Flexible longitudinal lighting device for a motor vehicle

Abstract

Method of manufacturing a flexible longitudinal lighting device comprising the following steps: - a strip (8) of an electrically conductive material is provided; - said strip (8) is cut to form a plurality of plates (11) spaced apart from each other and successively connected to each other by two power supply elements (12) and at least two control elements (13), the plates (11) each having two peripheral power supply terminals (15) opposite each other and at least four control terminals (16); - a plurality of electronic boards (9) are fixed respectively on the plates (11), each electronic board (9) being connected to the peripheral power supply terminals (15) and to the control terminals (16) on either side of the plate (11) on which it is fixed; - a plurality of intelligent light-emitting diodes (10) are fixed respectively on said plurality of electronic boards (9);- the said strip (8) is cut so as to isolate the power supply elements (12) and the control elements (13) from each other; and, - the assembly (7) is encapsulated in a flexible rod, said assembly (7) comprising the strip (8), the plurality of electronic boards (9) and the plurality of intelligent light-emitting diodes (10). Figure to be published with the abbreviation: Fig. 3;

Description

Title of the invention: Flexible longitudinal lighting device for a motor vehicle

[0001] The present invention relates to a lighting device for a motor vehicle.

[0002] Light-emitting diode (LED) lighting systems, particularly in the automotive field, are increasingly being used to create light animations and visual effects to enhance the user experience, whether for welcome, information or ambiance sequences.

[0003] To date, existing solutions are mainly based on LEDs mounted on rigid electronic boards. This approach restricts design flexibility, limiting the possibilities for 3D shapes and making it difficult to adapt to curved or complex structures, while also resulting in high production and validation costs. Indeed, each new application often requires a complete redesign, lengthening the development process and increasing expenses.

[0004] The use of LEDs mounted on flexible printed circuit boards offers an alternative that provides a degree of flexibility in lighting applications. However, this technology remains limited in terms of three-dimensional curvature and presents increased risks to quality, particularly at the solder joints. Furthermore, any modification to the LED arrangement (such as their spacing) requires a new validation process, making this solution poorly suited to a variety of configurations.

[0005] One possible solution is Lumileds' LUXEON 3D LED technology, which offers a flexible silicone light strip in which the LEDs are integrated to ensure homogeneous light diffusion while allowing for a degree of flexibility. This design makes it possible to integrate lighting into spaces with complex shapes while ensuring uniform illumination.

[0006] However, this solution has significant limitations, particularly regarding the independent control of each LED. In this case, the intensity, color, or illumination of each LED cannot be controlled separately, which restricts the possibilities for animations or customization of lighting sequences.

[0007] There is therefore a need to develop a lighting solution as well as a method for manufacturing this solution, offering flexibility in two dimensions and in torsion, durable and allowing individualized control of each LED to modulate lighting sequences.

[0008] To this end, and according to a first object, a method for manufacturing a flexible longitudinal lighting device is proposed, comprising the following steps: - a strip of electrically conductive material is provided; - the said strip is stamped and cut to form a plurality of plates spaced apart from each other and successively connected to each other by two power supply elements and at least two control elements, each plate having two peripheral power supply terminals opposite each other and at least four control terminals distributed, between the said peripheral power supply terminals, two by two opposite each other; - a plurality of electronic boards are fixed respectively on the boards of said plurality of boards, each electronic board being connected to the peripheral power supply terminals and to the control terminals on either side of the board on which it is fixed; - a plurality of intelligent light-emitting diodes are fixed respectively on said plurality of electronic boards; - the said strip is cut at the level of the said two peripheral terminals and the said at least four control terminals so as to isolate the power supply elements and the control elements from each other; and, - the assembly including the strip, the plurality of electronic boards and the plurality of intelligent light-emitting diodes is encapsulated in a flexible rod.

[0009] A feature of the invention lies in the use of an electrically conductive strip that is stamped and cut so that it is flexible in two dimensions as well as in torsion. This flexibility contributes to the durability of the lighting device, which becomes less vulnerable to breakage.

[0010] Moreover, its longitudinal and flexible structure facilitates its integration into different locations of the vehicle, regardless of the shape or size of these areas.

[0011] The integration of a flexible rod also enhances the overall flexibility of the device, while providing additional protection, making it more resistant to wear and, consequently, more durable.

[0012] Furthermore, the manufacturing process can be implemented continuously, thus making it possible to produce a lighting device with adjustable length according to requirements.

[0013] The use of intelligent light-emitting diodes, which can also integrate an emitting component, often red-green-blue (whose acronym is RGB in English), a diode driver component, control logic and / or a communication component, offers individualized control of each diode, allowing the modulation of lighting sequences and adjustment, for example, of their color and intensity.

