USING REFLECTIVE SURFACES THICK LOOKING LENS AND VEHICLE WITH A COMPONENT WITH SUCH A LENS

Abstract

Aspects of the disclosure include a relatively thin lens that utilizes reflective surfaces to create the appearance of a thick lens and methods of manufacturing the same. An exemplary 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 an 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 located between the first reflector surface and the second reflector surface and configured such that light can pass through the third surface and into the air gap.The path of the light within the air gap is extended by internal reflections between the first and second reflector surfaces, providing an infinity mirror effect.

Description

INTRODUCTION

[0001] The present invention relates to lighting systems and lenses, and in particular to a relatively thin lens that uses reflective surfaces to provide the appearance of a thick lens. Specifically, the invention relates to a lens according to the preamble of claim 5 and to a vehicle with a component having such a lens according to the preamble of claim 1, as is substantially known from DE 10 2010 046 342 A1 or JP 2002 - 109 905 A.

[0002] Further details of the state of the art can be found in the publications DE 20 2018 102 965 U1, US 2008 / 0 118 215 A1, US 2023 / 0 213 776 A1 and DE 10 2015 116 341 A1.

[0003] Lighting systems play a central role in enhancing the aesthetics, functionality, and ambiance of spaces across various sectors, from architecture and interior design to the automotive and entertainment industries. At the heart of these systems are light sources and lenses that work together to control and influence 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 tailored to the specific needs of a given application.

[0004] In the context of lighting systems, lenses are optical elements designed to modify the behavior of the light emitted by the light source. Lenses can be made from various materials such as glass or plastic and control factors like the angle of dispersion, beam width, and focus. Lenses can be used to direct light in a specific direction, diffuse it for uniform illumination, and / or create optically pleasing effects through refraction or reflection. When a lens is integrated with a light source in a lighting system, it can produce a range of lighting effects, such as…The focusing of the light in a specific area or its scattering for more diffuse illumination (directional effect), the determination of the width or narrowness of the light distribution (beam control), the changing of the color temperature or the color rendering properties of the light (color and color temperature control), as well as various special optical effects, such as scattered light, halo effects and / or light patterns. SUMMARY

[0005] According to the invention, a vehicle is presented which is characterized by the features of claim 1.

[0006] The lens comprises a hollow optical fiber designed such that opposing sidewalls of the hollow optical fiber face each other across an air gap, a first reflector surface with a first reflective material formed on one sidewall of the opposing sidewalls, a second reflector surface with a second reflective material formed on a second sidewall of the opposing sidewalls, and a third surface located between the first and second reflector surfaces, designed such that light can pass through the third surface and into the air gap. The path of the light within the air gap is lengthened by internal reflections between the first and second reflector surfaces, thus providing an infinity mirror effect.

[0007] In addition to one or more of the features described herein, the hollow light guide has a nominal sidewall thickness of less than 5.0 mm in some embodiments.

[0008] In some embodiments, the third surface is essentially free of reflective material, except for parts of the third surface which are covered by a thickness of the first reflector surface and a thickness of the second reflector surface.

[0009] In some designs, the first reflective material and the second reflective material are identical.

[0010] Furthermore, according to the invention, a lens is presented which is characterized by the features of claim 5.

[0011] The lens comprises a hollow optical fiber designed such that opposing sidewalls of the hollow optical fiber face each other across an air gap, a first reflector surface with a first reflective material formed on one sidewall of the opposing sidewalls, a second reflector surface with a second reflective material formed on a second sidewall of the opposing sidewalls, and a third surface located between the first and second reflector surfaces, designed such that light can pass through the third surface and into the air gap. The path of the light within the air gap is lengthened by internal reflections between the first and second reflector surfaces, thus providing an infinity mirror effect.

[0012] In some designs, the hollow light guide has a nominal sidewall thickness of less than 5.0 mm.

[0013] In some embodiments, the third surface is essentially free of reflective material, except for parts of the third surface which are covered by a thickness of the first reflector surface and a thickness of the second reflector surface.

[0014] In some designs, the first reflective material and the second reflective material are identical.

[0015] In yet another exemplary embodiment, a method may comprise the following steps: providing a hollow optical waveguide designed such that opposing side walls of the hollow optical waveguide face each other across an air gap; forming a first reflector surface on a first side wall of the opposing side walls, wherein the first reflector surface comprises a first reflective material; forming a second reflector surface on a second side wall of the opposing side walls, wherein the second reflector surface comprises a second reflective material; and forming a third surface located between the first reflector surface and the second reflector surface, wherein the third surface is designed such that light can pass through the third surface and into the air gap.In some designs, the light path within the air gap is lengthened by internal reflections between the first reflector surface and the second reflector surface, thus providing an infinity mirror effect.

[0016] In some designs, the hollow light guide has a nominal sidewall thickness of less than 5.0 mm.

[0017] In some embodiments, the third surface is essentially free of reflective material, except for parts of the third surface which are covered by a thickness of the first reflector surface and a thickness of the second reflector surface.

[0018] In some designs, the first reflective material and the second reflective material are identical.

