Good diffuse lighting and pattern effects on automotive surface panels

Abstract

The present invention relates to an automotive body panel illumination system designed to achieve the whitest diffuse appearance with maximum light intensity transmission. The automotive light emitting panel system includes a light emitting unit configuration defined by an anti-fog diffusive coating applied to a light-transmitting substrate. A corresponding masked cover lens is patterned with a bleed gap. The bleed gap is configured to transmit incident light directly through the patterned optical configuration and to operate the light emitting unit in both hidden and illuminated modes.

Description

[Technical Field]

[0001] The present invention relates to diffused light formulations and light pattern effects for automotive plastic panels. More specifically, the present invention relates to a mask construction coated along the surface panel or cover lens of an automotive light emitting unit to provide a "ghost effect" transition from a hidden appearance to a lit appearance for road or sign lighting. [Background technology]

[0002] In the automotive field of vehicle lighting, manufacturers are seeking improved luminous effects for illumination and signage functions, and are seeking further technological improvements to achieve strong luminous and aesthetic effects. Certain vehicle signage applications (e.g., daytime running lights (DRLs)) require high-intensity lighting with high uniformity to overcome common concerns associated with LED-based lighting, which typically exhibit poor uniformity and hot spots.

[0003] Among improvement goals, automobile manufacturers are seeking strong, diffuse white lighting that provides lighting units whose visible appearance when lit is different from the unit's appearance when it is off, with the potential for a pattern that is visible when the lighting unit is activated. Additionally, automobile manufacturers have sought strong, diffuse light formulations that are clearly visible along plastic panels between the hidden and lit modes of automotive lighting units. To date, manufacturers have relied on applying particulate additives suspended in a light-transmitting medium to achieve this white, diffuse appearance. This approach has produced unsatisfactory results, resulting in a grayish "milk bottle look" rather than a crisp, uniform appearance of strong white.

[0004] Because these traditional approaches to achieving a balance between diffusion uniformity and luminous intensity have significant drawbacks in vehicle applications (e.g., marking lights) where high uniformity is required, designers have applied diffusion techniques such as films, surface glazes, layered coatings, doped optical elements, doped suspensions, or impregnation of optically transmissive media with special optical filters to correct or reduce non-uniform luminous intensity and hot spot effects. While such approaches improve uniformity, they also result in loss of light intensity due to scattering or other mechanisms, often resulting in significant light loss.

[0005] Therefore, there is a need in the automotive field for LED-based lighting units with high light uniformity, strong light diffusion, milky white effect, and aesthetic design adaptability to create a high-end appearance at low cost. The formulation of unique diffusion compositions through the light emission of panels and covers can solve and achieve the challenges required by industry and the commercial sector. Summary of the Invention

[0006] Therefore, it is an object of the present invention to overcome, among other things, the above-mentioned shortcomings of the prior art. One object of the present invention is to provide a good automotive solution that provides strong white lighting through a "ghost effect" technique. Another object is to produce highly uniform lighting for signage applications, including DRL applications, that require lighting patterns with high luminous intensity and high uniformity.

[0007] A further object is to simplify the manufacturing system and process to create a good, cost-effective, uniform light-emitting unit that produces an intense white light for automotive surface panels and good styling along with the cover lens. Also, an essential object is to provide the highest light transmission and whitest unlit appearance for a diffusive coating on a light-transmitting cover or panel.

[0008] In particular, the present invention proposes a lighting feature that has a veiled appearance or "ghost effect" when the light is off, and produces a clear, crisp, white, diffusely luminous appearance when the light is on. The present invention also provides a feature in which the light intensity appears constant and remains uniform without requiring technical complexity or additional processing of the transmissive medium. This is achieved while significantly simplifying the design and fabrication elements.