[0014] Advantageously, the strip has an end comprising two power supply elements and at least two control elements. For example, before encapsulation, at least four connecting wires are attached to this end so that they are respectively attached to the power supply elements, and during encapsulation, some of the connecting wires are encapsulated. The attachment of at least four connecting wires can also be carried out after encapsulation or by using a connector that allows the end of the strip to be connected to the at least four connecting wires.

[0015] This additional step allows the lighting device to be connected to a power source or a control module subsequently installed outside the rod.

[0016] Preferably, said connecting wires are connected to a control box. The control box regulates the smart LEDs for lighting sequences and also provides the power supply necessary for the operation of the entire device.

[0017] Preferably, a strip is provided made of a metallic material or an electrically conductive metallic alloy.

[0018] According to a second object, the invention relates to a flexible longitudinal lighting device comprising: - a strip of electrically conductive material stamped and cut so as to form a plurality of plates spaced apart from each other and connected successively to each other by two power supply elements and at least two control elements, said plates each having two peripheral power supply terminals opposite each other and at least four control terminals distributed, between said peripheral power supply terminals, two by two opposite each other, said plates being cut at said two peripheral terminals and said at least four control terminals so as to isolate the power supply elements and the control elements from each other; - a plurality of electronic boards fixed respectively on the plates of said plurality of plates, each electronic board being connected to the peripheral power supply terminals and to the control terminals on either side of the plate on which it is fixed; - a plurality of intelligent light-emitting diodes fixed respectively on said electronic boards of said plurality of electronic boards; - a flexible rod encapsulating the whole thing.

[0019] Advantageously, the strip has one end, said end having two power supply elements and at least two control elements. And, the device lighting includes at least four connecting wires, said connecting wires being fixed to said end of the strip so that they are fixed respectively to the power elements, and a portion of said connecting wires being encapsulated in the flexible rod.

[0020] Preferably, the lighting device includes a control box and the connecting wires are connected to the control box.

[0021] Preferably, the strip is made of a metallic material or an electrically conductive metallic alloy.

[0022] Other features and advantages of the invention will become apparent from the following description of several embodiments of the invention, given by way of example but not limitation, with reference to the accompanying drawings in which: - [Fig.1] is a schematic perspective view of a lighting device according to the invention; - [Fig.2a] is a schematic cross-sectional view of part of the lighting device according to the invention; - [Fig.2b] is a schematic cross-sectional view of part of the lighting device according to another embodiment of the invention; - [Fig.3] is a schematic perspective view of another part of the lighting device according to another embodiment of the invention; - [Fig.4] is a schematic perspective view from another angle of the same part of the lighting device shown in [Fig.3].

[0023] The invention relates to a method of manufacturing a longitudinal and flexible lighting device for a motor vehicle and to a lighting device manufactured according to this method.

[0024] Fig. 1 illustrates a lighting device 1 extending longitudinally and comprising a rod 2, a plurality of connecting wires 3 and a control box 4.

[0025] The bead 2 is a flexible band made of polymer material, designed to offer both robust protection and three-dimensional flexibility. It encapsulates a set of 7 smart light-emitting diodes.

[0026] The ring 2 can be made of a flexible polymer, such as silicone. This polymer material must be partially transparent to allow diffusion of the light emitted by the encapsulated diodes.

[0027] It may also include a transparent part and a reflective opaque part acting as a reflector for the light emitted by the diodes, directing it towards the transparent area. The integration of a reflective part optimizes the perceived brightness by minimizing light loss through reflection towards the transparent area.

[0028] For example, as illustrated in [Fig. 2a], the reflective portion 5 is extruded longitudinally to surround the assembly 7, while the transparent portion 6 is positioned above this assembly. The reflective portion 5 redirects some of the light scattered by the assembly 7, thus increasing luminous efficiency by concentrating more light upwards.

[0029] In another example, illustrated in [Fig. 2b], the reflective part 5 is also extruded longitudinally to surround the assembly 7, with the transparent part 6 positioned above it. An air gap is located between the assembly 7 and the reflective part 5, allowing the latter to reflect the lateral light diffused by the assembly 7 towards the transparent area 6.

[0030] The ring 2 also provides protection for the assembly, in particular the light-emitting diodes, against external elements such as dust and moisture.

[0031] The lighting device 1 also includes a control box 4, designed to perform two main functions: the management of communication signals and the regulation of the power required according to the length of the device and the number of light points it contains.

[0032] The control unit 4 can integrate a communication gateway that converts the protocol used into a signal compatible with the device's lighting elements. This protocol can be, for example, the open-source communication protocol Open Source Protocol (OSP), created by OSRAM, or the ISELED protocol, allowing direct integration of the device with the vehicle's control systems. This facilitates the synchronization of the lighting animations with other vehicle functions, such as turn signals, position lights, or welcome and ambient lighting sequences.