[0019] In some configurations, the component also includes a light source with one or more micro light-emitting diodes (LEDs).

[0020] In some embodiments, the one or more micro-LEDs comprise a first micro-LED that is positioned within the air gap in such a way that the light emitted by the first micro-LED is reflected through the air gap between the first reflector surface and the second reflector surface.

[0021] In some embodiments, the one or more micro-LEDs include a second micro-LED which is positioned in such a way that the light emitted by the second micro-LED is refracted through the hollow light guide at the first reflector surface or the second reflector surface.

[0022] The aforementioned features and advantages, as well as other features and advantages of the invention, are readily apparent from the following detailed description in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Further features, advantages and details are listed only as examples in the following detailed description, which refers to the drawings in which: Fig. 1 a vehicle designed according to one or more configurations, Fig. 2 shows a thin lens according to one or more embodiments in a cross-sectional view, Fig. 3 shows an exemplary holding device for selectively metallizing a hollow optical fiber enclosed by a thin lens according to one or more embodiments, Fig. 4A shows an alternative thin lens according to one or more embodiments in a view, Fig. 4B shows an alternative thin lens according to one or more embodiments in a view, Fig. 4C shows an alternative thin lens according to one or more embodiments in a view, Fig. 4D shows an alternative thin lens according to one or more embodiments in a view, Fig. 5A shows an alternative thin lens according to one or more embodiments in a view, Fig. 5B shows an alternative thin lens according to one or more embodiments in a view, Fig. 5C shows an alternative thin lens according to one or more embodiments in a view, Fig. 5D shows an alternative thin lens according to one or more embodiments in a view, Fig. 5E shows an alternative thin lens according to one or more embodiments in a view, Fig. 5F shows an alternative thin lens according to one or more embodiments in a view, and Fig. 6 shows a flowchart according to one or more configurations. DETAILED DESCRIPTION

[0024] Lenses are one of the most important components of many lighting systems. Lenses can provide a lighting system with a number of functional advantages, such as focusing light, collimating or parallelizing light, shaping the beam, magnifying or reducing it, dispersion, and / or image formation, but 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 bars, have gained popularity in various applications, particularly in the automotive industry for headlight designs. Thick lenses are intended to create a visually striking and distinctive aesthetic while also providing functional advantages. As used herein, a "thick lens" refers to a lens that incorporates a light bar construction with a thickness of at least 5.0 mm.In contrast, a "thin lens" or standard lens is a lens with a thickness of less than 5.0 mm. The typical thickness of component parts of a plastic lens, for example, is about 2.5 mm. A thick lens is therefore a lens that is at least twice as thick as a 2.5 mm standard lens. Thick lenses can be even thicker, with wall thicknesses exceeding 20 mm, e.g., 24 mm, 30 mm, 50 mm, etc. Thick lenses create a bold, strong, and high-quality appearance, especially when viewed from the front. Furthermore, a thick, solid-looking lens conveys a sense of strength and implies enhanced durability.

[0025] Unfortunately, current manufacturing processes for thick lens applications are limited to using physically thick lens parts, often produced with relatively thick lens injection molds. This significantly increases the mass of the resulting thick lens compared to standard lenses. For example, the mass of a 24 mm thick lens can be more than eight times that of a standard 2.5 mm thick lens. Increasing the mass of various vehicle components can lead to a number of negative consequences, such as exceeding packaging weight limits and reducing the driving range in an electric vehicle. Furthermore, such thick lenses naturally require more material, more time for the molding process, and higher part costs to achieve the desired thickness.Other challenges include thermal management, as a physically thick lens can make it difficult to dissipate the heat generated by intense light sources, and lower optical quality, as a physically thick lens can increase optical losses due to reflections and absorption, which can reduce the overall efficiency of the light output.

[0026] This invention introduces a relatively thin lens that provides the appearance of a thick lens. Instead of relying on a physically thick lens for thick lens applications, the present invention presents a way to utilize reflective surfaces to give a thin lens the appearance of a thick lens, thereby avoiding many of the inherent disadvantages of a physically thick lens. The result is a novel lens architecture that offers the aesthetic qualities of a thick lens while remaining lighter than thick lenses and can be manufactured with less material and relatively shorter processing times (e.g., reduced forming time).

[0027] In some embodiments, a thin lens is constructed as a hollow optical waveguide with relatively thin sidewalls (e.g., less than 5.0 mm, as in a standard lens design) that are bent in such a way that the opposing sidewalls of the hollow optical waveguide face each other. These facing sidewalls are then coated with a reflective surface. Due to an infinity mirror effect, these so-called coated reflector surfaces create the appearance of a thick lens, not unlike a refractive optic with total internal reflection (TIR). As used here, the term "infinity mirror effect" refers to the optical illusion that arises when two or more parallel mirrors are facing each other, as this arrangement produces a seemingly infinite series of reflections that appear to extend indefinitely into the distance.The coated reflective surfaces can be applied using metallization and / or multi-layer coating processes to adjust the degree of light reflection as desired. In some embodiments, the coated reflective surfaces feature stylized patterns to further enhance the unlit and / or illuminated appearance of the lighting system into which the lens is incorporated. Specifically, light sources can optionally be positioned below and / or within an air gap defined by the coated reflector surfaces to create illuminated light bar features. In some embodiments, the housing or frame of a lighting system can be combined with one half of a curved hollow light guide to provide the appearance of a thick lens.Advantageously, the hollow optical fiber (also known as a lens shell design) can have a mass that is at most 25 percent of the mass of a lens of the same size and physical thickness. For example, a physically thick lens with a width of 24 mm has almost four times the mass of a hollow optical fiber enclosed by a thin lens with a width of 24 mm, because the thin lens has an air gap cavity that is 60 percent or more (e.g., 60, 65, 70, 75, 80, 85, 90, 95 percent) of the total width.

