LIGHT STRIP FOR AN EXTERIOR LIGHTING ASSEMBLY

Abstract

A light strip (32), comprising: a body section (36) made of a substantially transparent material and having a generally plate-like shape with a mean height H in a z-direction, a mean width W in a y-direction and a mean thickness T in an x-direction, wherein the x-, y- and z-directions are orthogonal to each other and H > W > T; and a decorative element arranged within the body section (36) and having an outer surface (62), wherein at least a part of the outer surface (62) contains a light-scattering material, wherein the light bar (32) is configured for use in an external lighting assembly for a motor vehicle, wherein the external lighting assembly is at least one of the following assemblies: a headlight assembly, a brake light assembly, a turn signal assembly, a reversing light assembly, a parking / front position light assembly and a daytime running light assembly, wherein the entire decorative element (60) is made of the light-diffusing material, where the outer surface (62) generally points in the x-direction, wherein the light strip (32) is arranged such that when light rays are directed into the body section (36) towards the decorative element (60), a subset of the light rays falls on the decorative element (60) and is scattered in such a way that the decorative element (60) appears brighter than the transparent material surrounding the decorative element (60). the decorative element takes the form of a symbol, wherein the decorative element (60) is dimensioned with correspondingly visible height and width dimensions in the z and y directions, but with very small thickness dimensions in the x direction, so that the decorative element (60) is obviously visible from side and oblique views of the light strip (32), but along the y and z directions the decorative element (60) is more difficult to see due to its thinness, wherein the substantially transparent material is at least one of a polycarbonate, polymethyl methacrylate and an acrylic, wherein the light-scattering material is a talc, titanium dioxide and a combination of one of the aforementioned, at least a polycarbonate and polymethyl methacrylate, wherein the body section (36) is at least one of clear and coloured, wherein the body section (36) has an upper (38) and a lower (40) end which are opposite each other in the z-direction, wherein the light bar further comprises a first wing section (42) which is made of the substantially transparent material and has a first longitudinal axis and a first and a second end which are opposite each other along the first longitudinal axis, wherein the first end is adjacent to the upper end (40) and the first longitudinal axis is generally arranged in the x-direction, furthermore with a second wing section (48) which is made of the substantially transparent material and has a second longitudinal axis and opposing third and fourth ends along the second longitudinal axis, wherein the third end adjoins the lower end (40) and the second longitudinal axis is generally arranged in the x-direction.

Description

INTRODUCTION

[0001] This disclosure relates generally to light strips for exterior lighting assemblies of motor vehicles and methods for manufacturing such light strips.

[0002] Motor vehicles are generally required to have various exterior lights, such as headlights, brake lights, turn signals, parking / front position lights, and reversing lights. Some vehicles also have daytime running lights (DRL), which switch on automatically when the vehicle's engine is started. Daytime running lights can be lights that are separate from and mounted in addition to the other lights mentioned above, or the headlights themselves can be used as daytime running lights. In the latter case, the headlights can be operated in two modes. One is the "normal" headlight mode, in which the headlights can be switched on by the driver to emit low or high beams. The other is a "DRL" mode, in which the high beams are switched on, but at a lower than normal intensity.

[0003] Some vehicles have separate reversing lights, which may include light bars illuminated by light-emitting diodes (LEDs), high-intensity discharge lamps (HID lamps), or similar devices.

[0004] DE 195 14 649 A1 describes a display element based on the optical fiber principle and two manufacturing methods. The display elements can be used for control panels, illuminated displays, advertising purposes, and similar applications.

[0005] DE 297 12 530 A1 describes an escalator or moving walkway with a light-emitting image that appears as light emerging from a light-conducting material.

[0006] US 2009 / 0219731A1 describes an optical system for a motor vehicle, wherein the optical system performs at least one principal optical function and, in particular, a diffusion screen, at least one LED-type light source, wherein each LED of the optical system produces a set of light rays that propagate in the diffusion screen, the screen having the shape of a curved plate with an upper lateral region and a lower lateral region meeting at a periphery, which in particular has a rear surface and a front edge, and the principal function is substantially formed via an output surface of the screen formed by the front edge of the diffusion screen.

[0007] US 2011 / 0310610A1 describes a lighting system for a vehicle comprising a headlight light source. Adjacent to the light source is a trim piece having an inner surface illuminated by the light from the light source and an outer surface visible from outside the vehicle. The trim piece consists of a translucent plastic body with a signature image formed on the body, comprising a foreground area and a background area.

[0008] DE 10 2010 054 923 A1 describes a lighting device for a vehicle with at least one light source and an optical element which has a first area through which light emitted by the light source passes in order to provide a first lighting function.

