidewalls of the light pipe face each other across the air gap, a first reflector surface having a first reflective material formed on a first sidewall of the opposing sidewalls, a second reflector surface having a second reflective material formed on a second sidewall of the opposing sidewalls, and a third surface having a third reflective material formed on a third sidewall of the opposing sidewalls. The first reflector surface has a first reflective material formed on a first side wall of the opposing side walls, the second reflector surface has a second reflective material formed on a second side wall of the opposing side walls, and the third surface is located between the first reflector surface and the second reflector surface and is configured such that light can pass through the third surface and enter the air gap. The optical path within the air gap is extended due to internal reflection between the first reflector surface and the second reflector surface, providing an infinite mirror effect.

Description

Technical Field

[0001] This disclosure relates to lighting systems and lenses, and more particularly to relatively thin lenses that utilize reflective surfaces to provide the appearance of thick lenses. Background Technology

[0002] Lighting systems play a crucial role in enhancing the aesthetics, functionality, and atmosphere of spaces across a wide range of sectors, from architecture and interior design to the automotive and entertainment industries. At the heart of these systems are light sources and lenses, which work together to control and manipulate the distribution, intensity, direction, and quality of light. Light sources are the fundamental components that emit light energy, such as incandescent bulbs, fluorescent tubes, LEDs (light-emitting diodes), halogen lamps, and so on. Each type of light source offers different color temperatures, energy efficiency levels, and lifespans, allowing lighting systems to be customized to the specific needs of a given application.

[0003] In the context of lighting systems, lenses are optical elements designed to modify the behavior of light emitted from a light source. Lenses can be made of various materials such as glass or plastic, and factors such as the light scattering angle, beam width, and focal point can be controlled. Lenses can be used to guide light in a specific direction, diffuse it for uniform illumination, and / or produce visually appealing effects by refracting or reflecting light. When integrated with a light source in a lighting system, lenses can produce a range of lighting effects, such as focusing light on a specific area or scattering it for more diffuse illumination (directivity), determining how wide or narrow the light distribution will be (beam control), altering the color temperature or color rendering properties of the light (color and color temperature control), and various specialized visual effects such as lens flash, halo effects, and / or light patterns. Summary of the Invention

[0004] In one exemplary embodiment, the vehicle includes a component having a lens. The lens includes a light tube, a first reflector surface, a second reflector surface, and a third surface. The light tube is configured such that opposite sidewalls of the light tube face each other across an air gap. The first reflector surface has a first reflective material formed on a first sidewall of the opposite sidewalls, the second reflector surface has a second reflective material formed on a second sidewall of the opposite sidewalls, and the third surface is located between the first and second reflector surfaces and configured such that light can pass through the third surface and enter the air gap. Due to internal reflection between the first and second reflector surfaces, the light path within the air gap is extended, thereby providing an infinite mirror effect.

[0005] In addition to one or more features described herein, in some embodiments, the light tube includes a nominal sidewall thickness of less than 5.0 mm.

[0006] In some embodiments, the third surface is substantially free of reflective material, except for a portion of the third surface that is covered by the thickness of the first reflector surface and the thickness of the second reflector surface.

[0007] In some embodiments, the first reflective material and the second reflective material are the same.

[0008] In some embodiments, the component further includes a light source having one or more miniature light-emitting diodes (LEDs).

[0009] In some embodiments, the one or more microLEDs include a first microLED positioned within the air gap such that light emitted from the first microLED is reflected through the air gap between the first reflector surface and the second reflector surface.

[0010] In some embodiments, the one or more microLEDs include a second microLED positioned such that light emitted from the second microLED is refracted through the light tube against one of the first reflector surface and the second reflector surface.

[0011] In another exemplary embodiment, the lens includes a light tube, a first reflector surface, a second reflector surface, and a third surface. The light tube is configured such that opposite sidewalls of the light tube face each other across an air gap. The first reflector surface has a first reflective material formed on a first sidewall of the opposite sidewalls, the second reflector surface has a second reflective material formed on a second sidewall of the opposite sidewalls, and the third surface is located between the first and second reflector surfaces and is configured such that light can pass through the third surface and enter the air gap. Due to internal reflection between the first and second reflector surfaces, the light path within the air gap is extended, thereby providing an infinite mirror effect.

[0012] In some implementations, the light tube includes a nominal sidewall thickness of less than 5.0 mm.

[0013] In some embodiments, the third surface is substantially free of reflective material, except for a portion of the third surface that is covered by the thickness of the first reflector surface and the thickness of the second reflector surface.

[0014] In some embodiments, the first reflective material and the second reflective material are the same.

[0015] In some embodiments, the component further includes a light source having one or more miniature light-emitting diodes (LEDs).

[0016] In some embodiments, the one or more microLEDs include a first microLED positioned within the air gap such that light emitted from the first microLED is reflected through the air gap between the first reflector surface and the second reflector surface.

[0017] In some embodiments, the one or more microLEDs include a second microLED positioned such that light emitted from the second microLED is refracted through the light tube against one of the first reflector surface and the second reflector surface.

[0018] In yet another exemplary embodiment, a method may include providing a light tube configured such that opposing sidewalls of the light tube face each other across an air gap, forming a first reflector surface on a first sidewall of the opposing sidewalls, the first reflector surface comprising a first reflective material, forming a second reflector surface on a second sidewall of the opposing sidewalls, the second reflector surface comprising a second reflective material, and forming a third surface located between the first reflector surface and the second reflector surface. The third surface is configured such that light can pass through the third surface and enter the air gap. In some embodiments, the light path within the air gap is extended due to internal reflection between the first and second reflector surfaces, thereby providing an infinite mirror effect.