[0028] A vehicle according to an exemplary design is in Fig. 1 generally designated 100. The vehicle 100 is shown in the form of a passenger car with a body 102. The body 102 comprises a passenger compartment 104 in which a steering wheel, front seats and rear passenger seats (not shown separately) are arranged. The body 102 also comprises a series of lighting assemblies 106 made of glass, plastic and / or polymer laminate (also referred to as lighting units or lamp housings) in which a variety of lighting elements are housed, such as headlights, taillights, turn signals, reversing lights, decorative lighting, etc.

[0029] The in Fig. The particular lighting arrangements 106 highlighted in Figure 1 (i.e., headlights, turn signals, rear passenger window, and taillights) are emphasized only for clarity and discussion. It is understood that every aspect of the present invention can be applied to any lens in the vehicle 100. Furthermore, the location, size, arrangement, etc., of the lighting arrangements 106 and the shape, size, positioning, etc., of their elements (e.g., lenses) are not subject to any particular restrictions. Moreover, the aspects described herein, although primarily discussed in connection with a lighting arrangement 106 of a vehicle 100, can be similarly integrated into any system (vehicle, building, workpiece, or other) with one or more lens elements, and all such designs and applications fall within the intended scope of this invention.

[0030] As explained in more detail below, one or more of the lighting arrangements 106 comprise a hollow optical waveguide enclosed by a thin lens, which has the appearance of a thick lens. An exemplary hollow optical waveguide enclosed by a thin lens is described in more detail with respect to Fig. 2 is discussed. An exemplary holding device for the selective metallization of a hollow optical fiber enclosed by a thin lens is described in relation to Fig. 3. Alternative interpretations of the hollow light guide enclosed by a thin lens are discussed in relation to Fig. 4A, Fig. 4B, Fig. 4C and Fig. 4D is discussed. Exemplary microstructures for a thin lens are presented in relation to Fig. 5A, Fig. 5B, Fig. 5C, Fig. 5D, Fig. 5E and Fig. 5F discussed.

[0031] Fig. Figure 2 illustrates a thin lens 200 according to one or more embodiments in a cross-sectional view. The thin lens 200 can be incorporated into any component of any system with at least one lens element (e.g., into the lighting arrangement 106 of the vehicle 100). Fig. 1) As in Fig. As shown in Figure 2, the thin lens 200 comprises a hollow optical fiber 202 designed (e.g., bent, curved, etc.) such that the opposing side walls 204, 206 of the thin lens 200 face each other across an air gap 208. While the design of the thin lens 200 is not subject to any particular restrictions, the hollow optical fiber 202 can, for example, be bent into a "U" shape, an "N" shape (as shown), and / or into another shaped design with opposing side walls (e.g., the thin lens 200 can also have a convex and / or rounded topography).

[0032] In some embodiments, the hollow optical fiber 202 can have a nominal sidewall thickness W of less than 5.0 mm (within the tool limits). For example, the thickness W of the sidewalls 204, 206 can 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 the sidewalls 204 and 206 is the same or substantially the same within the tool limits. In some embodiments, the thickness W of the sidewalls 204 and 206 is different (see, e.g., Fig. 4B).

[0033] In some embodiments, the thin lens 200 can have a total thickness (e.g., diameter) D of at least three times the thickness W. In some embodiments, the thin lens 200 can have a total thickness D between 5.0 mm and 50.0 mm, for example, 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 can have a total thickness D of more than 50.0 mm, for example, 75.0 mm. In particular, the thin lens 200 can have a total thickness D that is greater than that which can be achieved with physically thick lenses and conventional shaping methods, which are usually limited to approximately 24 mm.

[0034] In some embodiments, the hollow light guide 202 can be constructed from two or more parts (shown as two parts separated by a seam 210). The various parts of the hollow light guide 202 can be joined together using known methods, e.g., by adhesive and / or interlocking parts. In some embodiments, the hollow light guide 202 can be constructed monolithically, i.e., using a single lens component (not shown separately). Such a design can be achieved, for example, with a single lens shape in a "U" or "N" shape.