[0009] US 2013 / 0094205A1 describes an illuminated display for representing a three-dimensional object, comprising a display element containing the object, wherein information becomes visible when light is coupled into the display element. The display element is transparent. The three-dimensional object is made of a first plastic material with a first refractive index and is partially or completely enclosed by a second plastic material with a second refractive index.

[0010] DE 10 2017 214 943 A1 shows a trim element on a vehicle, which consists of a trim element body and a machined design area, wherein the design area is formed from at least one plastic sheet which is structured by means of laser processing for a three-dimensional appearance, while the outer surface remains unaffected.

[0011] US 5,269,977 A discloses a light-reflecting body for panel lights or decorative elements with edge lighting, consisting of a transparent inorganic or organic cast glass, such as a transparent polymethyl methacrylate sheet, into which unevenly distributed layers of foam are embedded on the inner or outer surface. The organic cast glass is produced by gelling glass beads and monomer or prepolymer and casting them in a frame, or by applying the foam material to a finished sheet and curing it, or by firmly bonding a pre-fabricated foam layer to a sheet, such that in the first two methods the foam layer is completely bonded to the cast glass; the third method can also be used for inorganic cast glass.

[0012] CN 2 01 998 920 U shows a decorative insert for a vehicle light, featuring an opaque mounting structure on which a reflective layer is arranged. A light tube adjacent to the reflective layer is rotatably connected to a light source and contains an optical layer. A TIR shielding layer is located on the light tube, followed by a diffusion layer and then a decorative emission layer. The optical layer produces a visible light effect only when the light source is switched on. An environmental layer is arranged on top of the emission layer.

[0013] CN 1 09 681 845 A discloses a vehicle-compatible, light-guiding LOGO lamp and a method for its manufacture, consisting of a base housing with a centrally located mounting slot, a printed circuit board (PCB) with an integrated LED light source and control unit attached to the base housing. The back of the PCB is clamped in the mounting slot, and the LED light source and control unit are connected to an external power supply and control unit via cables. The light panel, cover, decorative frame, and LOGO lampshade are sequentially mounted on the front of the PCB. The PCB, light panel, and cover are optically designed so that the LED light is distributed uniformly by direct, total reflection, refraction, reflection, and re-reflection and is not affected by the shape of the LOGO, even with complex LOGO shapes.The controllable light path enables simulation and analysis using optical CAE to adapt light intensity, light shape and beam angle to the vehicle-specific requirements. DESCRIPTION

[0014] The object of the invention is to improve the properties of a light strip.

[0015] This task is solved by the subject matter of the independent claim.

[0016] According to one embodiment, a light bar comprises a body section made of a substantially transparent material and having a generally plate-like shape with an average height H in a z-direction, an average width W in a y-direction and an average thickness T in an x-direction, wherein the x-, y- and z-directions are orthogonal to each other and H > W > T, and a decorative element arranged within the body section and having an outer surface, wherein at least a portion of the outer surface contains a light-scattering material.The substantially transparent material may be at least one of a polycarbonate, a polymethyl methacrylate, and an acrylic, and the light-diffusing material may be at least one of talc, titanium dioxide, styrene-acrylonitrile, polyethylene terephthalate, and a combination of one of the foregoing and at least one of polycarbonate and polymethyl methacrylate. The light bar may be configured for use in an exterior lighting assembly of a motor vehicle, wherein the exterior lighting assembly may be at least one of a headlight assembly, a brake light assembly, a turn signal assembly, a reversing light assembly, a parking / front position light assembly, and a daytime running light assembly. The body panel may be at least either clear or colored. Substantially the entire decorative element may consist of the light-diffusing material, and at least a portion of the outer surface may generally point in the x-direction.

[0017] The body section can have an upper and a lower end opposite each other in the z-direction, and the light bar can further comprise a first wing section made of the substantially transparent material, having a first longitudinal axis and a first and a second end opposite each other along the first longitudinal axis, the first end being adjacent to the upper end and the first longitudinal axis generally being oriented in the x-direction. The light bar can further comprise a second wing section made of the substantially transparent material, having a second longitudinal axis and opposite third and fourth ends along the second longitudinal axis, the third end being adjacent to the lower end and the second longitudinal axis generally being oriented in the x-direction.The light strip can be produced by a multi-shot molding process, and the light strip can be arranged such that when light rays are directed into the body section towards the decorative element, a subset of the light rays will fall upon the decorative element and be scattered in such a way that the decorative element appears brighter than the essentially transparent material surrounding the decorative element.

