Illumination device cluster, display and manufacturing method

Abstract

A cluster of lighting devices, a display, and a method of manufacturing a display are described. The lighting device includes a mixing box, a light source, a transparent layer, and a light diffusing layer. The light source is embedded in the mixing box. The transparent layer is adjacent to the light source. The light diffusing layer is adjacent to the transparent layer. The surface emitter display includes a surface emitter cluster with a plurality of surface emitters. At least one circuit board is electrically coupled to at least one surface emitter of the plurality of surface emitters.

Description

[Technical field]

[0001] The present invention relates to a cluster of lighting devices, a display and a method of manufacture. [Background technology]

[0002] The grille may cover an opening in the vehicle body, allowing air to flow in and out of the opening to circulate cooling air to the vehicle's internal combustion engine and prevent overheating. The grille may also provide a visual design to the front of the vehicle, which may attract buyers and allow them to identify the make and model of the vehicle. In all-electric vehicles with electric motors, the grille may be outdated and unnecessary. Summary of the Invention

[0003] A cluster of lighting devices, displays, and methods of manufacturing displays are described. The lighting device includes a mixing box, a light source, a transparent layer, and a light diffusing layer. The light source is embedded in the mixing box. The transparent layer is adjacent to the light source. The light diffusing layer is adjacent to the transparent layer. [Brief description of the drawings]

[0004] A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings in which:

[0005] [Figure 1] FIG. 1 is a perspective view of an exemplary lighting device. [Diagram 2] 2 is a cross-sectional view of the exemplary lighting device of FIG. 1. [Diagram 3] FIG. 3 is a perspective view of the example lighting device of FIGS. 1 and 2 electrically coupled to a rigid printed circuit board (PCB) and a flexible PCB. [Figure 4] 1 is a perspective view of an exemplary cluster of lighting devices. [Diagram 5] FIG. 2 is a perspective view of an exemplary bezel. [Figure 6]FIG. 1 is a perspective view of an exemplary cluster of lighting devices pressed against a bezel via a grid. [Figure 7] FIG. 7 is an expanded view of the example grid of FIG. 6. [Figure 8A] 1A-1D show cross-sectional views of an exemplary lighting device at various stages of a first method for manufacturing the lighting device. [Figure 8B] 10A-10C show cross-sectional views of an exemplary lighting device at various stages of a second method for manufacturing the lighting device. [Figure 9] FIG. 1 is a perspective view of an exemplary lighting device electrically coupled to a flexible PCB. [Figure 10] 1 is a flow chart of an exemplary method for manufacturing a display. [Figure 11] FIG. 1 is a block diagram of an exemplary display system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] Examples of lighting devices, displays, and manufacturing methods are described in more detail below with reference to the accompanying drawings. These examples are not mutually exclusive, and features found in one example may be combined with features found in one or more other examples to achieve additional implementations. It is therefore understood that the examples shown in the accompanying drawings are provided for illustrative purposes only and are not intended to limit the present disclosure in any manner. Like numbers refer to like elements throughout.

[0007] In this specification, terms such as first, second, third, etc. may be used to describe various elements, but it is understood that the elements are not limited by these terms. These terms may be used to distinguish one element from another element. For example, a first element may be referred to as a second element and a second element may be referred to as a first element without departing from the scope of the present disclosure. As used herein, the term "and / or" may include any and all combinations of one or more of the associated listed items.

[0008] When an element, such as a layer, region, or substrate, is referred to as being "on" or extending "on" another element, it is understood that it may be directly on or extending directly onto the other element, or that intervening elements may also be present. In contrast, when an element is referred to as being "directly on" or extending "directly onto" another element, there may not be intervening elements present. Also, when an element is referred to as being "connected" or "coupled" to another element, it is understood that it may be directly connected or coupled to the other element and / or may be connected or coupled to the other element via one or more intervening elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements between the element and the other element. It is understood that these terms are intended to encompass different orientations of the elements in addition to any orientation depicted in the figures.

[0009] As used herein, relative terms such as "lower," "top," "upper," "bottom," "horizontal," or "vertical" may be used to describe the relationship of one element, layer, or region to another element, layer, or region as illustrated in the figures, unless expressly stated otherwise. It is understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.