[0009] When the light-emitting unit is in an off state, the panel lens formed by the pattern mask on the panel lens appears to hide visibility beyond the panel lens range. The superimposed pattern mask with a light-transmitting gap is expected to maintain the same pattern appearance when the light-emitting unit is off or on. However, when the light-emitting unit is in an on or off state, the visible appearance through the panel lens of the light-emitting unit maintains the same pattern, but the visibility to the observer changes between the on / off states. Therefore, the light-emitting unit's lit appearance is different from its unlit appearance. This causes the light-emitting unit to produce the so-called "ghost effect" according to the present invention.

[0010] Also, the light source beam or incident light intensity passing through the gap of the pattern mask may be different from that of other sections of the panel lens gap area, so that a uniform or gradient light intensity can be perceived on the panel lens or light-transmitting surface of the light-emitting unit over the entire illumination area.

[0011] These and other objects of the present disclosure may be achieved by one or more of the following aspects: Accordingly, the present invention proposes:

[0012] 1. A light-emitting panel having light-diffusing properties associated with an automotive lighting or signage system, comprising: a polymer panel of an optically transparent medium; a seal coat layer in contact with an outer surface of the polymer panel; a light-blocking mask in contact with the seal coat, the light-blocking mask including a pattern with a plurality of bleed gaps formed by a laser ablation process; and an anti-fog diffusing coating in contact with the opposite side of the outer surface.

[0013] An alternative embodiment of the lighting panel wherein the seal coat layer is pre-applied to or already incorporated into the polymer panel during manufacture of the polymer panel.

[0014] An alternative embodiment of the light emitting panel, wherein the composition of the polymer panel is formed from a polycarbonate (PC) or polymethyl methacrylate (PMMA) based material.

[0015] An alternative embodiment of the light-emitting panel in which the light-shielding mask composition is superimposed to a thickness (T) of about 12 microns to 15 microns (0.012 mm to 0.015 mm).

[0016] An alternative embodiment of the light emitting panel in which a plurality of bleed gaps are formed in the light blocking mask from the ablation process.

[0017] In an alternative embodiment of the light emitting panel, the anti-fog diffusing coating has a thickness (T) or layer depth of about 8 to 15 microns (0.008 mm to 0.015 mm).

[0018] In an alternative embodiment, the lighting panel having light diffusing properties is incorporated as part of an assembly or lighting unit for an automobile.

[0019] An alternative embodiment of the light emitting panel, wherein the seal coat layer overlies a light blocking mask and a plurality of bleed gaps along the polymer panel.

[0020] An alternative embodiment of the lighting panel, wherein the seal coat layer is a polyurethane-based material along the outer surface side of the polymer substrate.

[0021] An alternative embodiment of the lighting panel is configured to generate incident light that is free of hot spots and that is substantially uniform along a pattern in which multiple bleed gaps are formed when activated by multiple light sources of associated lighting units.

[0022] An alternative embodiment of the lighting panel is configured to produce a "ghost effect" characteristic to an observer, presenting a visible impression when the associated lighting unit is turned on and a different impression when the associated lighting unit is turned off.

[0023] 1. A light-emitting panel for a lighting system for a motor vehicle, comprising:

[0024] 1. A light emitting panel comprising: a polymer panel of a light-transmitting substrate; a seal coat layer in contact with an exterior side of the polymer panel; a light diffusing coating formulation in contact with the same side or opposite side as the exterior side; a mask coat having light modifying properties superimposed on the seal coat layer, the mask coat including a pattern having a plurality of bleed gaps created from an ablation process; and a plurality of light sources configured to transmit light through the plurality of bleed gaps after propagating through the light diffusing coating formulation, the polymer panel, and the plurality of bleed gaps between the interior side and the exterior side.