[0035] The hollow light guide 202 can be manufactured from a range of transparent and semi-transparent materials suitable for overmolding. For example, the hollow light guide 202 can be made from benzoxazine, a bis-maleimide (BMI), a cyanate ester, an epoxy, a phenol (PF), a polyacrylate (acrylic), a polyimide (PI), an unsaturated polyester, a polyurethane (PUR), a vinyl ester, a siloxane, co-transparent layers thereof, and combinations thereof. In certain aspects, the hollow light guide 202 may include or be manufactured from a thermoplastic transparent or semi-transparent layer 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), polymethyl methacrylate (PMMA), styrene methyl methacrylate (SMMA), methyl methacrylate acrylate acrylate butadiene styrene (MABS), polycarbonate (PC), polyaryletherketone (PAEK), polyetherketone ketone (PEKK), cotransparent layers thereof and combinations thereof.

[0036] In some embodiments, the air gap 208 can be filled with air. In some embodiments, the air gap 208 can be filled with another gas, such as argon and / or nitrogen, or a combination thereof with or without air, as desired. In some embodiments, the air gap 208 is cleared of gases before the thin lens 200 is sealed. For example, the air gap 208 can be vacuum-sealed after the seam 210 of the thin lens 200 has been sealed.

[0037] In some embodiments, the coated reflector surfaces 212 are reflective layers formed on the opposing side walls 204, 206. In some embodiments, the coated reflector surfaces 212 are applied to the side walls 204, 206. In some embodiments, the coated reflector surfaces 212 are applied to the side walls 204, 206 and / or metallized. The production / shaping of the coated reflector surfaces 212 is described in relation to Fig. 3 discussed in more detail. In some embodiments, the coated reflector surfaces 212 are formed to a thickness on the order of a few micrometers, e.g. between 0.5 micrometers and 8 micrometers or between 2.0 and 6.0 micrometers, such as 4.0 micrometers.

[0038] In some embodiments, the coated reflector surfaces 212 are made of a reflective material with a reflectance (the proportion of incident electromagnetic radiation reflected by the surface) of at least 70 percent, for example 70, 80, 85, 90, 92, 94, 95, 96, 98 and 99 percent. The reflective material is not subject to any particular restrictions and can, for example, include a metal such as aluminum (Al), silver (Ag), gold (Au), copper (Cu), rhodium (Rh), chromium (Cr), zinc (Zn) and alloys and / or combinations thereof. 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 aluminum oxide (Al2O3) and zirconium oxide (ZrO2), which can be polished to achieve a high degree of reflectivity (more than 90 percent).Other materials include transparent conductive oxide compounds (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 coated reflector surfaces 212 are made of a semi-reflective material with a reflectance between 30 and 70 percent. Exemplary materials include dielectric coatings such as silicon dioxide (SiO₂), titanium dioxide (TiO₂), and magnesium fluoride (MgF₂), ITO and ITO alloys, tinted 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 polycarbonate, and combinations thereof.

[0039] For simplicity, a single layer is shown, but in some embodiments, one of the two coated reflector surfaces 212 is multilayered. In some embodiments, the coated reflector surfaces 212 are, for example, dielectric Bragg mirrors with two or more layers. A dielectric Bragg mirror, also known as a dielectric reflector or dielectric mirror, is an optical component that reflects light according to the principle of Bragg reflection and comprises two or more alternating layers of dielectric materials with different refractive indices. In some embodiments, the coated reflector surfaces 212 are dielectric Bragg mirrors that have alternating dielectric layers with high and low refractive indices. Dielectric Bragg mirrors can have a very high reflectance (e.g.,Bragg mirrors achieve refractive indices exceeding 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 for Bragg mirrors include silicon dioxide (SiO2) and titanium dioxide (TiO2), silicon nitride (Si3N4) and silicon dioxide (SiO2), aluminum oxide (Al2O3) and magnesium fluoride (MgF2), and tantalum pentoxide (Ta2O5) and silicon dioxide (SiO2).

[0040] In some embodiments, one of the two coated reflector surfaces 212 is made of, or comprises, a material selected to shift a color of light naturally emitted by a light source (e.g., the micro-LEDs 214, which are discussed in more detail herein) into one or more colors specified by the selected material. In some embodiments, for example, one or both of the coated reflector surfaces 212 comprise a phosphor (e.g., red phosphor, yellow phosphor, etc.).

[0041] Red phosphors can be used to convert blue or ultraviolet (UV) light into red light. Examples of red phosphors include rare earth compounds such as europium-doped yttrium vanadate (YVO4:Eu), europium-doped yttrium oxide (Y2O3:Eu), yttrium aluminum garnet (YAG:Eu), yttrium aluminum borate (YAB:Eu), and yttrium orthovanadate (YVO4:Eu). Green phosphors are used to convert blue or UV light into green light. Green phosphors typically include rare earths such as terbium (Tb) or europium (Eu) combined with other compounds to achieve the desired emission wavelength. Blue phosphors are used to convert UV light into blue light. Blue phosphors include cerium-activated (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 contain a combination of rare earth elements such as ce, tub, or yen with other compounds. Orange phosphors are used to convert blue or UV light into orange light. Orange phosphors may contain eutronite and tubenite along with other co-activators (e.g., cetronite and strontium (Sr)). Cyan phosphors are used to convert blue or UV light into cyan light. Cyan phosphors may contain tubenite and eutronite with 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 contain a mixture of red, green, and blue (RGB) phosphors or a combination of blue and yellow phosphors.Alternatively or additionally, white light can be provided using a combination of a blue LED with a yellow phosphor.