[0010] A vehicle grille may cover an opening in the vehicle body to provide cooling air to the engine and to provide a visual component. An electric vehicle, which has an electric motor rather than an engine, does not need a body opening or grille to provide cooling air to the engine. In lieu of a grille, an electric vehicle is often left as a blank canvas, so to speak, without any visual appeal or branding. It may be desirable to take advantage of that blank canvas to include a display, for example, on the front of the vehicle. Thus, the display may take the place of a grille on the electric vehicle and may be used to communicate with other vehicles, pedestrians, and / or cyclists, and / or provide a visual component that the electric vehicle may otherwise lack.

[0011] This specification describes a display for an electric vehicle that may include an array of lighting devices. In some embodiments, the lighting devices are surface emitters, which may be either standalone LEDs or segments of a monolithic LED array. The terms lighting device and surface emitter may be used interchangeably herein. However, one of ordinary skill in the art will recognize that a variety of different types of lighting devices may be used that are consistent with the embodiments described herein.

[0012] Conventional automotive luminaires tend to have a longer depth and a larger profile due to the need to cover a larger area laterally. It is challenging to create a low profile optical display system that covers a large lateral area and at the same time emits homogeneous light. In the embodiments described herein, this can be achieved using a scattering layer by spreading the light laterally and adapting the diffusion of the light. This creates a homogeneous illuminated surface. In this way, the surface emitters in the display can provide a Lambertian distribution of light to provide excellent visibility. The surface emitters may provide homogeneity as multiple surface emitters and as individual surface emitters. The surface emitters may have different shapes and may be individually controlled, for example, to provide different unique displays for different makes and models of vehicles and to provide cues to other vehicles and pedestrians. Furthermore, the surface emitters may have a lower profile compared to conventional automotive luminaires, which may be an important feature at the front of the vehicle.

[0013] FIG. 1 is a perspective view of an exemplary lighting device or surface emitter 100. The lighting device or surface emitter 100 may include a mixing box 110. Although FIG. 1 shows the mixing box 110 in the shape of a triangle, the mixing box 110 may be other shapes including, but not limited to, rectangular, square, and circular. The mixing box 110 may be formed of silicone. The mixing box 110 may be molded to that shape. The mixing box 110 may be a white mixing box configured to recycle light and increase light intensity by reflecting light. The lighting device or surface emitter 100 may further include a light exit surface 120. The light exit surface 120 may disperse light. The light exit surface 120 does not need to be planar. The mixing box 110 may be made of any flexible material, such as silicone, to allow for some degree of non-planarity of the lighting device or surface emitter 100.

[0014] FIG. 2 is a cross-sectional view of the lighting device or surface emitter 100 of FIG. 1. The lighting device or surface emitter 100 may include a mixing box 110. The lighting device or surface emitter 100 may also include a light source 130 in the mixing box 110. The light source 130 may be or may include one or more LEDs. The light source 130 may be embedded, bonded, or otherwise connected to the mixing box 110, for example, by inserting the light source 130 into an opening in the surface of the surface emitter 100 opposite the light exit surface 120. The light source 130 may be bonded or connected to the mixing box 110 by molding or gluing. The walls of the mixing box 110 may be configured to reflect light from the light source 130 back into the mixing box 110.

[0015] The lighting device or surface emitter 100 may further include a transparent layer 140. The transparent layer 140 may be silicone. The transparent layer 140 may be adjacent to the light source 130. In some embodiments, the transparent layer 140 may be directly adjacent to the light source 130 such that there is no air gap between the light source 130 and the transparent layer 140. This may allow more light to exit through the light exit surface 120. The transparent layer 140 may be molded into the mixing box 110. The transparent layer 140 may spread the light from the light source 130 laterally into the mixing box 110. The transparent layer 140 may be optically coupled to the light source 130 to enhance light extraction.

[0016] The lighting device or surface light emitter 100 may further include a light diffusion layer 150. The light diffusion layer 150 may be adjacent to the transparent layer 140. The transparent layer 140 and the light diffusion layer 150 may fill the mixing box 110. The light diffusion layer 150 may be a partially transparent light scattering layer. The light diffusion layer 150 may be made of silicone. The light diffusion layer 150 may be made of transparent white particles. The light diffusion layer may be made of silicone filled with TiO2 particles, for example. The shape of the light diffusion layer 150 may be formed by molding or casting. The light diffusion layer 150 may adapt the lateral luminance distribution of the light from the light source 130. Since the light from the light source 130 may be stronger when it is closest to the light source 130, as shown in FIG. 2, the light diffusion layer 150 may be thicker closer to the light source 130 to laterally distribute the light from the light source 130. The transparent layer 140 may be thinner closer to the light source 130 to accommodate the thicker positions of the light diffusing layer 150, and thicker closer to the wall of the mixing box 110 to accommodate the thinner positions of the light diffusing layer 150.