[0025] A light-emitting panel, comprising:

[0026] 1. A light emitting panel comprising: a light-transmitting polymer substrate; an anti-fog diffusing coating formulation along an inner surface side of the polymer substrate, the anti-fog diffusing coating formulation performing anti-fog and light planarizing functions in an integrated layer configured to provide an anti-fog diffusion value and a predetermined light diffusion value to an observer at a specific light emission intensity; a mask coat of a light modifying composition applied along an outer surface side or an inner surface side of the polymer substrate; and a plurality of bleed gaps in the mask coat configured to receive a plurality of beams of diffused light transmitted through the anti-fog diffusing coating formulation, the bleed gaps having moisture hiding properties and light diffusing properties, wherein the plurality of bleed gaps are formed in the mask coat by a laser ablation process, the diffused light being configured to be modified or blocked during transmission through the mask coat and the polymer substrate, and the diffused light being adapted to traverse the plurality of bleed gaps, i.e., unobstructed areas, of the light emitting panel.

[0027] An alternative embodiment of the light emitting panel, wherein the anti-fog diffusive coating on the inner surface of the polymer substrate has a thickness of about 8 microns to about 15 microns (0.008 mm to 0.015 mm).

[0028] An alternative embodiment of the light emitting panel in which the light-shielding mask composition is superimposed at a thickness (T) of about 12 microns to 15 microns (0.012 mm to 0.015 mm).

[0029] A method for producing a light-emitting panel, comprising:

[0030] 1. A method comprising: developing a polymer panel of a light-transmitting substrate; applying a seal coat layer to an exterior side of the polymer panel; applying a light-diffusing coating formulation to the same side or opposite side as the exterior side; applying a mask coat having light-altering capabilities in superposition with the seal coat layer or a side of the polymer panel; forming a plurality of bleed gaps containing a pattern in the mask coat having light-altering capabilities from an ablation process; providing a plurality of light sources that transmit light through the plurality of bleed gaps; and propagating the light-diffusing coating formulation through the polymer panel and the plurality of light sources configured to transmit light through the plurality of bleed gaps between the interior side and the exterior side.

[0031] A method for producing a light-emitting panel, comprising:

[0032] 1. A method comprising: developing a polymer panel of a light-transmitting substrate having a seal coat layer applied thereto; applying a light-diffusing coating formulation on the same side as or opposite to an exterior side; applying a mask coat having light-altering properties superimposed along an interior surface or the exterior side; forming a plurality of bleed gaps containing a pattern in the mask coat having light-altering properties from an ablation process; and providing a plurality of bleed gaps adapted to transmit ambient light or transmitted light through the light-diffusing coating formulation and the polymer panel between the exterior side and the interior side.

[0033] Some descriptions contained herein refer to components that are "configured" or "adapted" to function in a particular manner. In this regard, such components are "configured" or "adapted" to embody particular properties or functions in a particular manner, and such descriptions are structural descriptions as opposed to descriptions of intended use. More specifically, references herein to how a component is "configured" or "adapted" refer to the existing physical condition of the component and should therefore be interpreted as express descriptions of the structural characteristics of the component.

[0034] Changes and modifications can be made to the above-described structures without departing from the concepts of the present invention. The above-described embodiments and examples should be understood as non-limiting, as other embodiment variations may exist within the present invention as shown and described herein. Furthermore, such concepts are intended to be covered by the following claims, unless those claims expressly state otherwise by their language.

[0035] The accompanying drawings, which embody and constitute a part of this specification, and together with the description, illustrate various embodiments and explain these embodiments. For this reason, the accompanying drawings are not necessarily drawn to scale. Any values ​​or dimensions shown in the accompanying graphs and drawings are for illustrative purposes only and may or may not represent actual or preferred values ​​or dimensions. Where applicable, some or all features may not be shown to aid in the explanation of underlying features. [Brief explanation of the drawings]