[0042] With renewed reference to Fig. 2 In some embodiments, the coated reflector surfaces 212 serve to reflect light 216 that enters the air gap 208 between the coated reflector surfaces 212. In some embodiments, a third surface 217 of the hollow light guide 202 is not coated with reflective material. In some embodiments, the third surface 217 of the hollow light guide 202 is essentially free of reflective material, meaning that the third surface 217 is free of reflective material except for incidental coverage due to the thickness of the coated reflector surfaces 212 (as shown). That is, the third surface 217 can be essentially free of reflective material, except for portions of the third surface 217 that are covered by the thickness of the respective coated reflector surfaces 212.In some embodiments, the light 216 is reflected regardless of whether it originates from outside (e.g., from the environment such as sunlight, as shown) or from inside (e.g., from micro-LED(s) 214). The third surface 217 can be arranged between the opposing side walls 204, 206 of the thin lens 200 and / or between the coated reflector surfaces 212 (as shown). In some embodiments, the third surface 217 is designed such that light 216 can pass through the third surface 217 and into the air gap 208 (as shown).

[0043] The path of the light 216 is lengthened, particularly compared to the natural path the light would take without the presence of the coated reflector surfaces 212 (i.e., the straight path). In this way, the coated reflector surfaces 212 provide an infinity mirror effect, and the thin lens 200 therefore appears relatively thicker than its actual thickness. In other words, the thin lens 200 gives the appearance of a thick lens.

[0044] In some configurations, the thin lens 200 and / or the lighting arrangement 106 (see Fig. 1) comprise one or more light sources, such as one or more micro-LEDs 214. In some embodiments, the micro-LEDs 214 are mounted on or electrically coupled to a special driver circuit 218 (also referred to as a lighting substrate and / or backplane). In some embodiments, the micro-LEDs 214 each comprise a single LED element (see Fig. 4B). In some embodiments, the micro-LEDs 214 each comprise a plurality of micro-LED elements (as shown).

[0045] For the sake of simplicity, the thin lens 200 is shown with only a specific number of micro-LEDs 214 (in this case, two). It is understood, however, that the number, size, layout, orientation, center-to-center-line spacing, etc., of the micro-LEDs 214 can vary depending on the requirements of a particular display application. For example, the micro-LEDs 214 can comprise two or more elements (subpixels) of the same color (e.g., blue) and one element of another color (e.g., red, red and green, yellow, etc.). Furthermore, it is not necessary for the micro-LEDs 214 to each comprise the same number of elements. For example, some of the micro-LEDs 214 may comprise a first number of elements (e.g. 1, 2, 3, 4, 10 etc.), while some of the micro-LEDs 214 may comprise a second (or third etc.) number of elements (e.g. 1, 2, 3, 4, 10 etc.).

[0046] The micro-LEDs 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, depending on the desired emission color of the respective micro-LED, for example, 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 micro-LEDs 214 comprise several stacked layers, e.g., a stack of indium gallium nitride / gallium nitride (InGaN / Gan) formed on a silicon or sapphire substrate to produce blue and green devices.

[0047] In some embodiments, one or more of the micro-LEDs 214 are mounted on the driver circuit 218. In some embodiments, the driver circuit 218 may include internal electrical connections and components (not shown separately) designed to individually control each of the micro-LEDs 214 using electrical signals. For example, a driver circuit 218 may control one of the micro-LEDs 214 by selectively applying a driver voltage to the micro-LED 214.

[0048] Fig. Figure 3 illustrates an exemplary holding device 300 for the selective metallization of a hollow optical fiber enclosed by a thin lens (e.g. the thin lens 200 of Fig. 2) according to one or more configurations. As in Fig. As shown in Figure 3, the holding device 300 can have a series of surfaces 302 with any shape and / or topography. In some embodiments, the hollow light guide 202 is formed and / or positioned against the surfaces 302 of the holding device 300, thereby assuming the topography of the surfaces 302. In some embodiments, the holding device 300 is a molded part against which the hollow light guide 202 can be positioned, formed, injection molded, and / or applied.

[0049] In some embodiments, a masking layer 304 can be placed over parts of the hollow light guide 202. The masking layer 304 is not subject to any particular restrictions, but could, for example, comprise: a photoresist that is structured using photolithography techniques to create any desired mask pattern; hard masks, such as metallic hard masks like thin layers of metals comprising chromium, nickel, and titanium, which are applied to the hollow light guide 202 and structured using techniques such as photolithography and etching; oxide hard masks, such as those made of silicon dioxide and aluminum oxide; polymer masks, such as...The masking layer consists of polyimides, epoxy resins, and / or polyurethanes, which are spin-deposited and / or printed onto the optical waveguide 202 and structured using techniques such as photolithography and laser ablation; self-assembled monolayers (SAMs) formed by chemical adsorption and / or covalent bonding and structured using techniques such as microcontact printing and / or electron beam lithography; and / or lift-off resists such as sacrificial photoresists, which are removed (peeled or lifted off) after metal deposition. It is understood that the specific design of the masking layer 304 is shown for illustrative purposes only. The masking layer 304 can have any pattern, thereby enabling selective metal deposition on the unmasked areas of the optical waveguide 202.

