FIBER OPTIC-BASED CHROME-LOOK LAMP

Abstract

A light guide lamp comprises a light guide. A light source positioned at one edge of the light guide directs light, generated by exciting the light source, along a length of the light guide's reflective layer. A graphic pattern is formed on the light guide, defining the optical pattern at the nanoscale by surface etching. A polymer coating is applied over the light source, the light guide, and the reflective layer. This coating is applied using a wet coating process, a dry coating process, an in-mold injection molding or laminating process, or a post-molding process.

Description

[0001] The present disclosure relates to optical fibers used in vehicle emblem and information display.

[0002] During vehicle operation, it is desirable to display emblems and information using fiber-optic illuminated displays. Light sources used to illuminate the fibers are typically positioned behind a reflective chrome layer of the display, and multiple light sources are used to ensure that light effectively penetrates the reflective chrome layer to reach the fibers.

[0003] DE 20 2006 017 445 U1 discloses a light module comprising a light-guiding plate with two opposing surfaces, a lateral connecting surface, and a light source. Light or air chambers are formed by recesses in the area of ​​spaced-apart adhesive frames, between which at least one diffuser film is arranged, such that this film maintains a distance from the light-guiding plate and the underside of the lettering plate. The entire structure is inserted into the recess of a potting frame and filled with a potting compound.

[0004] DE 20 2021 104 561 U1 discloses a flat lighting device with a cover layer, a foil-like light guide, means for guiding light coupled into the light guide, means for directing light for the purpose of coupling light out of a flat side of the light guide, and at least one light source arranged for coupling light into an end face of the light guide. As a means for guiding light, a light-guiding coating made of a transparent or translucent material with a lower optical density than the material of the light guide is provided on the light-exit side and on the side of the light guide opposite the light-exit side.As a means of light control, light-reflecting scattering centers are arranged on the surface of the light guide opposite the light exit side in those surface areas that are opposite a surface area on the light exit side of the light guide from which light is emitted when the lighting device is in operation.

[0005] While current systems and methods for providing fiber optic-based displays fulfill their intended purpose, there is therefore a need for a new and improved system and method for displaying vehicle emblems and information.

[0006] From several perspectives, a light guide-based lamp comprises a light source. A light guide is positioned adjacent to the light source. A reflective layer is arranged on the light guide. A polymer material coating encloses the light source, the light guide, and the reflective layer. The light guide includes a curved segment. A nanolayer is locally applied to a section of an inner concave surface on the curved segment. The nanolayer is designed to reduce light passing through the curved segment to produce homogeneous illumination from the light guide and to mitigate light spots within the light guide.

[0007] In another aspect of the present disclosure, the reflective layer is defined as a chromium layer.

[0008] In another aspect of the present disclosure, the chromium layer is one of: a pre-coating applied to the optical fiber using a physical vapor deposition (PVD) process, a pre-coating applied to the optical fiber using an in-mold decoration treatment (IMDTR) process, and a lamination.

[0009] In another aspect of the present disclosure, the optical fiber defines an optical fiber layer made of a polyethylene terephthalate (PET) material or a polycarbonate (PC) material, wherein the optical fiber layer is positioned on and connected to the reflective layer, the reflective layer being connected to a molded part.

[0010] In another aspect of the present disclosure, the light source is oriented towards an edge E1 of the optical fiber layer in order to guide light along a length L1 of the optical fiber layer; and the reflecting layer reflects light rays generated by the light source from the optical fiber layer from the reflecting layer generally in a direction D1 substantially perpendicular to the optical fiber layer.

[0011] In another aspect of the present disclosure, a hard coating is applied over the polymer material coating. The hard coating is applied using one of the following methods: a wet coating process, a dry coating process, an in-mold injection molding or lamination process, and a post-molding process.

[0012] In another aspect of the present disclosure, the optical fiber is defined as an optical fiber plate, wherein the light source directs light into an edge E2 of the optical fiber plate. The optical fiber plate is one of transparent and translucent materials and one of polycarbonate and one of polymethyl methacrylate (PMMA) materials. The reflective layer is applied to the optical fiber plate as a chromium material.

[0013] In another aspect of the present disclosure, graphics of the optical fiber-supported lamp define nanoscale optical patterns formed on the optical fiber by surface etching of the optical fiber.

[0014] In another aspect of the present disclosure, the light source, the light guide, the reflective layer and the polymer material coating are jointly manufactured using a lamination process and an injection molding process.