[0036] [Figure 1] FIG. 1 is an embodiment and cross section of a light emitting panel according to the present invention. [Figure 2] FIG. 2 is an embodiment of a cross section of a lighting panel showing an alternative construction layup laminate according to the present invention. [Figure 3A]FIG. 3A is a sample embodiment of a lighting panel showing a perspective view of the "ghost effect" in the hidden (invisible) or unlit mode according to the present invention. [Figure 3B] FIG. 3B is a sample embodiment of a lighting panel showing a perspective view of the "ghost effect" in visible or lit mode according to the present invention. [Figure 4] FIG. 4 is an embodiment of a cross section of a lighting panel showing an alternative construction layup laminate according to the present invention. [Figure 5] FIG. 5 is a non-limiting illustrative embodiment of an ablation mask pattern applied to a light emitting panel according to the present invention. [Figure 6] FIG. 6 is a non-limiting example of an ablation mask pattern that can be applied to a light-emitting panel according to the present invention. [Figure 7] FIG. 7 is a non-limiting example of an ablation mask pattern that can be applied to a light-emitting panel according to the present invention. [Figure 8] FIG. 8 is a non-limiting example of an ablation mask pattern that can be applied to a light-emitting panel according to the present invention. [Figure 9] FIG. 9 is a non-limiting example of an ablation mask pattern that can be applied to a light-emitting panel according to the present invention. [Figure 10] FIG. 10 is a non-limiting example of an ablation mask pattern that can be applied to a light emitting panel according to the present invention. [Figure 11] FIG. 11 is a non-limiting example of an ablation mask pattern that can be applied to a light-emitting panel according to the present invention. [Figure 12] FIG. 12 is a non-limiting example of an ablation mask pattern that can be applied to a light-emitting panel according to the present invention. [Figure 13] FIG. 13 is a non-limiting example of various shapes and optical features that may be embedded in a substrate and applied to a lighting panel according to the present invention. [Figure 14]FIG. 14 is a non-limiting example of various shapes and optical features that may be embedded in a substrate and applied to a lighting panel according to the present invention. [Figure 15] FIG. 15 is a non-limiting example of various shapes and optical features that may be embedded in a substrate and applied to a lighting panel according to the present invention. [Figure 16] FIG. 16 illustrates an exemplary flow chart method for making a light diffusion panel system according to the present invention. [Figure 17] FIG. 17 illustrates an alternative embodiment of an exemplary flow chart method for making a light diffusion panel system according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0037] The following description, taken in conjunction with the accompanying drawings, is intended to illustrate various embodiments of the disclosed subject matter and is not necessarily intended to represent a particular selected embodiment. In certain instances, the description may include specific details for the purpose of providing an understanding of the disclosed embodiments. However, it will be apparent to those skilled in the art that the disclosed embodiments may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form so as not to obscure the concepts or design diversity of the disclosed subject matter.

[0038] It should be understood that terms such as "front / forward / front", "rear / rear / rear", etc., that may be used herein merely indicate points of reference and do not necessarily limit embodiments of the present disclosure to a particular orientation or configuration. Furthermore, terms such as "first", "second", "third", etc., merely identify one of multiple parts, components, and / or points of reference disclosed herein and, similarly, do not necessarily limit embodiments of the present disclosure to a particular configuration or orientation.

[0039] Furthermore, terms such as "about," "approximately," "approximately," "a small amount," and similar terms generally refer to a range that includes, or any value therebetween, the value specified within a margin of 20 percent, 10 percent, or preferably 5 percent in certain embodiments.

[0040] In the automotive field of vehicle lighting, automobile manufacturers are seeking to improve the luminous effect of lighting and sign functions and seek further technological improvements to achieve luminous and aesthetic effects that satisfy vehicle buyers and mutually improve design satisfaction ratings, which in turn enhance the manufacturers' brand image in a cost-effective manner.

[0041] A common existing concern with light-emitting diodes (LEDs) is that they tend to produce highly directional light, resulting in poor uniformity and hot spots. Because high luminous intensity with high uniformity is required for certain vehicle marking applications (e.g., daytime running lights (DRLs)), a common existing concern with LEDs is that they tend to produce highly directional light, resulting in poor uniformity and hot spots.