[0050] In some embodiments, the coated reflector surfaces 212 are formed on the exposed portions of the waveguide 202 (i.e., the portions of the waveguide 202 not covered by the masking layer 304). Several methods exist for applying and / or metallizing a coating of reflective material onto an underlying substrate, and the method is not subject to any particular restrictions. In some embodiments, the coated reflector surfaces 212 on the waveguide 202 are formed using physical vapor deposition (PVD), wherein a reflective material (e.g., aluminum, silver, chromium, etc.) is evaporated in a high-vacuum environment and then condensed onto the waveguide 202. Evaporation can be achieved by techniques such as thermal evaporation, electron beam evaporation, and sputtering.In some embodiments, the coated reflector surfaces 212 on the hollow light guide 202 are formed using chemical vapor deposition (CVD), whereby gaseous precursors containing the selected metal species are introduced into a vacuum chamber, and the material reacts and is deposited as a metal film on the hollow light guide 202. Other methods are possible, such as electroplating, wet chemical deposition, and spin coating, although other methods are also conceivable. After the deposition and / or metallization process, the hollow light guide 202 and / or the coated reflector surfaces 212 can be subjected to additional treatments, such as protective coatings, annealing, and / or polishing, to modify and / or improve the reflectance, durability, and optical properties of the 200.

[0051] Fig. Figure 4A illustrates an alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The lens shown in 4A can be manufactured in a similar manner and from similar materials as the thin lens 200 shown in Fig. 2 is shown, with the exception that the alternative thin lens 200, which is in Fig. Figure 4A shows an opening 402 in one (as shown) or both (not shown separately) of the coated reflector surfaces 212 of the hollow optical fiber 202. In this configuration, the opening 402 can be structured such that the coated reflector surfaces 212 emit the 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 subject to any particular restrictions and can be designed, for example, in the form of desired lettering, logos, messages, patterns, etc. In designs where one or both of the coated reflector surfaces 212 have an opening 402, the hollow light guide 202 can be similarly structured and / or made of a transparent and / or semi-transparent material, so that light 216 passing through the opening 402 can also pass through the hollow light guide 202 at the position of the opening 402.

[0052] Fig. Figure 4B illustrates an alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The lens shown in 4B can be manufactured in a similar manner and from similar materials as the thin lens 200 shown in Fig. 2 is shown, with the exception that the alternative thin lens 200, which is in Fig. As shown in Figure 4B, the hollow light guide 202 provides one of the opposing side walls 204, 206, and a housing 404 (or a frame, etc.) provides the other of the opposing side walls 204, 206. This type of design has the advantage that the housing 404 can be reused, thus avoiding the additional weight, manufacturing time, and complexity associated with designs incorporating a curved hollow light guide 202 (see Figure 4B). Fig. 2) This allows the weight to be further reduced by approximately half the weight of the hollow light guide 202.

[0053] Fig. Figure 4C illustrates another alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The lens shown in 4C can be manufactured in a similar way and from similar materials as the thin lens 200 shown in Fig. 2 is shown, with the exception that the alternative thin lens 200, which is in Fig. As shown in Figure 4C, the micro-LEDs 214 are positioned relative to the coated reflector surfaces 212 such that the light 216 is reflected in the air gap 208 and refracted in the hollow light guide 202. For example, according to the invention, one or more micro-LEDs 214 can be positioned in the air gap 208 to reflect light, and one or more micro-LEDs 214 can be positioned in and / or below the hollow light guide 202 to refract light. In this configuration, the hollow light guide 202 can be made of a transparent and / or semi-transparent material, as previously described.

[0054] Fig. 4D illustrates an additional alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The 4D lens shown can be manufactured in a similar way and from similar materials as the thin 200 lens shown in Fig. 2 is shown, with the exception that the alternative thin lens 200, which is in Fig. As shown in Figure 4D, the coated reflector surfaces 212 are shaped into a variety of reflective elements. The reflective elements can be shaped using any masking and / or structuring (see, for example, Figure 4D). Fig. 3) The coated reflector surfaces 212 can be manufactured in the same shape, size and / or orientation (as shown) or alternatively in different combinations of shape, size and / or orientation, as desired.

[0055] Fig. Figure 5A illustrates an alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The lens shown in 5A can be manufactured in a similar manner and from similar materials as the thin lens 200 shown in Fig. Figure 2 is shown, except that in this alternative thin lens 200, a microstructure 500 is shaped, structured, molded, etc., to obscure underlying component interfaces and to interrupt the natural optical transmission along an edge and / or sidewall of the hollow optical guide 202 and / or to otherwise achieve one or more desired optical properties. As used herein, the term “microstructure” refers to those parts of the underlying structure (i.e., the alternative thin lens 200) that have been modified in their geometry and / or reflectance to modify the optical properties of the ambient light 502 passing through and / or into the alternative thin lens 200. Microstructures can be produced using forming processes and / or by incorporating reflective surfaces (see Figure 2). Fig. 3) In the design, which is in Fig. As shown in Figure 5A, the microstructure 500 is shaped, for example, in such a way that the ambient light 502 is reflected in an upper part 504 of the alternative thin lens 200. In this way, the ambient light 502 is deflected along the upper part 504 in such a way that the internal structures of the alternative thin lens 200 are obscured, which contributes to the alternative thin lens 200 acting like a thick lens (see Figure 5A). Fig. 2).