[0018] According to one embodiment, an exterior lighting assembly for a motor vehicle consists of a housing, a light bar, and a light source. The light bar is attached to the housing and comprises a body section made of a substantially transparent material, generally having a plate-like shape with an average height H in the z-direction, an average width W in the y-direction, and an average thickness T in the x-direction, wherein the x-, y-, and z-directions are orthogonal to each other and H > W > T, and a decorative element arranged within the body section, having an outer surface, at least one portion of which contains a light-diffusing material. The light source is attached to the housing and configured to emit visible light into the body section.The exterior lighting assembly may comprise at least a headlight assembly, a brake light assembly, a turn signal assembly, a reversing light assembly, a parking / front position light assembly, or a daytime running light assembly. The body panel may have upper and lower ends opposite in the z-direction, and the light bar may further comprise a first wing section made of the substantially transparent material, with a first longitudinal axis and opposite first and second ends along the first longitudinal axis, the first end being adjacent to the upper end and the first longitudinal axis generally oriented in the x-direction. Substantially the entire decorative element may be made of the light-diffusing material, and the light bar may be manufactured by a multi-stage injection molding process.The light strip can be arranged so that when light rays from the light source are directed into the body section towards the decorative element, a subset of the light rays strikes the decorative element and is scattered in such a way that the decorative element appears brighter than the essentially transparent material surrounding the decorative element.

[0019] According to one embodiment, a method for forming a light bar comprises: (a) injecting a first shot of a substantially transparent material into a mold to form a first layer of the substantially transparent material, the first layer having a first principal surface and an outer perimeter around the first principal surface; (b) arranging a decorative element on the first principal surface within the outer perimeter, the decorative element having an outer surface, at least a portion of the outer surface comprising a light-scattering material; and (c) injecting a second shot of the substantially transparent material into the mold to form a second layer of the substantially transparent material covering the decorative element and in contact with the first principal surface.The disposal step may include injecting a shot of the light-diffusing material into the mold to form the decorative element. Alternatively, the disposal step may include applying the decorative element in solid form to the first main surface within the outer circumference, with the decorative element being formed separately from the mold. The light bar may be configured for use in an exterior lighting assembly for a motor vehicle, wherein the exterior lighting assembly is at least one of the following: a headlight assembly, a brake light assembly, a turn signal assembly, a reversing light assembly, a parking / front position light assembly, and a daytime running light assembly.

[0020] The above-mentioned features and advantages, as well as other features and advantages of the present teaching, are readily apparent from the following detailed description of some of the preferred embodiments and other embodiments for carrying out the present teaching as defined in the attached claims, in conjunction with the attached figures. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 is a schematic top view of a motor vehicle with exterior lighting assemblies. Fig. Figure 2 is a schematic front view of a headlight exterior lighting assembly, seen along line 2-2 of Fig. 1. Fig. Figure 3 is a schematic front view of a rear light exterior lighting assembly, seen along line 3-3 of Fig. 1. Fig. 4A is a perspective schematic view of a segment of a light bar. Fig. 4B is an enlarged schematic view from above of a decorative element as it appears along line 4B-4B from Fig. 4A can be seen. Fig. 5A, Fig. 5B and Fig. 5C are schematic top, front and side views of the in Fig. 4 segments of a light strip shown. Fig. Figure 6 is a perspective view of the in Fig. 2 schematically represented light strips. Fig. 7 and Fig. Figure 8 shows flowcharts of two respective methods for forming a light bar for an exterior lighting assembly of a motor vehicle. Fig. 9A, Fig. 9B and Fig. Figures 9C are schematic front views showing a layer structure for forming a light bar according to the method of Fig. 7 illustrate. Fig. 10A, Fig. 10B and Fig. Figures 10C are schematic front views showing an alternative layer structure for forming a light bar according to the method of Fig. 7 illustrate. Fig. 11A and Fig. Figure 11B shows schematic front views illustrating the steps for forming a light bar according to the method of Fig. 8 illustrate. Fig. Figure 12 is a schematic top view of the first layer and the decorative element of Fig. 9B.

[0021] As used here, “ Fig. 4" on the Fig. 4A and Fig. 4B together, “ Fig. 5” refers to the Fig. 5A, Fig. 5B and Fig. 5C together, “ Fig. 9” refers to the Fig. 9A, Fig. 9B and Fig. 9C together, “ Fig. “10” refers to the Fig. 10A, Fig. 10B and Fig. 10C together and “ Fig. 11” refers to the Fig. 11A and Fig. 11B together. DETAILED DESCRIPTION

[0022] With reference to the figures, in which similar reference numerals in the different views indicate similar parts, a light bar 32 for an external lighting assembly (ELA) 20 of a motor vehicle 10 and a method 100, 200 for manufacturing the light bar 32 are shown and described here.