[0015] A nanolayer can be applied to a section of an inner, concave surface of the curved segment. The nanolayer can have a first refractive index that differs from the second refractive index of the optical fiber.

[0016] From several perspectives, a light guide lamp comprises a light guide. A light source is positioned facing one edge of the light guide to direct light, generated by energizing the light source, along a length of the light guide. A reflective layer is placed on the light guide. A graphic pattern is formed on the light guide. A polymer material coating is applied over the light source, the light guide, and the reflective layer.A coating is applied over the polymer material coating, the coating being applied using one of a wet coating process, which defines a method for applying a liquid coating to a substrate, a dry coating process, which defines a method for applying particles or a pigment coating material to a substrate, an in-mold injection molding or laminating layer application, and a post-molding process.

[0017] In another aspect of the present disclosure, the graphic pattern defines optical patterns on the nanoscale, which are produced as etchings on a surface of the light guide.

[0018] In another aspect of the present revelation, the etchings define several valleys and peaks to redirect light rays.

[0019] In another aspect of the present disclosure, a curved segment of the optical fiber has a reduced density of optical patterns in order to decrease light emitted at the curved segment, thereby producing a homogeneous light output from the optical fiber.

[0020] In another aspect of the present disclosure, the optical fiber is defined as consisting of a transparent polymer material and a translucent polymer material, which is provided as a layer and a printed circuit board.

[0021] In another aspect of the present disclosure, the reflective layer is defined as a chromium layer produced using a physical vapor deposition process.

[0022] In another aspect of the present disclosure, the reflective layer is defined as a chromium layer applied to the light guide as one consisting of an improved mirror reflector layer and a Bragg mirror foil.

[0023] According to several aspects, a process for forming a light guide-supported lamp includes: positioning a reflective layer, a light guide, and a light source within a cavity of a first mold section; bringing a second mold section into contact with the first mold section to close the mold; injecting a polymer resin into the cavity to surround the reflective layer, the light guide, and the light source; applying a force to the second mold section to compress the polymer resin within the cavity, thereby creating a sealed assembly of the reflective layer, the light guide, and the light source; lifting the second mold section away from the first mold section; and removing the sealed assembly from the cavity of the first mold section.

[0024] In another aspect of the present disclosure, the method further comprises holding the force for a predetermined period of time, which allows the polymer resin to harden before the second mold section is lifted off.

[0025] In another aspect of the present disclosure, the method further comprises pre-coating the reflective layer using chromium on the light guide. Fig. Figure 1 is a side view of a fiber optic lamp according to an exemplary aspect; Fig. Figure 2 is a side view of a first aspect of the fiber optic-supported lamp of Fig. 1; Fig. Figure 3 is a top view of a second aspect of the fiber optic-supported lamp. Fig. 1; Fig. Figure 4 is a top view of a vehicle window. Fig. 1, where the fiber optic lamp is switched off; Fig. Figure 5 is a side view of the vehicle window. Fig. 4, which is modified to represent the light guide-supported lamp when it is switched on; Fig. Figure 6 is a top view of the fiber optic-supported lamp from Fig. 5; Fig. Figure 7 is a side view of an open press mold for forming a light guide-supported lamp of the present disclosure; Fig. 8 is a side view of the press mold of Fig. 7 in a closed position; Fig. Figure 9 is a side view taken from Fig. 8 is modified to represent a polymer material during injection; Fig. Figure 10 is a side view of the press mold of Fig. 9 in an open mold state after injection; Fig. Figure 11 is a side view of a reflective chromium layer prepared for a light guide in a pre-coating process; Fig. Figure 12 is a side view of a reflective chromium layer being added to a light guide during a co-molding process; Fig. Figure 13 is a side view of a graphically embossed layer formed using an in-mould decoration treatment (IMDTR) process; Fig. Figure 14 is a side view of a curved optical fiber; Fig. 15 is a top view of the curved light guide of Fig. 14; Fig. Figure 16 is a side view of a curved optical fiber with a nanolayer locally applied to an inner radius of the curved optical fiber; and Fig. Figure 17 is a top view of the locally applied nanolayer. Fig. 16.