[0019] In some implementations, the light tube includes a nominal sidewall thickness of less than 5.0 mm.

[0020] In some embodiments, the third surface is substantially free of reflective material, except for a portion of the third surface that is covered by the thickness of the first reflector surface and the thickness of the second reflector surface.

[0021] In some embodiments, the first reflective material and the second reflective material are the same.

[0022] In some embodiments, the component further includes a light source having one or more miniature light-emitting diodes (LEDs).

[0023] In some embodiments, the one or more microLEDs include a first microLED positioned within the air gap such that light emitted from the first microLED is reflected through the air gap between the first reflector surface and the second reflector surface.

[0024] In some embodiments, the one or more microLEDs include a second microLED positioned such that light emitted from the second microLED is refracted through the light tube against one of the first reflector surface and the second reflector surface.

[0025] The above-described features and advantages, as well as other features and advantages of this disclosure, will become apparent when taken in conjunction with the accompanying drawings and the following detailed description. Attached Figure Description

[0026] Other features, advantages, and details appear by way of example only in the following detailed description, which refers to the accompanying drawings, wherein:

[0027] Figure 1 It is a vehicle configured according to one or more embodiments;

[0028] Figure 2 It is a cross-sectional view of a thin lens according to one or more embodiments;

[0029] Figure 3 This is an example holding fixture for selectively metallizing thin lens tubes according to one or more embodiments;

[0030] Figure 4A This is a view of an alternative thin lens according to one or more embodiments;

[0031] Figure 4B This is a view of an alternative thin lens according to one or more embodiments;

[0032] Figure 4C This is a view of an alternative thin lens according to one or more embodiments;

[0033] Figure 4D This is a view of an alternative thin lens according to one or more embodiments;

[0034] Figure 5A This is a view of an alternative thin lens according to one or more embodiments;

[0035] Figure 5B This is a view of an alternative thin lens according to one or more embodiments;

[0036] Figure 5C This is a view of an alternative thin lens according to one or more embodiments;

[0037] Figure 5D This is a view of an alternative thin lens according to one or more embodiments;

[0038] Figure 5E This is a view of an alternative thin lens according to one or more embodiments;

[0039] Figure 5F It is a view of an alternative thin lens according to one or more embodiments; and

[0040] Figure 6 It is a flowchart according to one or more embodiments. Detailed Implementation

[0041] The following description is exemplary in nature only and is not intended to limit this disclosure, its application, or use. It should be understood that throughout the drawings, corresponding reference numerals denote the same or corresponding parts and features. As used herein, the term module refers to processing circuitry, which may include application-specific integrated circuits (ASICs), electronic circuitry, processors (shared, dedicated, or grouped) and memories executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components that provide the described functionality.

[0042] Lenses are one of the key components of many lighting systems. While lenses can provide a range of functional benefits to lighting systems, such as focusing, collimating or parallelizing light, beam shaping, magnification or reduction, dispersion, and / or image formation, lenses can also contribute to the overall aesthetics of a lighting system. For example, so-called thick lenses (also known as thick optics or light blades) have become popular in a variety of applications, particularly in the automotive industry for headlight design. Thick lenses are designed to create a visually striking and distinctive aesthetic while also providing functional benefits. As used herein, a “thick lens” refers to a lens with a light blade construction that is at least 5.0 mm thick. Conversely, a “thin lens” or standard lens is a lens with a thickness less than 5.0 mm. For example, a typical thickness of a plastic lens sub-component is about 2.5 mm. Therefore, a thick lens is a lens that is at least twice the thickness of a standard 2.5 mm lens. Thick lenses can even be thicker, with wall thicknesses greater than 20 mm, such as 24 mm, 30 mm, 50 mm, etc. Thick lenses produce a bold, substantial, and high-quality appearance, especially when viewed from the front. In addition, thick, sturdy-looking lenses add a sense of strength and greater durability.

[0043] Unfortunately, current manufacturing processes for thick lens applications are limited to using physically thick lens components, typically produced using relatively thick lens injection molds. However, in this way, the resulting thick lens has a significantly increased mass compared to a standard lens. In fact, a 24mm thick lens can have more than eight times the mass of a standard 2.5mm thick lens. Increasing the mass of various vehicle components can lead to a range of negative consequences, such as exceeding packaging design weight limits and reducing driving range in electric vehicles. Furthermore, such thick lenses naturally require more material, molding time, and component costs to achieve the desired thickness. Other challenges include thermal management, as physically thick lenses may make it more difficult to dissipate heat generated by high-intensity light sources, and reduced optical quality, as physically thick lenses may increase optical losses due to reflection and absorption, potentially reducing overall light output efficiency.

[0044] This disclosure introduces a relatively thin lens with the appearance of a thick lens. Instead of relying on physically thick lenses for thick lens applications, this disclosure introduces a method of using reflective surfaces to give a thin lens the appearance of a thick lens, thereby avoiding many of the inherent tradeoffs of physically thick lenses. The result is a new lens architecture that provides the aesthetic qualities of a thick lens while remaining lighter and able to be manufactured using less material and with relatively lower processing time (e.g., lower die-cutting time).