[0056] Fig. Figure 5B illustrates an alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The lens shown in 5B can be manufactured in a similar manner and from similar materials as the thin lens 200 shown in Fig. Figure 2 shows, with the exception that in this alternative thin lens 200, a microstructure 500 is formed, structured, cast, etc., to conceal underlying component interfaces and to interrupt the natural optical transmission along an edge and / or side wall of the hollow light guide 202 and / or to otherwise achieve one or more desired optical properties. In the embodiment shown in Fig. As shown in Figure 5B, the microstructure 500 is shaped such that the ambient light 502 is reflected along one or more edges 506 from one or both of the coated reflector surfaces 212. In this way, the internal structure of the alternative thin lens 200 is concealed, which contributes to the effectiveness of the alternative thin lens 200 in appearing like a thick lens (see Figure 5B). Fig. 2).

[0057] Fig. Figure 5C illustrates an alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The 5C shown can be manufactured in a similar way and from similar materials as the thin lens 200 shown in Fig. Figure 2 shows, with the exception that in this alternative thin lens 200, a microstructure 500 is formed, structured, cast, etc., to conceal underlying component interfaces and to interrupt the natural optical transmission along an edge and / or side wall of the hollow light guide 202 and / or to otherwise achieve one or more desired optical properties. In the embodiment shown in Fig. As shown in Figure 5C, the microstructure 500 is shaped in such a way that the ambient light 502, which comes into contact with one or more edges 508 of the thin lens 200, is reflected back from the hollow light guide 202. In this way, the internal structure of the alternative thin lens 200 is concealed, which contributes to the effectiveness of the alternative thin lens 200 in appearing like a thick lens (see Figure 5C). Fig. 2).

[0058] Fig. 5D illustrates an alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is in Fig. The 5D lens shown can be manufactured in a similar way and from similar materials as the thin 200 lens shown in Fig. Figure 2 shows, with the exception that in this alternative thin lens 200, a microstructure 500 is formed, structured, cast, etc., to conceal underlying component interfaces and to interrupt the natural optical transmission along an edge and / or side wall of the hollow light guide 202 and / or to otherwise achieve one or more desired optical properties. In the embodiment shown in Fig. As shown in 5D, the microstructure 500 is shaped in such a way that the ambient light 502 is reflected away from one or more edges 510 of the thin lens 200. In this way, the internal structure of the alternative thin lens 200 is concealed, which contributes to the effectiveness of the alternative thin lens 200 in appearing like a thick lens (see 5D). Fig. 2).

[0059] Fig. Figure 5E illustrates an alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The 5E shown can be manufactured in a similar way and from similar materials as the thin lens 200 shown in Fig. Figure 2 shows, with the exception that in this alternative thin lens 200, a microstructure 500 is formed, structured, cast, etc., to conceal underlying component interfaces and to interrupt the natural optical transmission along an edge and / or side wall of the hollow light guide 202 and / or to otherwise achieve one or more desired optical properties. In the embodiment shown in Fig. As shown in Figure 5E, the microstructure 500 is shaped in such a way that the ambient light 502 is scattered at one or more edges 512 of the thin lens 200. In this way, the internal structure of the alternative thin lens 200 is concealed, which contributes to the effectiveness of the alternative thin lens 200 in appearing like a thick lens (see Figure 5E). Fig. 2).

[0060] Fig. Figure 5F illustrates an alternative thin lens 200 according to one or more embodiments in a single view. The alternative thin lens 200, which is shown in Fig. The 5F shown can be manufactured in a similar way and from similar materials as the thin 200 lens shown in Fig. Figure 2 shows, with the exception that in this alternative thin lens 200, a microstructure 500 is formed, structured, cast, etc., to conceal underlying component interfaces, to interrupt the natural optical transmission along an edge and / or side wall of the hollow optical guide 202, and / or to otherwise achieve one or more desired optical properties. In the embodiment shown in Fig. As shown in Figure 5F, the microstructure 500 is shaped in such a way that the ambient light 502 is split at one or more edges 514 of the thin lens 200. In this way, the internal structure of the alternative thin lens 200 is concealed, which contributes to the effectiveness of the alternative thin lens 200 in appearing like a thick lens (see Figure 5F). Fig. 2).

[0061] With the following reference to Fig. Figure 6 shows a general flowchart 600 to provide a relatively thin lens that uses reflective surfaces to create the appearance of a thick lens, according to one embodiment. The flowchart 600 is shown with reference to Fig. 1 to 5F described and may include additional steps that are in Fig. 6 not shown, include. The in Fig. Although the 6 blocks shown are presented in a specific order, they can be rearranged, subdivided and / or combined.