[0023] Fig. Figure 1 shows a schematic top view of a motor vehicle 10 with several ELAs 20. It should be noted that in the drawings and in this description, the reference numeral 20H can refer to an ELA for headlights, the reference numeral 20T to an ELA for taillights, and the reference number 20 (without a subscript) can refer to one or both types of ELAs. An ELA can comprise a headlight assembly, a brake light assembly, a turn signal assembly, a reversing light assembly, a parking / front position light assembly, and / or a daytime running light assembly. The front 12 of the vehicle 10 has two headlight ELAs 20H (one facing left 16 of the vehicle 10 and one facing right 18), and the rear 14 has two taillights ELAs 20T (also facing left and right 16 and 18, respectively). As can be seen from the description below, a light bar 32 may be used in a headlight ELA 20H or a taillight ELA 20T in accordance with this notice.(It should be noted that "front", "rear", "left" and "right", as used here, can refer to the respective parts 12, 14, 16, 18 of a vehicle 10 or to corresponding areas outside the vehicle 10. For example, "in front" of a vehicle 10 can refer to a perspective or view taken from a point located some distance from the "front 12" of the vehicle 10, but looking rearward in the direction of the "front 12" of the vehicle 10).

[0024] Fig. Figure 2 shows a schematic front view of a headlight ELA 20H, which includes a housing 22, one or more headlights or headlights 24 (e.g., low and high beam), a light bar 32, and various mountings 23. Although not shown in this view, the headlight ELA 20H can also include a turn signal. In the configuration shown, the light bar 32 can serve as a DRL 30, but it should be noted that the light bar 32 can also be used as part of, or in conjunction with, the headlights 24, the turn signal, the parking / front position light, or as a decorative element. In the configurations described in this communication, the light bar 32 includes a body section 36, which is made of a substantially transparent material and has a generally "plate-like" shape, and which can extend outwards from the ELA 20 to which the light bar 32 belongs.(As used here, a "plate" is defined as an element with a generally rectangular prism shape whose thickness is less than, and can be much less than, its height and width, such as a rectangular prism with a height of 5 inches, a width of 3 inches, and a thickness of half an inch. Thus, a "generally plate-like shape" can include both a rectangular prism shape whose thickness is less than its height and width, and shapes whose cross-sectional area may deviate from strictly rectangular, such as trapezoidal shapes, generally rectangular / trapezoidal shapes with one or more rounded corners, spherical shapes, etc.) Is the light bar 32, for example?If the light bar 32 is part of a headlight ELA 20H installed in a vehicle 10, the plate-shaped form of the light bar 32 protrudes forward, and if the light bar 32 is part of a taillight ELA 20T installed in a vehicle 10, the plate-shaped form of the light bar 32 protrudes backward. With reference to the conventional and mutually orthogonal x, y and z directions shown in the drawings (where the x direction points to the right, the y direction forward and the z direction upward with respect to a vehicle 10), the plate-like shape of the body section 36 of the light bar 32 has an average height H, measured in the upward / downward or z direction, an average width W, measured in the forward / backward or y direction, and an average thickness T, measured in the left / backward or x direction, where H > W > T.In other words, the plate-like shape of body section 36 is relatively thin (in the x-direction) compared to the height and width dimensions H and W of the shape, and the height (or length) H of body section 36 is greater than the width W. It should be noted that, while body section 36 is depicted in the drawings as a generally rectangular cross-sectional profile that appears uniform or unchanging along the height H or z-direction (e.g., like a rectangular prism), this is only for illustrative purposes, as the profile can also take on other shapes and vary in form along the height H or z-direction.

[0025] The essentially transparent material used in Body Section 36 can be a polymer that is either clear (e.g., like window glass) or colored (e.g., red, amber, or yellow). Suitable polymers for the essentially transparent material include, for example, polycarbonates (PC), polymethyl methacrylates (PMMAs), acrylates, or similar. The polymer in its preformed state (e.g., pellets) does not need to be essentially transparent, but the polymer should give the molded or finished part an essentially transparent appearance. As used here, "essentially transparent" describes a material that transmits light without being substantially scattered; in other words, most or all of the light rays incident on the material will continue essentially the same path through the material with little or no deviation.Materials exhibiting such essentially transparent properties include glass, polycarbonates (PCs), polymers of PMMA, and PC / PMMA blends. In contrast, a "light-scattering" material is one that scatters or occludes light rays within the material; that is, light rays entering such a material will rebound and diverge considerably as they pass through it, typically exiting in a significantly different direction than the direction of entry. Examples of light-scattering materials include talc, titanium dioxide, styrene-acrylonitrile (SAN), polyethylene terephthalate (PET), and all combinations of the aforementioned materials with PC, PMMA, or PC / PMMA.