[0045] In some embodiments, the thin lens is constructed as a light tube with relatively thin sidewalls (e.g., less than 5.0 mm as in a standard lens construction), which are bent such that opposite sidewalls of the light tube face each other. The facing sidewalls of the light tube are then coated with reflective surfaces. These so-called facing reflector surfaces produce a thick lens appearance due to the infinity mirror effect, unlike refractive optics with total internal reflection (TIR). As used herein, the “infinity mirror effect” refers to the optical illusion produced when two or more parallel mirrors face each other, as this arrangement forms an seemingly infinite series of reflections that appear to recede into the distance. The facing reflective surfaces can be mounted by metallization processes and / or by multilayer coating processes to adjust the degree of light reflection as needed. In some embodiments, the facing reflective surfaces are configured with stylized patterns to further enhance the unlit and / or lit appearance of the lens-mounted illumination system. Notably, the light source can be optionally positioned below and / or within the air gap cavity defined by the facing reflector surfaces to allow for light-emitting blade features. In some embodiments, the housing or frame of the lighting system can be combined with half of a bent light tube to provide the same thick lens appearance. Advantageously, the light tube (also known as a lens housing design) can have a mass of 25% or less of that of a physically thick lens of equivalent size. For example, a physically thick lens with a width of 24 mm will have nearly four times the mass of a thin lens light tube with a width of 24 mm, because the thin lens will have an air gap cavity of 60% or more (e.g., 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%) of the total width.

[0046] According to an exemplary embodiment, the vehicle is in Figure 1 The vehicle 100 is generally designated as 100. The vehicle 100 is shown in the form of an automobile having a body 102. The body 102 includes a passenger compartment 104, within which a steering wheel, front seats, and rear passenger seats (not shown separately) are arranged. The body 102 also includes a plurality of glass, plastic, and / or polymer laminated lighting assemblies 106 (also referred to as lighting units or lamp housings) that house various lighting elements, such as, for example, headlights, taillights, turn signals, reversing lights, decorative lighting, etc.

[0047] Figure 1 The specific lighting components 106 highlighted herein (i.e., headlights, turn signals, rear passenger window lights, and taillights) are emphasized only for ease of illustration and discussion. It should be understood that any aspect of this disclosure can be applied to any lens in vehicle 100. Furthermore, the location, size, arrangement, etc., of the lighting components 106, as well as the shape, size, and positioning of their elements (e.g., lenses), are not intended to be particularly limited, and all such configurations are within the scope of this disclosure. Moreover, although discussed primarily in the context of the lighting components 106 of vehicle 100, the aspects described herein can be similarly incorporated into any system (vehicle, building, workpiece, or otherwise) having one or more lens elements, and all such configurations and applications are within the scope of this disclosure.

[0048] As will be detailed herein, one or more of the lighting components 106 include a thin lens tube having the appearance of a thick lens. Regarding Figure 2 A more detailed discussion of the illustrative thin-lens light tube. Regarding Figure 3 An example holding fixture for selectively metallizing thin lens light tubes is discussed. Regarding... Figure 4A , Figure 4B , Figure 4C and Figure 4D Alternative thin-lens optical tube configurations were discussed. Regarding Figure 5A , Figure 5B , Figure 5C , Figure 5D , Figure 5E and Figure 5F An example microstructure of a thin lens was discussed.

[0049] Figure 2 A cross-sectional view of a thin lens 200 according to one or more embodiments is shown. The thin lens 200 can be incorporated into any component of any system having at least one lens element (e.g., Figure 1 The lighting components 106 of vehicle 100. Figure 2 As shown, the thin lens 200 includes a light tube 202, which is configured (e.g., bent, flexed, etc.) such that the opposing sidewalls 204, 206 of the thin lens 200 face each other across the air gap 208. While the configuration of the thin lens 200 is not intended to be particularly limited, the light tube 202 can be bent into, for example, a "U" shape, an "N" shape (as shown), and / or into any other configuration with opposing sidewalls (e.g., the thin lens 200 can also have a dome and / or circular topography).

[0050] In some embodiments, the light tube 202 may always have a nominal sidewall thickness W of less than 5.0 mm (within tool limitations). For example, the thickness W of sidewalls 204 and 206 may be 4.9 mm, 4.5 mm, 4.0 mm, 3.0 mm, 2.5 mm, 2.0 mm, 1.5 mm, 1.0 mm, 0.5 mm, etc. In some embodiments, the thickness W of sidewalls 204 and 206 is the same or substantially the same within tool limitations. In some embodiments, the thickness W of sidewalls 204 and 206 is different (see, for example...). Figure 4B ).

[0051] In some embodiments, the thin lens 200 may have a total thickness (e.g., diameter) D that is at least three times the thickness W. In some embodiments, the thin lens 200 may have a total thickness D between 5.0 mm and 50.0 mm, such as 8.0 mm, 10.0 mm, 12.0 mm, 15.0 mm, 18.0 mm, 20.0 mm, 22.0 mm, 24.0 mm, 26.0 mm, 28.0 mm, 30.0 mm, 40.0 mm, and 50.0 mm. In some embodiments, the thin lens 200 may have a total thickness D greater than 50.0 mm, such as 75.0 mm. It is worth noting that the thin lens 200 may have a total thickness D that is greater than the total thickness D achievable using physically thick lenses and conventional manufacturing processes, which is typically limited to about 24 mm.