[0026] With reference to Fig. 1 is a light-guided lamp 10 provided with a vehicle 12, such as a sedan, SUV, truck, or van, wherein the vehicle 12 is defined as a gasoline-powered vehicle, a battery-powered vehicle, or an autonomous vehicle. The light-guided lamp 10 comprises a light guide 14, for example, made of a transparent or translucent polymer material, provided as a layer or a circuit board. A reflective layer 16, such as a chromium layer, is arranged on the light guide 14. The light-guided lamp 10 defines a concealed-until-illuminated lamp with an emblem 18 that is initially concealed until it is illuminated by light passing through the light guide 14 by exciting a light source 20, such as a light-emitting diode (LED), a micro-LED (uLED), or multiple light sources.Energy to illuminate the light source 20 is provided by a power source 22 of the vehicle 12, such as a battery or an alternator. The fiber-guided lamp 10 can be positioned on, in, or at any feature of the vehicle 12, including a window 24, a door 26, a hood 28, or a trunk or rear panel 30.

[0027] With reference to Fig. 2 and again on Fig. 1 can refer to Fig. The described light-guided lamp 10 can take several forms, comprising a first light-guided lamp 32 according to several aspects. The first light-guided lamp 32 comprises a multilayer arrangement 34 with a coating 36 of a thermosetting polymer material, such as polyurethane, applied to a separate layer that defines a light guide layer 38 made of polyethylene terephthalate (PET) or polycarbonate (PC) material. The light guide layer 38 is positioned on a reflective layer 40, such as a chromium layer, which itself is connected to, and may be bonded to, a molded part 42.Instead of guiding light from a light source 20a through the reflective layer 40 into the light guide layer 38, the light source 20a is positioned at an edge E1 of the light guide layer 38 and thereby guides light along a length L1 of the light guide layer 38, wherein the reflective layer 40 deflects light rays that are reflected or refracted by the light guide layer 38 from the reflective layer 40 and from the first light guide-supported lamp 32 through the coating 36 generally in a direction D1 perpendicular to the light guide layer 38.

[0028] With reference to Fig. 3 and again on Fig. 1 and Fig. 2. The several forms of the with reference to Fig. The light-guided lamp 10 described in Section 1 may also include a second light-guided lamp 44 according to several aspects. The second light-guided lamp 44 comprises an embedded light guide and reflective layer arrangement 34 with a light source 20b that directs light into an edge E2 of a shaped light guide plate 48. The light guide plate 48 is transparent or translucent and can be made of a PC material or a polymethyl methacrylate (PMMA) material. A reflective layer 50 is applied to the light guide plate 48, which can be a chromium material and is similar to that described in Section 1. Fig. The reflective layer 40 described in section 2 functions. The reflective layer 50 emits light rays generated by the light source 20b into the light guide plate 48 and from the second light guide-supported lamp 44, generally in one direction D2.

[0029] With reference to Fig. 4 and again on Fig. 1 to Fig. 3. The several forms of the with reference to Fig. In addition to the light-guided lamp 10 described in Section 1, a third light-guided lamp 52 may also be included according to several aspects. According to several aspects, when positioned on the window 24 of the vehicle 12, the third light-guided lamp 52 may be opaque or substantially invisible to an observer positioned outside the vehicle 12 when it is not switched on, as shown.

[0030] With reference to Fig. 5 and again on Fig. 4 is the third light guide-supported lamp 52, which, when switched on, is clearly visible to the observer positioned outside the vehicle 12. An exemplary emblem 54, when switched on and visible to the observer, can take any visible form chosen by the designer, including but not limited to a vehicle designation, brand or model emblem, advertising information, sales information, or the like.

[0031] With reference to Fig. 6 and again on Fig. 4 and Fig. 5 Graphics of the third optical fiber-supported lamp 52 can be generated by forming nanoscale optical patterns on an optical fiber 56, such as a first nanoscale optical pattern 58, a second nanoscale optical pattern 60, and a third nanoscale optical pattern 62, which can be generated, for example, by etching a surface 64 of the optical fiber 56. The etching can include forming multiple valleys 66 and peaks 68 that redirect light rays 70 generated by switching on a light source 20c directed at an edge E3 of the optical fiber 56.

[0032] With reference to Fig. 7 and again on Fig. 1 to Fig. 6 An exemplary injection molding process can be used to produce light-guided lamps 10 of the present disclosure. In a first molding step, components of a light-guided lamp 72, similar to the second light-guided lamp 44 and comprising a reflective layer 74, a light guide 76, and a light source 20d, are positioned in a mold 78. The components of the light-guided lamp 72 are positioned in a cavity 80 of a first mold section 82 of the mold 78. A second mold section 84 is initially spaced apart from the first mold section 82 to allow loading of the mold 78.