[0026] Although in Fig. Not shown in Figure 2, the ELA 20H also contains a light source 90 that emits visible light in the light bar 32. For example, as in Fig. As shown in Figures 4-5, where a selected segment 34 of the body section 36 is shown, one or more light sources 90 can be arranged near an edge of the body section 36 so that light 92 can be transmitted into and through the light strip 32. The light source 90 can be a line source, as shown in Fig. 4 shown, or a collection of point sources 90 (e.g., individual light-emitting diodes or LEDs), as in Fig. 5 shown, or any other suitable arrangement, including the use of light guides, light louvers, fiber optic elements, reflectors / directors 98 and the like, arranged between the light source 90 and the surface of the light bar 32. In the Fig. In the configuration shown in 4A, visible light would be emitted from the line source 90 along the entire height H of the line source 90 into body section 36, but for illustration purposes, it shows Fig. 4A only selected light rays or rays 92 emanating from a single point 91. Rays 92A, 92B, and 92C are directed in the horizontal (xy) plane, with 92A directed in the negative y-direction, 92B in the negative y-direction and positive x-direction, and 92C in the negative y- and x-directions. Ray 92D is directed "above" the plane of 92A, 92B, and 92C in the negative y-direction and positive z-direction, and ray 92E is directed "below" the aforementioned plane in the negative y- and z-directions. (Note that in the drawings and in this description, the designations 92A, 92B, 92C, 92D, 92E, 94, 95, 96 and 97 refer to specific light rays or beams, while the designation 92 (without a subscript) may refer to some or all of these light rays or beams.)

[0027] As in Fig. As shown in Figures 2-6, the light strip 32 also includes a decorative element 60 arranged within the body section 36. The decorative element 60 has an outer surface 62, wherein at least part (i.e., some or all) of the outer surface 62 contains a light-diffusing material. In addition to the outer surface 62 containing light-diffusing material, the interior 64 of the decorative element 60 can also consist wholly or partially of light-diffusing material. (Alternatively, the interior 64 of the decorative element 60 can consist of PC, PMMA, PC / PMMA, or another suitable, substantially transparent material, such as the same material used to manufacture the body section 36. Or, as a further alternative, the interior 64 can be made of a translucent or opaque material, such as a black or colored polymer, for aesthetic reasons.)The decorative element 60 can be dimensioned and oriented within the body section 36 such that the part of the outer surface 62 containing the light-scattering material generally points in the x-direction.

[0028] The decorative element 60 can be an aesthetic or expressive element and can take the form of a logo, emblem, badge, symbol, distinctive shape, or any other desired aesthetic element. For example, an automobile manufacturer may use a badge or symbol representing the make or model of a particular vehicle in the front and / or rear ELAs 20H, 20T of the vehicle. Similarly, aftermarket parts suppliers may offer light bars 32 with distinctive decorative elements 60 as replacement parts.

[0029] As in Fig. As shown in Figures 4-5, the decorative element 60 can be dimensioned with correspondingly visible height and width dimensions in the z and y directions, but with very small thickness dimensions in the x direction. This means that the decorative element 60 is clearly visible from side and oblique views of the light bar 32 (i.e., along the x direction and along directions oblique to the x direction), but due to its thinness, the decorative element 60 may be more difficult to see along the y and z directions. For example, if the left front headlight ELA 20H were made of Fig. If the decorative element 60 were attached to a vehicle 10, it would be easily visible from the left and right sides of the vehicle 10, but would appear very thin (and perhaps difficult to see) from a point in front of the vehicle 10 looking rearward towards the headlight ELA 20H. Similarly, if the rear left taillight ELA 20T were attached to a vehicle 10, it would appear very thin (and perhaps difficult to see). Fig. If the light bar 32 were attached to a vehicle 10, the decorative element 60 would be clearly visible from the left and right sides of the vehicle 10, but would appear very thin (and perhaps difficult to see) from a point behind the vehicle 10 looking forward toward the rear light ELA 20T. In other words, if the light bar 32 is installed in an ELA 20 such that the plate-like shape of the light bar 32 projects forward or backward, or extends forward or backward, the decorative element 60 would be clearly visible from side and perspective views of the light bar 32, but would be difficult to see from a front or rear view. This feature makes the decorative element 60 much less visible to drivers in following vehicles looking forward toward the decorative element 60, and to drivers in preceding vehicles looking backward toward the decorative element 60.

[0030] One advantage offered by the decorative element 60 is that the diffused light 96 is not only aesthetically pleasing but can also help to meet the photometric requirements for side lighting (i.e., the supply of a specific amount of light to the side of the vehicle 10, measured at various angles relative to the y-direction or the forward / reverse direction of the vehicle). Furthermore, the use of a decorative element 60 capable of diffusing light as described here can allow the use of light bars 32 that are wider in width W (measured in the y-direction of the vehicle or in the forward / reverse direction) than light bars that do not use such decorative elements 60. Note also that while the decorative element 60 is described here as "decorative," it can also, or instead, have a non-decorative or purely superficial function and effect, such as...an advantageous scattering of light in desired directions and quantities.