[0052] In some embodiments, the light tube 202 may be composed of two or more components (as shown, two components separated by seam 210). The various components of the light tube 202 may be fastened to each other using known processes, such as via adhesives and / or via interlocking components as needed. In some embodiments, the light tube 202 may be constructed integrally; that is, using a single lens component (not shown separately). Such a configuration may be achieved using a single lens mold, for example, having a “U” or “N” shape.

[0053] The light tube 202 can be made from a range of transparent and translucent materials suitable for overmolding. For example, the light tube 202 can be made from benzoxazine, bismaleimide (BMI), cyanate ester, epoxy resin, phenolic resin (PF), polyacrylate (acrylic acid), polyimide (PI), unsaturated polyester, polyurethane (PUR), vinyl ester, siloxane, their co-transparent layers, and combinations thereof. In some aspects, the light tube 202 may include or be made of a thermoplastic transparent or translucent layer, said thermoplastic transparent or translucent layer being selected from the group consisting of: polyethyleneimine (PEI), polyamide-imide (PAI), polyamide (PA) (e.g., nylon 6, nylon 66, nylon 12, nylon 11, nylon 6-3-T), polyetheretherketone (PEEK), polyetherketone (PEK), polyvinyl chloride (PVC), polyphenylene sulfide (PPS), thermoplastic polyurethane (TPU), polypropylene (PP), polycarbonate / acrylonitrile butadiene styrene (PC / ABS), high-density polyethylene (HDPE), polyethylene terephthalate (PET), poly(methyl methacrylate) (PMMA), methyl styrene methacrylate (SMMA), methyl methacrylate acrylonitrile butadiene styrene (MABS), polycarbonate (PC), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), cotransparent layers thereof, and combinations thereof.

[0054] In some embodiments, the air gap 208 may be filled with air. In some embodiments, the air gap 208 may be filled with another gas, such as argon and / or nitrogen, or a combination with or without air, as needed. In some embodiments, the gas in the air gap 208 is purged before sealing the thin lens 200. For example, after sealing the seam 210 of the thin lens 200, the air gap 208 may be placed under a vacuum.

[0055] In some embodiments, the facing reflector surface 212 is a reflective layer formed on the opposing sidewalls 204, 206. In some embodiments, the facing reflector surface 212 is coated onto the sidewalls 204, 206. In some embodiments, the facing reflector surface 212 is deposited and / or metallized onto the sidewalls 204, 206. Relative to Figure 3 The fabrication / forming of the facing reflector surface 212 is discussed in more detail. In some embodiments, the facing reflector surface 212 is formed to a thickness on the order of a few micrometers, for example, between 0.5 micrometers and 8 micrometers, or between 2.0 micrometers and 6.0 micrometers, such as 4.0 micrometers.

[0056] In some embodiments, the facing reflector surface 212 is made of a reflective material having a reflectivity of at least 70% (the fraction of incident electromagnetic radiation reflected from its surface), such as 70%, 80%, 85%, 90%, 92%, 94%, 95%, 96%, 97%, 98%, and 99%. The reflective material is not intended to be particularly limited, but may include, for example, metals such as aluminum (Al), silver (Ag), gold (Au), copper (Cu), rhodium (Rh), chromium (Cr), zinc (Zn), and their alloys and / or combinations. Other materials include stainless steel, polymers such as polytetrafluoroethylene (PTFE) and polyethylene terephthalate (PET) with reflective additives, coatings, and / or surface treatments, and / or ceramics such as alumina (Al₂O₃) and zirconium oxide (ZrO₂), which may be polished to achieve a high (greater than 90%) reflectivity. Other materials include transparent conductive oxide (TCO) compounds, such as indium tin oxide (In₂O₃:Sn,ITO), fluorine-doped tin oxide (FTO), aluminum-doped zinc oxide (AZO), gallium-doped zinc oxide (GZO), indium zinc oxide (IZO), and combinations thereof. In some embodiments, the facing reflector surface 212 is made of a semi-reflective material with a reflectivity between 30% and 70%. Exemplary materials include, for example, dielectric coatings such as silicon dioxide (SiO₂), titanium dioxide (TiO₂), and magnesium fluoride (MgF₂), ITO and ITO alloys, colored and / or coated glass such as low-emissivity (low-E) coatings, polycarbonate and acrylic sheets treated with coatings and / or surface modifications, metallized polymers such as PET, and polycarbonates, and combinations thereof.

[0057] Although shown as having a single layer for ease of illustration, in some embodiments, one of the two facing reflector surfaces 212 is a multilayer structure. For example, in some embodiments, the facing reflector surface 212 is a dielectric Bragg mirror having two or more layers. A dielectric Bragg mirror (also called a dielectric reflector or dielectric mirror) is a type of optical component that reflects light by means of the Bragg reflection principle and comprises two or more alternating layers of dielectric material with contrasting refractive indices. In some embodiments, the facing reflector surface 212 is a dielectric Bragg mirror having alternating layers of high-refractive-index dielectric and low-refractive-index dielectric. Dielectric Bragg mirrors can achieve very high reflectivity (e.g., greater than 99%) for a specific wavelength or wavelength range, depending on the number of layers and the refractive index contrast between the respective materials. Some common examples of alternating dielectric materials used in Bragg reflectors include silicon dioxide (SiO2) and titanium dioxide (TiO2), silicon nitride (Si3N4) and silicon oxide (SiO2), aluminum oxide (Al2O3) and magnesium fluoride (MgF2), and tantalum pentoxide (Ta2O5) and silicon dioxide (SiO2).