[0033] With reference to Fig. 8 and again on Fig. In a second forming step, the second mold section 84 is lowered onto the first mold section 82 to close the mold 78. A transparent or translucent resin 86, such as PC or PMMA resin, is injected into the cavity 80 and surrounds the components of the light guide-supported lamp 72.

[0034] With reference to Fig. 9 and again on Fig. 7 and Fig. In a third forming step, a force 88 is applied to the second forming section 84 to compress the resin 86 within the cavity 80. After a predetermined time, which allows the resin 86 to harden the components of the light guide-supported lamp 72, the force 88 is removed.

[0035] With reference to Fig. 10 and again on Fig. 7 to Fig. 9 The second mold section 84 is lifted off from the first mold section 80. A sealed assembly 89, in which the resin 86 has cured around the components of the light guide-supported lamp 72, is then removed from the mold 78.

[0036] With reference to Fig. 11 and again on Fig. 3. A light guide-supported lamp 90 can be manufactured using a pre-coating process to pre-coat a reflective layer 92 onto a light guide 94 using a reflective material such as chromium. A light source 20e is also provided with the light guide-supported lamp 90. The pre-coating of the reflective layer 92 can be achieved using a physical vapor deposition (PVD) process or an in-mold decoration treatment (IMDTR) process.

[0037] With reference to Fig. 12 and again referring to Fig. 7 to Fig. In the forming process described in section 10, a light guide-supported lamp 96 can be manufactured using a co-molding process, wherein a reflective material film 98 is joined to a light guide 100 using a printing mold 102. A light source 20f is also provided with the light guide-supported lamp 96. According to several aspects, the reflective material film 98 can define an enhanced specular reflector (ESR) layer or a Bragg mirror film, which defines a type of mirror consisting of several layers of a dielectric material, usually deposited on a substrate of a glass material or another optical material.

[0038] With reference to Fig. 13 and again on Fig. 7 to Fig. 10 and Fig. 11 can do the above with reference to Fig. 11 discussed In-Mould Decoration Treatment (IMDTR) process includes a graphically embossed layer 104, which is placed in shape 78.

[0039] With reference to Fig. 14 and again on Fig. 3. An optical fiber 110 used in an optical fiber-supported lamp of the present disclosure can include a curved segment 112. Due to a higher exit angle at the curved segment 112, more reflected light can exit the optical fiber 110 than at a straight segment 114 of the optical fiber 110. The increased reflected light can cause undesirable localized light hot spots.

[0040] With reference to Fig. 15 and again on Fig. 6 and Fig. 14 To counteract localized light hotspots, the light guide 110 can incorporate optical patterns with different grain densities that are selectively pre-positioned or formed within the light guide 110. Light hotspots are defined here as one or more areas within a space that receive a higher degree of illuminance compared to its immediate surroundings. For example, a first optical pattern 116 that produces a first degree of light brightness 118 can be located on or within the area referred to in Fig. The curved segment 112 described in section 14 is located there. A second optical pattern 120, which generates a second degree of light brightness 122 that is greater than the degree of light brightness 118, can be pre-positioned in the straight segment 114 of the light guide 110, where light hot spots are not a problem, thus producing homogeneous illumination from the light guide 110.

[0041] With reference to Fig. 16 and again on Fig. 14 and Fig. 15. A light guide-supported lamp 126 of the present disclosure can include a light guide 126 with a curved segment 128. To generate homogeneous illumination from the light guide 126 and to counteract light hot spots, a nanolayer 130 can be locally applied to a section of an inner concave surface 132 on the curved segment 128. The nanolayer 130 functions to reduce light passing through the curved segment 128.

[0042] With reference to Fig. 17 and again on Fig.16. Prior to the installation of the nanolayer 130, an optical interconnect layer 132 is adhered, bonded, or placed on a surface 134 of the optical fiber 126, where the concave surface 132 is located. The nanolayer 130 is then formed from several segments, which may include, for example, a first nanolayer segment 136, a second nanolayer segment 138, and a third nanolayer segment 140. The nanolayer segments are applied to an outward-facing surface 142 of the optical interconnect layer 132. According to several aspects, the optical interconnect layer 132 has a first refractive index n1, and the nanolayer 130 has a second refractive index n2, which differs from the first refractive index n1.