[0017] Alternatively, the transparent layer 140 and the light diffusing layer 150 may each have approximately the same thickness along the entire cross-sectional area of ​​the mixing box 110. In this embodiment, in order to uniformly distribute the light from the light source 130, the diffusing layer 150 may be less transparent (less transparent) closer to the light source 130 where the light is stronger, and more transparent (more transparent) closer to the wall of the mixing box 110 where the light is weaker.

[0018] Light from the light source 130 may pass through the transparent layer 140 and the light diffusing layer 150 and may exit from the light exit surface 120 of the light diffusing layer 150. For example, as described above, the layers 140, 150, including their color, transparency, scattering particles, shape, thickness, and location, may enable Lambertian luminance and a homogenous appearance. The properties of the light diffusing layer 150 and / or the transparent layer 140, including color, transparency, scattering particles, shape, thickness, and location, may be selected to optimize the uniformity and homogeneity of the light distribution from the light source 130. The properties of the light diffusing layer 150 and / or the transparent layer 140 may scatter or distribute the light from the light source 130 in a three-dimensional manner. The layers 140, 150 may also enable the surface emitter to have a lower profile than conventional vehicle lighting fixtures.

[0019] 3 shows the back surface 160 of the surface emitter 100. The back surface 160 is opposite to the light output surface 120 shown in FIG. 1 and FIG. 2. The light source 130 (not visible in FIG. 3) may be attached to and electrically coupled to a rigid printed circuit board (PCB) 170. The light source 130 may be electrically coupled to the flexible PCB 180 via solder pins connected to the rigid PCB 170 and the flexible PCB 180. The rigid PCB 170 may protect the solder pins from bending stress. The rigid PCB 170 and the flexible PCB 180 may provide electricity to power the light source 130.

[0020] FIG. 4 shows a cluster 400 of lighting devices or surface emitters 100. The cluster 400 may include a plurality of lighting devices or surface emitters 100a to 100n. Each lighting device or surface emitter 100 of the plurality of lighting devices or surface emitters 100a to 100n may be or may include the details and embodiments of the lighting device or surface emitter 100 described above. The plurality of lighting devices or surface emitters 100a to 100n may be arranged in a string 200. Each string 200 may be connected via a flexible PCB 180. The flexibility of the PCB 180 may allow the pitch of the string 200 and / or the cluster 400 to be changed. For example, the flexibility of the PCB 180 may allow the string 200 and / or the cluster 400 to be adapted to the curvature of the front of the vehicle. Each string 200 may be driven by at least one driver 190. Each driver 190 may electrically drive and control each lighting device or surface emitter 100 of the string 200 individually, or may drive and control the string 200 collectively.

[0021] FIG. 5 shows a bezel 500. The bezel 500 may be configured to couple to the cluster 400 of the lighting devices or surface emitters 100a-100n. The bezel 500 may be configured to cover a portion of each lighting device or surface emitter 100 in the cluster 400 of the lighting devices or surface emitters 100a-100n. The bezel 500 may be plastic, metal, or a layer of these materials. As shown in FIG. 5, the bezel 500 includes a number of openings 410a-410n. The openings 410a-410n of the bezel 500 may be formed by molding. The openings 410a-410n may be configured to be aligned with the lighting devices or surface emitters 100a-100n, allowing light emitted from the lighting devices or surface emitters 100a-100n to exit through the openings 410a-410n. The light coming out of the openings 410a-410n may be visible to other vehicles and pedestrians. The lighting device or surface light display may include the bezel 500 and the cluster 400 of the lighting devices or surface light emitters 100a-100n on the front of the vehicle and may function as a daytime running light or a signal light. The shape of the openings 410a-410n may affect the shape of the visible light emission. The shape of the openings 410a-410n may be the same shape as the mixing box 110 of the lighting device or surface light emitter 100. Or, the shape of the openings 410a-410n may be different or unique. The entire surface adjacent to the lighting devices or surface light emitters 100a-100n, or a section of the bezel 500, may be white to reflect the light from the light source 130 of the lighting device or surface light emitter 100. By reflecting light back into the mixing box 110, the bezel 500 can recycle light from the light source 130 within the mixing box 110, thereby increasing optical efficiency and making the light appear more intense.