[0033] In addition, the control box 4 may include a DC / DC module to convert the input voltage into a stable voltage suitable for the needs of the lighting device 1. This DC / DC module is specifically calibrated to fit the total length of the rod integrating the light elements, thus ensuring a homogeneous and sufficient supply of the light-emitting diodes.

[0034] To connect the control box 4 to the assembly 7 located inside the ring 2, the lighting device 1 is equipped with connecting wires 3. The connection will be explained below.

[0035] The lighting device 1 includes four connecting wires 3: two for power supply and two for the transfer of control signals from the control box 4. The number of wires may vary depending on the protocol used or the designer's specifications.

[0036] The wires are arranged in a linear fashion, which contributes to the suppleness and flexibility of the assembly.

[0037] The ring 2 encapsulates an assembly 7, illustrated in [Fig.3], comprising a stamped and cut strip 8, four electronic boards 9 and four intelligent light-emitting diodes 10.

[0038] The number of smart LEDs 10 can vary and depends in particular on the length of the desired lighting device. This number also influences the number of electronic boards 9.

[0039] The band 8 is made of an electrically conductive material, preferably a metal or a metal alloy such as brass, copper or aluminium.

[0040] The strip 8 is stamped and cut to form four plates 11, spaced apart and sized to accommodate the electronic boards. Each plate is of a similar size to the electronic board it supports.

[0041] The number of plates 11 is determined according to the desired length of the strip 8 as well as the number of light-emitting diodes required.

[0042] The plates 11 are successively connected to each other by two power supply elements 12 and at least two control elements 13.

[0043] The power supply elements 12 provide power to the electronic boards and diodes, while the control elements 13 allow the transmission of the control signals generated by the control box 4. The number of control elements may vary depending on the protocol used or the designer's specifications.

[0044] The power supply elements 12 and the control elements 13 are of low thickness, ranging from 5 millimeters to 35 millimeters. This thinness gives the assembly 7 flexibility in two dimensions as well as in torsion.

[0045] To further improve flexibility, the feed elements 12 and control elements 13 may have one or more undulations, allowing their extension or contraction during the shaping phase relative to their initial straight state.

[0046] The strip 8 is also cut to form two opposing peripheral power supply terminals 15 and at least four control terminals 16 distributed between the peripheral power supply terminals 15, as illustrated in [Fig. 4]. The control terminals 16 are arranged in opposing pairs on each plate.

[0047] The peripheral power supply terminals 15 are interconnected by the power supply elements 12, while the control terminals 16 are connected in pairs by the control elements 13.

[0048] To isolate the peripheral power supply terminals 15 and control terminals 16 from each other, the plates 11 are cut at the connections between each terminal, as illustrated in part A of [Fig.4].

[0049] On each plate 11, an electronic card 9 is fixed using six screws 14, but the number of screws may vary depending on the size of the electronic card or the shape of the plates 11 for example.

[0050] The strip 8 has an end 17. The end 17 also has two power supply elements 12 and at least two control elements 13.

[0051] To connect the strip 8 to the control box 4, the four connecting wires 3 are connected to the power supply elements 12 and to the control elements 13 of the end 17 by soldering in particular.

[0052] Each electronic card 9 is connected to the peripheral power supply terminals 15 and to the control terminals 16 on either side of the plate 11 on which it is fixed. The connections are, for example, made by soldering.

[0053] The electronic boards 9 play an essential role in the operation and control of the smart light-emitting diodes. They provide the necessary power supply and allow the adjustment of parameters such as the intensity, color, and lighting sequences of the diodes.

[0054] The electronic boards 9 convert the current into a form suitable for the diodes, often using conversion modules that stabilize the voltage and current according to the diodes' requirements. They also incorporate microcontrollers or specific chips, which interpret the commands sent by the control unit 4.

[0055] Finally, on each electronic card 9, an intelligent light-emitting diode 10 is fixed by soldering.

[0056] Smart light-emitting diodes 10, also called smart LEDs, are diodes incorporating advanced electronic control functions. They differ from conventional diodes in their ability to be controlled individually or in groups, thus allowing precise adjustment of parameters such as light intensity, color, and on / off sequences. This control is ensured by an integrated microcontroller or a control chip that interprets the signals sent.

[0057] The lighting device 1 is assembled according to the manufacturing method of the invention. Initially, a strip 8 of electrically conductive material is provided.

[0058] The strip 8 is stamped and cut to form spaced plates 11, connected successively to each other by two power supply elements 12 and at least two control elements 13.

[0059] In addition, each plate 11 is cut so as to have two opposing peripheral power supply terminals 15, as well as at least four control terminals 16 distributed between the peripheral power supply terminals 15, arranged in opposing pairs.