[0043] A light-guided lamp 10 of the present disclosure offers several advantages. These include: a light source, such as an LED, a uLED, or multiple light sources, which includes: a light guide layer or a printed circuit board; and a chromium or reflective layer. The reflective layer can be: pre-coated onto the light guide layer using a PVD process, pre-coated onto the light guide layer using an in-mold decoration process, or laminated onto a light guide layer. A polyurethane coating or a hard weathering layer is applied, depending on the application and material. The intensity of an optical pattern of the light-guided lamp is heterogeneous to achieve homogeneous illumination in non-planar components.A nanolayer with a refractive index different from that of the glass / polymer can be locally applied to achieve homogeneous illumination of non-planar components. The light guide-supported lamp can be manufactured using one of the following processes: a lamination process; or an injection molding process. A hard coating for UV / scratch and scratch / environmental protection can be applied via a wet coating process, a dry coating process, an in-mold injection molding or lamination application, or a post-molding application.

Claims

[1] Light guide-supported lamp (10), comprising: a light source (20); a light guide (14, 56, 76, 94, 100, 110, 126) positioned adjacent to the light source (20); a reflective layer (16, 50, 74, 92) arranged on the optical fiber (14, 128); a polymer material coating (36) that encloses the light source (20), the light guide (14, 56, 76, 94, 100, 110, 126) and the reflective layer (16, 50, 74, 92); wherein the optical fiber (14, 126) comprises a curved segment (128), and wherein a nanolayer (130) is locally applied to a section of an inner concave surface (132) on the curved segment (112, 128), and wherein the nanolayer (130) is designed to reduce light passing through the curved segment (112, 128) in order to produce homogeneous illumination of the light guide (14, 126) and to mitigate light spots of the light guide (14, 126). [2] Light guide supported lamp (10) according to claim 1, wherein the reflective layer (16, 50, 74, 92) defines a chromium layer. [3] Light guide supported lamp (10) according to claim 2, wherein the chromium layer is one of the following: a pre-coating applied to the optical fiber (14, 126) using a physical vapor deposition (PVD) process, a pre-coating applied to the optical fiber (14, 56, 76, 94, 100, 110, 126) using an in-mould decoration treatment (IMDTR) process, and a lamination. [4] Light guide-supported lamp (10) according to claim 1, wherein the light guide (14, 56, 76, 94, 100, 110, 126) defines a light guide layer (38) made of a polyethylene terephthalate (PET) material or a polycarbonate (PC) material, wherein the light guide layer (38) is positioned on and connected to the reflective layer (16, 50, 74, 92), wherein the reflective layer (16, 50, 74, 92) is connected to a molded part (42). [5] Light guide-supported lamp (10) according to claim 4, wherein: the light source (20) is positioned facing an edge E1 of the light guide layer (38) in order to guide light along a length L1 of the light guide layer (38); and the reflecting layer (16, 50, 74, 92) reflects light rays generated by the light source (20) from the light guide layer (38) generally in a direction D1 substantially perpendicular to the light guide layer (38). [6] Light guide supported lamp (10) according to claim 1, comprising a coating applied over the polymer material coating (36), wherein the coating is applied using a wet coating process, a dry coating process, an in-mold injection molding or lamination layer application and a post-molding process. [7] Light guide supported lamp (10) according to claim 1, wherein: The optical fiber (14, 56, 76, 94, 100, 110, 126) defines an optical fiber plate (48), wherein the light source (20) directs light into an edge E2 of the optical fiber plate (48), wherein the optical fiber plate (48) is one of transparent and translucent and one of a polycarbonate material and a polymethyl methacrylate (PMMA) material; and the reflective layer (16, 50, 74, 92) is applied to the light guide plate (48) as a chromium material. [8] Light guide-supported lamp (10) according to claim 1, further comprising graphics of the light guide-supported lamp (10) defining optical patterns on the nanoscale formed on the light guide (14, 56, 76, 94, 100, 110, 126) by surface etching of the light guide (14, 56, 76, 94, 100, 110, 126). [9] Light guide supported lamp (10) according to claim 1, wherein the light source (20), the light guide (14, 56, 76, 94, 100, 110, 126), the reflective layer (16, 50, 74, 92) and the polymer material coating (36) are jointly produced using a lamination process and an injection molding process. [10] Light guide supported lamp (10) according to claim 1, wherein the nanolayer (130) has a first refractive index which differs from a second refractive index of the light guide (14, 56, 76, 94, 100, 110, 126).

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