[0031] As in Fig. As further illustrated in Figures 4-5, some light rays 92 emitted by the light source 90 can pass through the essentially transparent material essentially without deviation, as shown in Figures 4-5. Fig. 5 rays designated with the number 94; other light rays 92, however, can be scattered (by the light-scattering material of the decorative element 60), such as the rays designated with dashed lines and the number 96. Fig. Figure 5B shows a light ray passing through the essentially transparent material "behind" the decorative element 60, designated by the numeral 95, and another light ray passing through the essentially transparent material "in front" of the decorative element 60, designated by the numeral 97. The combination of essentially transparent material for the body section 36 and light-diffusing material for the decorative element 60 allows most of the light 92 from the light source(s) 90 to pass through the light strip 32 without scattering, while light striking the decorative element 60 is scattered. This can cause the decorative element 60 to appear to "glow" because the scattered light is reflected off the light-diffusing material at its surface 62.Therefore, the light strip 32 can be arranged such that when light rays 92 are directed into the body section 36 towards the decorative element 60, a subset of the light rays 96 will fall upon the decorative element 60 and be scattered, causing the decorative element 60 to 'glow' or appear brighter than the essentially transparent material surrounding the decorative element 60.

[0032] As in Fig. 2 and Fig. As shown in Figure 6, the body section 36 can have opposite upper and lower ends 38, 40 in the height H or z-direction, and the light bar 32 can further comprise a first wing section 42 made of the same substantially transparent material. The first wing section 42 can have a first longitudinal axis 43 and opposite first and second ends 44, 46 along the first longitudinal axis 43, wherein the first end 38 (of the first wing section 42) adjoins the upper end 38 (of the body section 36) and the first longitudinal axis 43 is generally oriented in the x-direction. The light bar 32 can further comprise a second wing section 48, which can be made of the same substantially transparent material as the body section 36 and the first wing section 42.The second wing section 48 can have a second longitudinal axis 49 and opposing third and fourth ends 50, 52 along the second longitudinal axis 49, wherein the third end 50 (of the second wing section 48) adjoins the lower end 40 (of the body section 36) and the second longitudinal axis 49 is generally arranged in the x-direction. For example, the one in . Fig. The two ELA 20H headlights shown are mounted on the left front of a vehicle 10, wherein the body part 36 is generally oriented upright (i.e. generally runs along or parallel to the z-direction) and wherein the first and second wing parts 42, 48 are generally oriented horizontally (i.e. generally run along or parallel to the x-direction) and point towards the front grille (and also point towards the other ELA 20H headlight mounted on the right front of the vehicle 10).

[0033] Fig. Figure 3 shows a rear left taillight ELA 20T, which, compared to the headlight ELS 20H, is made of Fig. 2 has a different configuration of the light bar 32. The ELA 20T rear light has a housing 22, mounting bracket 23, indicator 26, reversing light 28 and light bar 32. It should be noted that, while the light bar 32 of Fig. 2 has a "lateral U" shape and contains a decorative element 60, the light strip 32 of Fig. 3 has a kind of "boomerang" shape and contains three decorative elements 60.

[0034] It should also be noted that reference is made here to the "average" dimensions H, W, T of the height, width, and thickness of body section 36. This is because one or more of these dimensions can vary in one or more directions. Furthermore, note that while the average height, width, and thickness dimensions H, W, T can be measured along the respective x, y, and z directions or axes, they can also be measured along directions or axes that are not orthogonal to each other. For example, the somewhat "boomerang-shaped" body section 36 and the light strip 32, which is located in Fig. Figure 3 shows that the components can be considered to have a longitudinal axis (and generally a vertical axis) running along the height of the light bar 32 in the z-direction. However, this axis may bend where the shape of the light bar 32 bends (i.e., next to the top of the indicator 26). Therefore, when using this "bent" longitudinal axis, the height H of the light bar 32 may be somewhat greater than a corresponding height measured along a conventional (and non-bent) vertical z-axis. Similarly, starting from the "bent" longitudinal axis, the width W of the light bar 32 at any point along its length can be considered as the lateral width of the light bar 32 measured at each point orthogonal to the bent longitudinal axis.It should be noted that the longitudinal axis of the light bar 32 may also be “bent” or “curved” in the forward and reverse directions; in fact, many automotive ELAs are not simply “planar”, as the simplified schematic diagrams of the . Fig. They do not simply show straight lines, but can curve and wave around all three x, y, and z directions. Thus, for each ELA 20 and each light strip 32, the upward / downward, left / right, and forward / backward directions can be defined according to their shape and orientation in 3D space.