[0022] 6 is a perspective view of a surface emitter display 610. The display 610 may include a cluster 400 of lighting devices or surface emitters 100a-100n, which is coupled to a bezel 500. A grid 600 may be used to couple the cluster 400 to the bezel 500. The grid 600 may be molded from plastic. The grid 600 may be screwed or otherwise connected to the bezel 500. FIG. 7 is a close-up view of a section of the grid 600 that presses the lighting device or surface emitter 100n against the bezel 500.

[0023] 8A illustrates an exemplary lighting device or surface emitter at various stages of a first method of manufacturing the lighting device or surface emitter. At 810, the light source 130 coupled to the rigid PCB 170 may be inserted into the mixing box 110. At 820, the transparent layer 140 may be molded in the mixing box 110. The transparent layer 140 may be vacuum formed. The light source 130 may be in optical contact with the transparent layer 140 with no air gap between the light source 130 and the transparent layer 140. At 830, the light diffusing layer 150 may be dispensed into the mixing box 110. In some embodiments, the light diffusing layer 150 may be molded or cast to form its shape before being dispensed into the mixing box 110.

[0024] 8B illustrates an exemplary lighting device at various stages of a second method of manufacturing a lighting device or surface emitter. At 840, the transparent layer 140 and the mixing box 110 are provided to a mold 842. At 850, the light source 130 coupled to the rigid PCB 170 may be inserted in a liquid state into the transparent layer 140. The transparent layer 140 may be molded. At 860, the light diffusing layer 150 may be dispensed into the mixing box 110. In some embodiments, the light diffusing layer 150 may be molded or cast to form its shape before being dispensed into the mixing box 110.

[0025] 9 is a cross-sectional view of a lighting device or surface emitter 100 electrically coupled to a flexible PCB 180. The pins 910 connected to the rigid PCB 170 may be connected and soldered to the flexible PCB 180. The pins 910 may be soldered to the flexible PCB 180 by wave soldering. In this manner, the light source 130 may be electrically coupled to the flexible PCB 180. Each surface emitter 100 may have its own rigid PCB 170, which allows each surface emitter 100 to be electrically driven and controlled individually.

[0026] FIG. 10 is a flow chart of a method for manufacturing a lighting device or surface emitter display 1100 (1000).

[0027] At 1010, a light source may be inserted into the mixing box. The mixing box may be shaped. The shape of the mixing box may be, but is not limited to, triangular, square, rectangular, or circular. The mixing box may be low profile, which may be ideal or required for use in front-of-vehicle displays. The low profile of the mixing box and lighting device or surface emitter reduces the volume and weight of the surface emitter display.

[0028] At 1020, a transparent layer may be molded within the mixing box. The transparent layer may be molded adjacent to the light source. The transparent layer encapsulates the light source.

[0029] At 1030, a light diffusing layer may be dispensed into the mixing box. The light diffusing layer may be thicker directly above the light source and thinner at the outer edge toward the mixing box. The light diffusing layer may fill the mixing box along with the transparent layer. The transparent layer may laterally diffuse the light before it reaches the light diffusing layer. The light diffusing layer may further diffuse the light. Without the transparent layer, the light from the light source may be overly diffused or diffused too quickly. The variation in thickness of the light diffusing layer and the thickness of the transparent layer along the lateral dimension of the mixing box may allow the transparent layer and the light diffusing layer to transmit the light from the light source homogenously and uniformly. The mixing box may reflect the light from the light source back to the transparent layer and the light diffusing layer, intensifying the light and making the light appear homogenous.

[0030] At 1040, the light source may be electrically coupled to at least one PCB. The at least one PCB may include a rigid PCB electrically coupled to a flexible PCB. The flexible PCB may be electrically coupled (at 1050) to a driver. The driver may send signals to the flexible PCB and the rigid PCB to electrically control the light source in the mixing box. Further, the driver may be communicatively coupled to a bus system, and the driver may be controlled via the bus system to control the light source in the mixing box.

[0031] FIG. 11 is a diagram of an exemplary lighting device or surface emitter display system 1100 that may incorporate one or more of the embodiments and examples described herein. The surface emitter display system 1100 shown in FIG. 11 includes a data bus system 1110, a power supply 1120, at least one driver 1130, and at least one light source 1140. Each light source 1140 may be a light source disposed in a mixing box of the lighting device or surface emitter. Although FIG. 11 shows three drivers 1130 and three light sources 1140, the surface emitter display system 1100 may include any number of drivers 1130 and light sources 1140.