[0062] In Block 602, the method comprises providing a hollow optical waveguide designed such that opposing side walls of the hollow optical waveguide face each other across an air gap.

[0063] In Block 604, the process comprises forming a first reflector surface on a first side wall of the opposing side walls. In some embodiments, the first reflector surface comprises a first reflective material.

[0064] In Block 606, the method involves forming a second reflector surface on a second side wall of the opposing side walls. In some embodiments, the second reflector surface comprises a second reflective material.

[0065] In Block 608, the method involves forming a third surface located between the first and second reflector surfaces. In some embodiments, the third surface is designed such that light can pass through it and into the air gap. In some embodiments, the light path within the air gap is lengthened by internal reflections between the first and second reflector surfaces, thereby providing an infinity mirror effect (see Fig. 2).

[0066] In some embodiments, the hollow light guide has a nominal sidewall thickness of less than 5.0 mm. In some embodiments, the hollow light guide is part of a lens or defines a lens. In some embodiments, the hollow light guide is therefore a thin lens with a nominal sidewall thickness of less than 5.0 mm.

[0067] In some embodiments, the third surface is essentially free of reflective material, except for parts of the third surface which are covered by a thickness of the first reflector surface and a thickness of the second reflector surface.

[0068] In some designs, the first and second reflective materials are identical. In other designs, the first and second reflective materials are made of different reflective materials.

[0069] In some embodiments, the component further comprises a light source. In some embodiments, the light source comprises one or more micro-light-emitting diodes (micro-LEDs). In some embodiments, the one or more micro-LEDs comprise a first micro-LED positioned within the air gap such that the light emitted by the first micro-LED is reflected through the air gap between the first reflector surface and the second reflector surface. In some embodiments, the one or more micro-LEDs comprise a second micro-LED positioned such that the light emitted by the second micro-LED is refracted by the hollow light guide at the first reflector surface or the second reflector surface.

Claims

[1] Vehicle (100) comprising: a component with a lens (200) and a light source (214), wherein the lens (200) comprises: a hollow light guide (202) configured such that opposing side walls (204, 206) of the hollow light guide (202) face each other across an air gap (208), a first reflector surface (212) comprising a first reflective material, wherein the first reflector surface (212) is formed on a first side wall (204) of the opposing side walls (204, 206), a second reflector surface (212) comprising a second reflective material, wherein the second reflector surface (212) is formed on a second side wall (206) of the opposing side walls (204, 206), and a third surface (217) extending between the first reflector surface (212) and the second reflector surface (212), wherein the third surface (217) is designed in such a way,that light (216) can pass through the third surface (217) and into the air gap (208), whereby a path of the light (216) within the air gap (208) is extended by internal reflections between the first and the second reflector surface (212), thereby providing an infinity mirror effect; characterized by , that the light source (214) comprises a first light source (214) which is arranged within the air gap (208) in such a way that the light emitted by the first light source (214) is reflected through the air gap (208) between the first reflector surface (212) and the second reflector surface (212); wherein the light source (214) further comprises a second light source (214) which is positioned in such a way that the light (216) emitted by the second light source (214) is refracted through the hollow light guide (202) at the first reflector surface (212) or the second reflector surface (212). [2] Vehicle (100) according to claim 1, wherein the hollow light guide (202) has a nominal side wall thickness of less than 5.0 mm. [3] Vehicle (100) according to claim 1, wherein the third surface (217) is substantially free of reflective material, except for parts of the third surface which are covered by a thickness of the first reflector surface (212) and a thickness of the second reflector surface (212). [4] Vehicle (100) according to claim 1, wherein the first reflective material and the second reflective material are identical. [5] Lens (200) comprising: a hollow optical waveguide (202) configured such that opposing side walls (204, 206) of the hollow optical waveguide (202) face each other across an air gap (208), a first reflector surface (212) comprising a first reflective material, wherein the first reflector surface (212) is formed on a first side wall (204) of the opposing side walls (204, 206), a second reflector surface (212) comprising a second reflective material, wherein the second reflector surface (212) is formed on a second side wall (206) of the opposing side walls (204, 206), and a third surface (217) located between the first reflector surface (212) and the second reflector surface (212), wherein the third surface (217) is configured in such a way is that light (216) can pass through the third surface (217) and into the air gap (208),wherein a path of light (216) within the air gap (208) is extended by internal reflections between the first and the second reflector surface (212), thereby providing an infinity mirror effect; characterized by , that a first light source (214) is arranged within the air gap (208) in such a way that the light emitted by the first light source (214) is reflected through the air gap (208) between the first reflector surface (212) and the second reflector surface (212); wherein a second light source (214) is positioned in such a way that the light (216) emitted by the second light source (214) is refracted through the hollow light guide (202) at the first reflector surface (212) or the second reflector surface (212). [6] Lens (200) according to claim 5, wherein the hollow optical fiber (202) has a nominal sidewall thickness of less than 5.0 mm. [7] Lens (200) according to claim 5, wherein the third surface (217) is substantially free of reflective material, except for parts of the third surface which are covered by a thickness of the first reflector surface (212) and a thickness of the second reflector surface (212).

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