[0060] For example, to form the feed elements 12 and control elements 13, stamping can be carried out using an adjustable tool allowing both cutting and the creation of corrugations.

[0061] Next, a plurality of electronic boards 9 are fixed respectively onto the different plates 11 by screwing. Each electronic board 9 is connected to the power supply elements 12 and control elements 13 on either side of the plate 11 on which it is fixed, for example by soldering.

[0062] A smart light-emitting diode 10 is then fixed on each electronic board 9.

[0063] Once the elements are assembled, the strip 8 is cut at the peripheral terminals 15 and the control terminals 16, so as to isolate the power supply elements 12 and the control elements 13 from each other.

[0064] Once assembled, connecting wires 3 can be attached to the first plate 11 of the strip 8, from one of its ends 17.

[0065] Finally, the assembly 7 is encapsulated in a flexible rod 2. The encapsulation is carried out in two stages, the rod 2 being made up of two parts which are assembled around the assembly 7. This encapsulation also allows part of the connecting wires 3 to protrude.

[0066] Once the junction 2 is installed, the connecting wires 3 can finally be connected to the control box 4.

Claims

1.

2. Demands Method for manufacturing a flexible longitudinal lighting device (1) comprising the following steps: - a strip (8) is provided made of an electrically conductive material; - the said strip (8) is stamped and cut to form a plurality of plates (11) spaced apart from each other and connected successively to each other by two power supply elements (12) and at least two control elements (13), the plates (11) each having two peripheral power supply terminals (15) opposite each other and at least four control terminals (16) distributed, between the said peripheral power supply terminals (15), two by two opposite each other; - a plurality of electronic cards (9) are fixed respectively on the plates (11) of said plurality of plates (11), each electronic card (9) being connected to the peripheral power supply terminals (15) and to the control terminals (16) on either side of the plate (11) on which it is fixed; - a plurality of intelligent light-emitting diodes (10) are fixed respectively on said plurality of electronic boards (9); - the said strip (8) is cut at the level of the said two peripheral power supply terminals (15) and the said at least four control terminals (16) so as to isolate the power supply elements (12) and the control elements (13) from each other; and, - the assembly (7) comprising the strip (8), the plurality of electronic boards (9) and the plurality of intelligent light-emitting diodes (10) is encapsulated in a flexible rod (2). Manufacturing method according to claim 1, characterized in that the strip (8) has an end (17) having two power supply elements (12) and at least two control elements (13) and in that, before encapsulation, at least four connecting wires (3) are fixed to this end (17) so that they are fixed

3.

4.

5.

6. respectively to the power supply elements (12) and the control elements (13) and during encapsulation, a portion of the connecting wires (3) are encapsulated. Manufacturing method according to claim 2, characterized in that said connecting wires (3) are connected to a control box (4). Manufacturing method according to any one of claims 1 to 3, characterized in that a strip (8) is supplied in a metallic material or an electrically conductive metallic alloy. Manufacturing method according to any one of the claims 1 to 4, characterized in that the rod (2) is separated into two parts and, during encapsulation, the rod (2) is assembled, enclosing the assembly (7). Flexible longitudinal lighting device (1) comprising: a strip (8) of an electrically conductive material stamped and cut so as to form a plurality of plates (11) spaced apart from each other and connected successively to each other by two power supply elements (12) and at least two control elements (13), said plates (11) each having two peripheral power supply terminals (15) opposite each other and at least four control terminals (16) distributed, between said peripheral power supply terminals (15), two by two opposite each other, said plates (11) being cut at said two peripheral terminals (15) and said at least four control terminals (16) so as to isolate the power supply elements (12) and the control elements (13) from each other; a plurality of electronic cards (9) fixed respectively on the plates (11) of said plurality of plate (11), each electronic card (9) being connected to the peripheral power supply terminals (15) and to the control terminals (16) on either side of the plate (11) on which it is fixed; a plurality of intelligent light-emitting diodes (10) fixed respectively on said electronic boards (9) of said plurality of electronic boards (9); - a flexible rod (2) encapsulating the assembly (7) comprising the strip (8), the plurality of electronic boards (9) and the plurality of intelligent light-emitting diodes (10).

7. Lighting device (1) according to claim 6, characterized in that the strip (8) has an end (17), said end (17) having two power supply elements (12) and at least two control elements (13) and in that the lighting device comprises at least four connecting wires, said connecting wires being fixed to said end (17) of the strip (8) so that they are fixed respectively to the power supply elements (12) and the control elements (13), and a portion of said connecting wires being encapsulated in the flexible rod.

8. Lighting device (1) according to claim 7, characterized in that it comprises a control box and the connecting wires are connected to the control box (4).

9. Lighting device according to any one of claims 6 to 8, characterized in that the strip (8) is made of a metallic material or an electrically conductive metallic alloy.

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