[0035] As in Fig. As illustrated in Figures 2-3, an ELA 20 for a motor vehicle 10 comprises a housing 22, a light bar 32, and a light source 90. The light bar 32 is attached to the housing 22 and includes a body section 36 made of a substantially transparent material and having a generally plate-like shape with an average height H in a z-direction, an average width W in a y-direction, and an average thickness T in an x-direction, where H > W > T. The light bar 32 also includes a decorative element 60, which is arranged within the body section 36 of the light bar 32 and has an outer surface, at least part of which contains a light-diffusing material. The light source 90 is attached to the housing 22 and configured to emit visible light 92 into the body section 36.The ELA 20 can be at least a headlight assembly, a brake light assembly, a turn signal assembly, a reversing light assembly, a parking / front position light assembly, or a reversing light assembly. The body part 36 can have upper and lower ends 38, 40 opposite in the z-direction, and the light bar 32 can further comprise a first wing part 42 made of the substantially transparent material with a first longitudinal axis 43 and opposite first and second ends 44, 46 along the first longitudinal axis 43, wherein the first end 44 adjoins the upper end 38 and the first longitudinal axis 43 is generally arranged in the x-direction.The light bar 32 can further comprise a second wing section 48, which is made of the substantially transparent material and has a second longitudinal axis 49 and opposing third and fourth ends 50, 52 along the second longitudinal axis 49, the third end 50 being adjacent to the lower end 40 and the second longitudinal axis 49 generally being oriented in the x-direction. In addition to the outer surface 62, which contains light-scattering material, the interior 64 of the decorative element 60 can also consist wholly or partially of light-scattering material. The light bar 32 of the ELA can be configured such that when light rays 92 are directed into the body section 36 toward the decorative element 60, a subset of the light rays 96 strikes the decorative element 60 and is scattered, causing the decorative element 60 to "glow" or appear brighter than the substantially transparent material surrounding the decorative element 60.

[0036] Fig. Figures 7-12 illustrate two related processes 100, 200 for the manufacture of a light bar 32 for an ELA 20 of a motor vehicle 10. Fig. Figures 7, 9-10, and 12 illustrate a multi-shot injection molding process 100 that begins at block 110. At block 120, a first shot of substantially transparent material is injected into a mold to form a first layer 70 of the substantially transparent material, the first layer 70 having a first principal surface 72 and an outer perimeter 74 around the first principal surface 72. The first layer 70 can be formed in one of two ways. As shown in Fig. As shown in 9A, the first principal surface 72 can generally be flat; or, as in Fig. As shown in Figure 10A, the first main surface 72 can have a depression 78 or other suitable features (e.g., projections, indentations, etc., optionally at different heights or depths) that define the shape and features of the decorative element 60. In block 130, a decorative element 60 (with an outer surface, at least part of which contains a light-diffusing material) is arranged on the first main surface 72 of the first layer 70 within the boundaries of the outer perimeter 74. The arrangement step of block 130 can be carried out in one of two ways. As shown in Fig. As shown in Figure 9B, the decorative element 60 can be applied to a generally flat first main surface 72, e.g., by injecting a shot of molten light-diffusing material onto the surface 72 (and clamped in a suitable mold half) to form the decorative element 60; alternatively, the disposal step can involve applying a pre-formed decorative element 60 to the surface 72 (e.g., by robot placement). In the latter of these two procedures, the decorative element 60 can be in solid form (as opposed to being molten, as in the former procedure), having been formed beforehand and separately (i.e., in another mold or mold cavity). As shown in Fig. As shown in Figure 10B, the decorative element 60 can either be injected into the recess 78 in molten form or inserted into the recess 78 in a pre-formed solid form. For block 140 and as shown in Fig. 9C and Fig. As shown in Figure 10C, a second shot of the substantially transparent material is injected into the mold to form a second layer 76 of the substantially transparent material, which covers the decorative element 60 and is in contact with the first principal surface 72 (thereby completely encapsulating the decorative element 60 in the substantially transparent material). At block 150, finally, the process 100 is completed. Note that, although a mold is not shown in the drawings, a mold of suitable size, shape, dimensions, and features would be capable of producing the layers 70, 76, and sequences shown in the drawings.