[0058] In some embodiments, one of the two facing reflector surfaces 212 is made of or contains a material selected to transform the color of the naturally emitted light from a light source (e.g., a micro LED 214, discussed in further detail herein) into a color specified by the selected material. For example, in some embodiments, one or both of the facing reflector surfaces 212 include a phosphor (e.g., a red phosphor, a yellow phosphor, etc.).

[0059] Red phosphors are used to convert blue or ultraviolet (UV) light into red light. Red phosphors can include compounds containing rare earth elements, such as europium-doped yttrium vanadate (YVO:Eu), europium-doped yttrium oxide (Y₂O₃:Eu), yttrium aluminum garnet (YAG:Eu), yttrium aluminum borate (YAB:Eu), and yttrium orthovanadate (YVO:Eu). Green phosphors are used to convert blue or UV light into green light. Green phosphors typically include rare earth elements such as terbium (Tb) or europium (Eu), which are combined with other compounds to achieve the desired emission wavelength. Blue phosphors are used to convert UV light into blue light. Blue phosphors can include cerium (Ce)-activated compounds, such as cerium-doped yttrium aluminum garnet (YAG:Ce). Blue phosphors absorb UV light and emit blue light through a process called photoluminescence. Yellow phosphors are used to convert blue or UV light into yellow light. Yellow phosphors may include combinations of rare earth elements such as Ce, Tb, or Y with other compounds. Orange phosphors are used to convert blue or UV light into orange light. Orange phosphors may include Eu and Tb, as well as other co-activators (e.g., Ce and Sr). Cyan phosphors are used to convert blue or UV light into cyan light. Cyan phosphors may include Tb and Eu, as well as other compounds (e.g., gadolinium (Gd), aluminum (Al), silicon (Si), oxygen (O), etc.). White phosphors are used to convert blue or UV light into white light. White phosphors may include blends of red, green, and blue (RGB) phosphors or combinations of blue and yellow phosphors. Alternatively or additionally, white light can be provided by using a combination of a blue LED and a yellow phosphor.

[0060] Refer again Figure 2In some embodiments, the facing reflector surfaces 212 are used to reflect light 216 entering the air gap 208 between the facing reflector surfaces 212. In some embodiments, the third surface 217 of the light tube 202 is not coated with a reflective material. In some embodiments, the third surface 217 of the light tube 202 is substantially free of reflective material, meaning that the third surface 217 is free of reflective material except for occasional coverage due to the thickness of the facing reflector surfaces 212 (as shown). That is, the third surface 217 may be substantially free of reflective material except for only a portion of the third surface 217 covered by the thickness of the respective facing reflector surfaces 212. In this way, in some embodiments, light 216 is reflected regardless of whether the light 216 originates externally (e.g., from environmental conditions, such as sunlight, as shown) or internally (e.g., from the micro-LED 214). The third surface 217 may be located between the opposing sidewalls 204, 206 of the thin lens 200 and / or between the facing reflector surfaces 212 (as shown). In some embodiments, the third surface 217 is configured such that light 216 can pass through the third surface 217 and enter the air gap 208 (as shown).

[0061] It is worth noting that the path of light 216 is elongated relative to the natural path (i.e., a straight path) that light would take in the absence of the facing reflector surface 212. In this way, the facing reflector surface 212 provides an infinity mirror effect, so the thin lens 200 appears relatively thicker than its actual thickness. In other words, the thin lens 200 provides the appearance of a thick lens.

[0062] In some embodiments, the thin lens 200 and / or the illumination assembly 106 (see reference) Figure 1 The device may include one or more lighting sources, such as one or more microLEDs 214. In some embodiments, the microLEDs 214 are formed on or electrically coupled to a dedicated driving circuit 218 (also referred to as an illumination substrate and / or backplane). In some embodiments, each microLED 214 includes a single LED element (see reference). Figure 4B In some embodiments, each of the microLEDs 214 includes a plurality of microLED elements (as shown in the figure).

[0063] For ease of discussion and illustration only, the thin lens 200 is shown as having a specific number of micro-LEDs 214 (two in this case). However, it should be understood that the number, size, configuration, orientation, center-to-center spacing, etc., of the micro-LEDs 214 may vary depending on the needs of a given display application. For example, a micro-LED 214 may include two or more elements (sub-pixels) of the same color (e.g., blue) and one element of another color (e.g., red, red and green, yellow, etc.). Furthermore, each micro-LED 214 need not each include the same number of elements. For example, some of the micro-LEDs 214 may include a first number of elements (e.g., 1, 2, 3, 4, 10, etc.), while some of the micro-LEDs 214 may include a second (or third, etc.) number of elements (e.g., 1, 2, 3, 4, 10, etc.). All these configurations are within the scope of this disclosure.

[0064] Depending on the desired emission color of the respective microLED, the microLED 214 can be formed from a range of known suitable materials, such as semiconductor materials (e.g., silicon, gallium nitride, indium gallium nitride, etc.) and sapphire. Examples include gallium nitride (GaN) for blue LEDs, indium gallium nitride (InGaN) for green LEDs, and aluminum gallium indium phosphide (AlGaInP) for red LEDs. In some embodiments, the microLED 214 comprises several stacked layers, such as indium gallium nitride / gallium nitride (InGaN / GaN) stacks formed on silicon or sapphire substrates to produce blue and green devices.