[0032] The power supply 1120 may have an input (terminal) that accepts power from the vehicle. The data bus system 1110 may have inputs / outputs (terminals) that can exchange data between the vehicle and the lighting device or surface emitter display system 1100. For example, the lighting device or surface emitter display system 1100 may accept indications from other locations in the vehicle, such as an indication that the vehicle is on, the location of the vehicle, or a signal that the vehicle is turning, and may transmit feedback to other locations in the vehicle as desired. The bus system 1110 may provide additional data to the lighting device or surface emitter display system 1100 or other locations in the vehicle. The additional data may relate, for example, to environmental conditions (e.g., time of day, rain, fog, or ambient light level), vehicle status (e.g., parked, moving, driving speed, or driving direction), and the presence / location of other objects (e.g., vehicles or pedestrians). The driver 1130 in FIG. 11 may be a microcontroller. The driver 1130 may be communicatively coupled to the bus system 1110 .

[0033] The driver 1130 may provide a driving current to power the light source 1140 via the flexible PCB 1150. The bus system 1110 may communicate with the driver 1130. The driver 1130 and the bus system 1110 may be integrated into one integrated circuit (IC). Each light source may be controlled individually, or multiple light sources may be controlled collectively.

[0034] Although the embodiments have been described in detail, those skilled in the art will understand that, in view of the description herein, modifications may be made to the embodiments described herein without departing from the spirit of the disclosed concepts. Therefore, it is not intended that the scope of the disclosure be limited to the specific embodiments shown and described, but the scope of protection is limited only by the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims shall not be interpreted as limiting the scope.

Claims

1. 1. A cluster of lighting devices, comprising: a plurality of lighting devices electrically coupled to each other; Each lighting device is Mixing box and a light source embedded in the mixing box; a transparent layer adjacent to the light source; a light diffusing layer adjacent to the transparent layer; A cluster of lighting fixtures.

2. The device cluster of claim 1 , wherein the light diffusing layer is thicker directly adjacent the light source and thinner closer to the walls of the mixing box.

3. The device cluster of claim 1 , wherein the light diffusing layer is more transparent closer to the walls of the mixing box and less transparent directly adjacent the light source.

4. The device cluster of claim 1 , wherein the light diffusing layer is configured to scatter light from the light source in three dimensions.

5. The device cluster of claim 1 , wherein each lighting device of the plurality of lighting devices has at least one of the following shapes: rectangular, square, circular, or triangular.

6. The device cluster of claim 1 , wherein each lighting device of the plurality of lighting devices is configured to be individually electrically controlled.

7. A plurality of surface light emitters, each of the plurality of surface light emitters including a mixing box, a light source embedded in the mixing box, a transparent layer adjacent to the light source, and a light diffusion layer adjacent to the transparent layer; at least one circuit board electrically coupled to at least one surface emitter of the plurality of surface emitters; a bezel including at least one aperture coupled to the plurality of surface emitters; A display having:

8. The display of claim 7 , wherein surfaces of the bezel adjacent to the plurality of surface emitters are configured to reflect and recycle light from the light sources back into the mixing box.

9. The display of claim 7 , wherein at least one of the circuit boards is flexible.

10. The display of claim 7 , further comprising at least one driver unit electrically coupled to at least one of said circuit boards.

11. The display of claim 10 , further comprising a bus system communicatively coupled to at least one of the driver units.

12. The display of claim 7 , wherein each surface emitter of the plurality of surface emitters is individually controlled.

13. The display of claim 7 , further comprising a grid configured to press the plurality of surface emitters against the bezel.

14. The display of claim 7 , wherein the light diffusing layer is configured to scatter light from the light source in three dimensions.

15. 1. A method of manufacturing a lighting device display, comprising the steps of: Producing a lighting device by inserting a light source into a mixing box, molding a transparent layer in the mixing box, and dispensing a light diffusing layer into the mixing box; electrically coupling one or more of said lighting devices to each other; A method for providing the same.

16. The method of claim 15 , further comprising electrically coupling the light source to a circuit board.

17. 17. The method of claim 16, further comprising electrically coupling the circuit board to a driver that is communicatively coupled to a bus system.

18. The method of claim 15 , further comprising connecting one or more of the lighting devices to a bezel that includes at least one opening.

19. The method of claim 15 , wherein the light diffusing layer is configured to scatter light from the light source in three dimensions.

Images