[0037] Fig. 8 and Fig. Figure 11 illustrates an alternative method 200 for forming a light strip 32 for an exterior lighting assembly 20 of a motor vehicle 10, starting at block 210. At block 220, a decorative element 60 (with an outer surface, wherein at least part of the outer surface contains a light-diffusing material) is arranged within a mold or mold cavity. (The reference numeral 80 indicates an outer enclosure of the mold or mold cavity.) The decorative element 60 can be injected in place in molten form within the outer enclosure 80 of the mold (e.g., within a first mold cavity that is smaller than and located within the entire outer enclosure 80), or the decorative element 60 can be introduced into the mold in a pre-formed solid form.When the decorative element 60 is placed in the mold in a solid form, an edge of the decorative element 60 can be held or gripped by the mold to keep the decorative element 60 in the desired position. At block 230, substantially transparent material is injected into the mold to encapsulate the decorative element 60 substantially within a surrounding layer 82 of the substantially transparent material, and at block 240, the process 200 is completed. If the decorative element 60 is injected in a molten form, or if it is placed in the mold in a pre-formed solid form without the mold gripping or holding an edge of the decorative element 60, then it can be positioned completely within the outer enclosure 80 of the mold, and the surrounding layer 82 of substantially transparent material can completely encapsulate the decorative element 60.However, if the decorative element 60 is placed in the mold in a pre-formed, rigid shape, and the mold grips or holds an edge of the decorative element 60, then the entire decorative element 60, with the exception of the edge (and perhaps a small part of the decorative element 60 immediately adjacent to the edge), can be encapsulated by the essentially transparent material. It should be noted that, although a mold in . Fig. 11 not shown, a form of suitable size, shape, dimensions and features would be able to correctly position the decorative element 60 and produce the surrounding layer 82 of substantially transparent material, as shown in the drawings.

[0038] The above description is intended to be illustrative and not limiting. Although various specific embodiments have been presented, those familiar with this field will recognize that the disclosure can be practiced with various modifications within the spirit and scope of the claims. For example, the dimensions and types of materials described here are for illustrative purposes only and are by no means limiting; they represent exemplary embodiments. Furthermore, in the following claims, the use of the terms "first," "second," "upper," "lower," and the like is purely descriptive, and no numerical or positional requirements are intended to be imposed on their objects.In the form used here, an element or stage recited in the singular and preceded by the word "a" or "an" is to be understood as not excluding the plurality of such elements or stages, unless such exclusion is expressly stated. Additionally, the phrase "at least one of A and B" and the phrase "A and / or B" should each be understood as meaning "only A, only B, or both A and B." Furthermore, unless expressly stated otherwise, embodiments that "include" or "have" an element or plurality of elements possessing a certain property may include additional such elements that do not possess that property. And where broadly descriptive adverbs such as "essentially" and "generally" are used here to modify an adjective, as in, for example,In the phrase “essentially transparent”, these adverbs mean “mostly”, “to a considerable extent” and / or “to a high degree” and do not necessarily mean “perfectly”, “completely”, “strictly” or “entirely”.

[0039] This written description uses examples, including a preferred embodiment, to enable skilled workers to manufacture and use devices, systems, and compositions of matter, and to perform methods according to this disclosure. The following claims, including equivalents, define the scope of this disclosure.

Claims

[1] A light strip (32) comprising: a body section (36) made of a substantially transparent material and having a generally plate-like shape with a mean height H in a z-direction, a mean width W in a y-direction and a mean thickness T in an x-direction, wherein the x-, y- and z-directions are orthogonal to each other and H > W > T; and a decorative element arranged within the body section (36) and having an outer surface (62), wherein at least a part of the outer surface (62) contains a light-scattering material, wherein the light bar (32) is configured for use in an external lighting assembly for a motor vehicle, wherein the external lighting assembly is at least one of the following assemblies: a headlight assembly, a brake light assembly, a turn signal assembly, a reversing light assembly, a parking / front position light assembly and a daytime running light assembly, wherein the entire decorative element (60) is made of the light-diffusing material, where the outer surface (62) generally points in the x-direction, wherein the light strip (32) is arranged such that when light rays are directed into the body section (36) towards the decorative element (60), a subset of the light rays falls on the decorative element (60) and is scattered in such a way that the decorative element (60) appears brighter than the transparent material surrounding the decorative element (60). the decorative element takes the form of a symbol, wherein the decorative element (60) is dimensioned with correspondingly visible height and width dimensions in the z and y directions, but with very small thickness dimensions in the x direction, so that the decorative element (60) is obviously visible from side and oblique views of the light strip (32), but along the y and z directions the decorative element (60) is more difficult to see due to its thinness, wherein the substantially transparent material is at least one of a polycarbonate, polymethyl methacrylate and an acrylic, wherein the light-scattering material is a talc, titanium dioxide and a combination of one of the aforementioned, at least a polycarbonate and polymethyl methacrylate, wherein the body section (36) is at least one of clear and coloured, wherein the body section (36) has an upper (38) and a lower (40) end which are opposite each other in the z-direction, wherein the light bar further comprises a first wing section (42) which is made of the substantially transparent material and has a first longitudinal axis and a first and a second end which are opposite each other along the first longitudinal axis, wherein the first end is adjacent to the upper end (40) and the first longitudinal axis is generally arranged in the x-direction, furthermore with a second wing section (48) which is made of the substantially transparent material and has a second longitudinal axis and opposing third and fourth ends along the second longitudinal axis, wherein the third end adjoins the lower end (40) and the second longitudinal axis is generally arranged in the x-direction.

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