[0065] In some embodiments, one or more of the microLEDs 214 are formed on a driving circuit 218. In some embodiments, the driving circuit 218 may include internal electrical connections and components (not shown separately) configured to individually control a respective microLED 214 using electrical signals. For example, the driving circuit 218 may control a respective microLED 214 by selectively delivering a driving voltage to the microLED 214.

[0066] Figure 3 An illustration shows an option for selectively metallizing a thin lens tube (e.g., according to one or more embodiments). Figure 2 Example of a thin lens 200) holding clamp 300. Figure 3 As shown, the retaining clamp 300 may include a plurality of surfaces 302 having any desired shape and / or morphology. In some embodiments, the light tube 202 is formed and / or positioned against the surfaces 302 of the retaining clamp 300 to achieve the morphology of the surfaces 302. In some embodiments, the retaining clamp 300 is a molded part, against which the light tube 202 may be positioned, formed, injected, and / or deposited.

[0067] In some embodiments, mask layer 304 may be placed above a portion of the light pipe 202. Mask layer 304 is not intended to be particularly limited, but may include, for example, photoresist patterned using photolithography to produce any desired mask pattern, hard masks (such as metal hard masks, such as thin metal layers including chromium, nickel, and titanium deposited and patterned on the light pipe 202 using techniques like photolithography and etching), oxide hard masks (such as silicon dioxide and alumina), polymer masks (such as polyimide, epoxy, and / or polyurethane, which are spin-coated and / or printed onto the light pipe 202 and patterned using techniques like photolithography and laser ablation), self-assembled monolayers (SAMs) formed by chemisorption and / or covalent bonding and patterned using techniques such as microcontact printing and / or electron beam lithography, and / or stripping resists, such as sacrificial photoresist, which are removed (stripped or peeled) after metal deposition. It should be understood that the specific configuration of mask layer 304 is shown for illustrative purposes only. The mask layer 304 can have any desired pattern, thereby allowing metal to be selectively deposited onto the unmasked area of ​​the light pipe 202 as needed.

[0068] In some embodiments, the facing reflector surface 212 is formed on the exposed portion of the light pipe 202 (i.e., those portions of the light pipe 202 not covered by the mask layer 304). Several methods are available for depositing and / or metallizing a reflective material coating onto the underlying substrate, and these methods are not intended to be particularly limited. In some embodiments, the facing reflector surface 212 is formed on the light pipe 202 using physical vapor deposition (PVD), whereby a reflective material (e.g., aluminum, silver, chromium, etc.) evaporates in a high vacuum environment and then condenses onto the light pipe 202. Evaporation can be achieved using techniques such as thermal evaporation, electron beam evaporation, and sputtering. In some embodiments, the facing reflector surface 212 is formed on the light pipe 202 using chemical vapor deposition (CVD), whereby a gaseous precursor containing a selected metallic substance is introduced into a vacuum chamber, and the material reacts and deposits as a metallic film on the light pipe 202. Other processes are possible, such as electroplating, wet chemical deposition, and spin coating, but other processes are also possible and are within the scope of this disclosure. Following the deposition and / or metallization process, the light tube 202 and / or the reflector surface 212 facing it may undergo additional treatments, such as protective coatings, annealing, and / or polishing, to alter and / or enhance the reflectivity, durability, and optical properties of 200.

[0069] Figure 4A A view of an alternative thin lens 200 according to one or more embodiments is shown. Figure 4A The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that... Figure 4A The alternative thin lens 200 shown may include an opening 402 in one (as shown) or both (not shown separately) of the facing reflector surfaces 212 of the light tube 202. In this configuration, the opening 402 may be patterned such that the facing reflector surfaces 212 will emit light 216 in any desired shape (i.e., in the shape of the opening 402). The shape and / or geometry of the opening 402 is not intended to be particularly limited, but can be shaped as needed, for example, as desired text, logo, message, pattern, etc. In a configuration where one or both of the facing reflector surfaces 212 have openings 402, the light tube 202 may similarly be patterned and / or made of transparent and / or translucent material, such that light 216 passing through the opening 402 may also pass through the light tube 202 at the location of the opening 402.

[0070] Figure 4B A view of an alternative thin lens 200 according to one or more embodiments is shown. Figure 4B The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that... Figure 4B In the alternative thin lens 200 shown, the light tube 202 provides one of the opposing sidewalls 204, 206, and the housing 404 (or frame, etc.) provides the other of the opposing sidewalls 204, 206. This type of configuration advantageously changes the purpose of the housing 404, thereby avoiding the use of the curved light tube 202 (see [link to image]). Figure 2 The implementation of this embodiment is associated with increased weight, manufacturing time, and complexity. This could further reduce the weight by approximately half that of the light tube 202.

[0071] Figure 4C A view of another alternative thin lens 200 according to one or more embodiments is shown. Figure 4C The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that... Figure 4C In the alternative thin lens 200 shown, a micro-LED 214 is positioned relative to the facing reflector surface 212 such that light 216 is reflected within the air gap 208 and refracted within the light tube 202. For example, one or more micro-LEDs 214 may be positioned in and / or below the air gap 208 for reflecting light, and one or more micro-LEDs 214 may be positioned in and / or below the light tube 202 for refracting light. In this configuration, the light tube 202 may be made of a transparent and / or translucent material as described above.

[0072] Figure 4D A view of an additional alternative thin lens 200 according to one or more embodiments is shown. Figure 4D The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that... Figure 4D In the alternative thin lens 200 shown, the facing reflector surface 212 is shaped into a plurality of reflective elements. The reflective elements can be shaped using any desired mask and / or patterning (see, for example...). Figure 3 The reflector surface 212 facing the surface can be made to have the same shape, size and / or orientation (as shown in the figure), or alternatively, it can be made to have different combinations of shape, size and / or orientation as needed.

[0073] Figure 5A A view of an alternative thin lens 200 according to one or more embodiments is shown. Figure 5A The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that in this alternative thin lens 200, the microstructure 500 is shaped, patterned, molded, etc., to shield the interface of the underlying components, to disrupt the natural optical read-through along the edges and / or sidewalls of the light tube 202, and / or otherwise achieve any desired optical properties. As used herein, microstructure refers to those portions of the underlying structure (i.e., the alternative thin lens 200) that have been varied in geometry and / or reflectivity to modify the optical properties of ambient light 502 passing through and / or entering the alternative thin lens 200. Microstructures can be fabricated using molding processes and / or by incorporating reflective surfaces (see [link to documentation]). Figure 3 For example, in Figure 5A In the illustrated embodiment, the microstructure 500 is shaped such that ambient light 502 is reflected within the top 504 of the alternative thin lens 200. In this way, the ambient light 502 is redirected along the top 504, causing the internal structure of the alternative thin lens 200 to be shielded, thereby helping the alternative thin lens 200 to behave as a thick lens (see [link]). Figure 2 The effectiveness of ).

[0074] Figure 5B A view of an alternative thin lens 200 according to one or more embodiments is shown. Figure 5B The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2The thin lens 200 shown is made of a similar material, except that in this alternative thin lens 200, the microstructure 500 is shaped, patterned, molded, etc., to shield the interface of the underlying components, disrupt the natural optical transmission along the edges and / or sidewalls of the light tube 202, and / or otherwise achieve any desired optical properties. For example, in Figure 5B In the illustrated embodiment, the microstructure 500 is shaped such that ambient light 502 is reflected along one or both edges 506 of the facing reflector surfaces 212. In this way, the internal structure of the alternative thin lens 200 is shielded, thereby helping the alternative thin lens 200 to behave as a thick lens (see [link]). Figure 2 The effectiveness of ).

[0075] Figure 5C A view of an alternative thin lens 200 according to one or more embodiments is shown. Figure 5C The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that in this alternative thin lens 200, the microstructure 500 is shaped, patterned, molded, etc., to shield the interface of the underlying components, disrupt the natural optical transmission along the edges and / or sidewalls of the light tube 202, and / or otherwise achieve any desired optical properties. For example, in Figure 5C In the illustrated embodiment, the microstructure 500 is shaped such that ambient light 502, which contacts the edge 508 of the thin lens 200, is reflected back from the light tube 202. In this way, the internal structure of the alternative thin lens 200 is shielded, thereby helping the alternative thin lens 200 to behave as a thick lens (see [link]). Figure 2 The effectiveness of ).

[0076] Figure 5D A view of an alternative thin lens 200 according to one or more embodiments is shown. Figure 5D The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that in this alternative thin lens 200, the microstructure 500 is shaped, patterned, molded, etc., to shield the interface of the underlying components, disrupt the natural optical transmission along the edges and / or sidewalls of the light tube 202, and / or otherwise achieve any desired optical properties. For example, in Figure 5D In the illustrated embodiment, the microstructure 500 is shaped such that ambient light 502 is reflected away from the edge 510 of the thin lens 200. In this way, the internal structure of the alternative thin lens 200 is shielded, thereby helping the alternative thin lens 200 to behave as a thick lens (see [link]). Figure 2 The effectiveness of ).

[0077] Figure 5E A view of an alternative thin lens 200 according to one or more embodiments is shown. Figure 5E The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that in this alternative thin lens 200, the microstructure 500 is shaped, patterned, molded, etc., to shield the interface of the underlying components, disrupt the natural optical transmission along the edges and / or sidewalls of the light tube 202, and / or otherwise achieve any desired optical properties. For example, in Figure 5E In the illustrated embodiment, the microstructure 500 is shaped such that ambient light 502 is scattered at the edge 512 of the thin lens 200. In this way, the internal structure of the alternative thin lens 200 is shielded, thereby helping the alternative thin lens 200 to behave as a thick lens (see [link]). Figure 2 The effectiveness of ).

[0078] Figure 5F A view of an alternative thin lens 200 according to one or more embodiments is shown. Figure 5F The alternative thin lens 200 shown can be used with Figure 2 The thin lens 200 shown is similar in manner and is composed of... Figure 2 The thin lens 200 shown is made of a similar material, except that in this alternative thin lens 200, the microstructure 500 is shaped, patterned, molded, etc., to shield the interface of the underlying components, disrupt natural optical transmission along the edges and / or sidewalls of the light tube 202, and / or otherwise achieve any desired optical properties. For example, in Figure 5F In the illustrated embodiment, the microstructure 500 is shaped such that ambient light 502 is split at the edge 514 of the thin lens 200. In this way, the internal structure of the alternative thin lens 200 is shielded, thereby helping the alternative thin lens 200 to behave as a thick lens (see [link]). Figure 2 The effectiveness of ).

[0079] Now for reference Figure 6 A flowchart 600 for providing a relatively thin lens that utilizes a reflective surface to achieve the appearance of a thick lens, is generally shown according to an embodiment. (Reference) Figures 1 to 5F Describe flowchart 600, and flowchart 600 may include Figure 6 Additional steps not depicted. Although depicted in a specific order, Figure 6 The boxes depicted in the text can be rearranged, subdivided, and / or combined.

[0080] At block 602, the method includes providing a light tube configured such that opposite sidewalls of the light tube face each other across an air gap.

[0081] At frame 604, the method includes forming a first reflector surface on a first sidewall opposite to the sidewall. In some embodiments, the first reflector surface includes a first reflective material.

[0082] At frame 606, the method includes forming a second reflector surface on a second sidewall opposite to the sidewall. In some embodiments, the second reflector surface comprises a second reflective material.

[0083] At block 608, the method includes forming a third surface located between the first reflector surface and the second reflector surface. In some embodiments, the third surface is configured such that light can pass through the third surface and enter an air gap. In some embodiments, the light path within the air gap is elongated due to internal reflection between the first and second reflector surfaces, thereby providing an infinite mirror effect (see...). Figure 2 ).

[0084] In some embodiments, the light pipe includes a nominal sidewall thickness of less than 5.0 mm. In some embodiments, the light pipe is part of or defines a lens. Therefore, in some embodiments, the light pipe is a thin lens having a nominal sidewall thickness of less than 5.0 mm.

[0085] In some embodiments, the third surface is substantially free of reflective material, except for a portion of the third surface that is covered by the thickness of the first reflector surface and the thickness of the second reflector surface.

[0086] In some embodiments, the first reflective material and the second reflective material are the same. In some embodiments, the first reflective material and the second reflective material are made of different reflective materials.

[0087] In some embodiments, the component further includes a light source. In some embodiments, the light source includes one or more miniature light-emitting diodes (LEDs), but other light sources (e.g., halogen, LEDs, etc.) are also possible and within the scope of this disclosure. In some embodiments, the one or more miniature LEDs include a first miniature LED positioned within the air gap such that light emitted from the first miniature LED is reflected through the air gap between the first reflector surface and the second reflector surface. In some embodiments, the one or more miniature LEDs include a second miniature LED positioned such that light emitted from the second miniature LED is refracted through the light tube against one of the first reflector surface and the second reflector surface.

[0088] The terms “a” and “an” do not indicate a limitation of quantity, but rather that at least one of the referenced items is present. Unless the context clearly indicates otherwise, the term “or” means “and / or”. Throughout the specification, reference to “aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner in the aspects.

[0089] When an element, such as a layer, film, region, or substrate, is referred to as being “on” another element, it can be directly on the other element, or there may be intermediate elements present. Conversely, when an element is referred to as being “directly” on another element, there are no intermediate elements present.

[0090] Unless otherwise stated herein, all test standards are the most recent standards in effect as of the date of filing of this application, or, if priority is claimed, the date of filing of the earliest priority application in which a test standard appears.

[0091] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0092] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A vehicle comprising: The component includes a lens, the lens comprising: A light tube, configured such that opposite sidewalls of the light tube face each other across an air gap; A first reflector surface, comprising a first reflective material, is formed on a first sidewall of the opposing sidewall; A second reflector surface, comprising a second reflective material, is formed on the second sidewall of the opposing sidewall; and A third surface, located between the first reflector surface and the second reflector surface, is configured such that light can pass through the third surface and enter the air gap; In this process, due to the internal reflection between the first reflector surface and the second reflector surface, the path of light within the air gap is extended, thereby providing an infinite mirror effect.

2. The vehicle according to claim 1, wherein, The light tube has a nominal sidewall thickness of less than 5.0 mm.

3. The vehicle according to claim 1, wherein, Except for a portion of the third surface that is covered by the thickness of the first reflector surface and the second reflector surface, the third surface is substantially free of reflective material.

4. The vehicle according to claim 1, wherein, The first reflective material and the second reflective material are the same.

5. The vehicle according to claim 1, wherein, The component also includes a light source.

6. The vehicle according to claim 5, wherein, The light source includes a first light source positioned within the air gap, such that light emitted from the first light source is reflected between the surface of the first reflector and the surface of the second reflector through the air gap.

7. The vehicle according to claim 6, wherein, The light source further includes a second light source, which is positioned such that light emitted from the second light source is refracted by the light tube against one of the surfaces of the first reflector and the second reflector.

8. A lens, the lens comprising: A light tube, configured such that opposite sidewalls of the light tube face each other across an air gap; A first reflector surface, comprising a first reflective material, is formed on a first sidewall of the opposing sidewall; The second reflector surface, comprising a second reflective material, is formed on the second sidewall of the opposite sidewall; as well as A third surface, located between the first reflector surface and the second reflector surface, is configured such that light can pass through the third surface and enter the air gap; In this process, due to the internal reflection between the first reflector surface and the second reflector surface, the path of light within the air gap is extended, thereby providing an infinite mirror effect.

9. The lens of claim 8, wherein the light tube has a nominal sidewall thickness of less than 5.0 mm.

10. The lens according to claim 8, wherein, Except for a portion of the third surface that is covered by the thickness of the first reflector surface and the second reflector surface, the third surface is substantially free of reflective material.

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