[0042] Among the improvement goals, automobile manufacturers and customers are seeking strong, diffused white lighting with a "ghost effect" technique. The "ghost effect" technique provides a lighting unit with an on-appearance that creates a visible impression or is unexpectedly different from the off-appearance of the lighting unit. For example, when off, the lighting unit may have a plain, glossy black appearance or a dark background appearance. The dark background appearance gives the observer a hidden view or an impression different from when the lighting device is turned on. This can result in a uniform lighting impression when on. Additionally, when the lighting unit is activated, a lighting pattern can appear. Such a lighting pattern can be purely decorative, include a manufacturer's logo, or perform an indicator function such as a nighttime positioning light. While there may be various competing solutions in the field that create a "ghost effect" in the field, there remains a demand for continuous improvements or refinements to further solutions.

[0043] Another specific improvement sought by automakers is the characteristic of bright white, uniform illumination. Automakers' request is for an intense white formulation that is visible along the automotive plastic panels between the "ghost effect" hidden mode and the illuminated mode of the light-emitting unit. To achieve this diffuse white appearance, manufacturers have often resorted to embedding or suspending particulate additives in a light-transmitting medium, but these have not provided satisfactory results, resulting in a grayish "milk bottle look" rather than a bright white, crisp, uniform appearance.

[0044] As a result, for vehicle applications requiring a high degree of uniformity (e.g., marking lights), traditional constraints and practices have significant drawbacks. These constraints have led designers to apply diffusion techniques, such as films, surface polishing, layered coatings, doped optical elements, doped suspensions, or impregnation of optically transmissive media with special optical filters, to correct or reduce non-uniform luminous intensity and hot spot effects. These traditional approaches result in loss of light intensity through scattering or other mechanisms, often resulting in significant light loss.

[0045] Therefore, there is a need in the automotive field for an LED-based lighting unit with high light uniformity, strong light diffusion, milky white effect, and aesthetic design adaptability for achieving a high-end appearance at low cost. Therefore, embodiments of the present invention address the goal of achieving a lighting effect that provides uniform illumination with bright or strong white light for good styling along cover lenses and automotive surface panels through a good and cost-effective approach.

[0046] To provide additional background on the simplest concept of a lighting product, a lighting unit typically includes an enclosure frame, a lenticular body, or a cover lens with a light source within the enclosure. Manufacturing a lighting unit for an automobile involves securing a cover lens to the enclosure of the lighting unit. The lenticular body is placed into an opening in the enclosure frame, closing it to form the housing of the lighting unit. Often, when powered on, emitted light shines through the cover lens or lenticular body. It is the emission of light through the panel or lens cover that creates a diffusing configuration to address and solve the objectives sought through various embodiments of the present invention.

[0047] A lighting unit for an automobile is intended to refer interchangeably to a rear light of a vehicle or a front light of a vehicle, or to be referred to interchangeably as a headlamp or headlight. As is well known, a lighting unit for an automobile may function as an exterior light of the vehicle having an illumination or indication function directed toward the exterior of the vehicle. The lighting unit may potentially function as a position indicator light, a turn signal light, a daytime running light (DRL), a brake light, a fog light, a backup light, a low beam headlight, a high beam headlight, or a combination thereof, by way of example.

[0048] LED sign assemblies are currently being used with great practical effect. In the automotive industry, many motor vehicles today use LED-based lighting assemblies. Much of the engineering work related to these vehicle lighting assemblies has focused on reducing their overall dimensions. Furthermore, LED-based vehicle assemblies typically rely on multiple LED light sources. Each LED light source inherently produces high light intensity at a small beam angle. Therefore, many LED-based lighting assemblies, including "low-profile" assemblies, produce individual light "hot spots" associated with each LED light source. The present invention addresses the goal of how to configure and design LED-based vehicle lighting units and assemblies to produce highly uniform illumination for sign applications, including DRL applications, where high luminous intensity and uniform lighting patterns are required.

[0049] 1, light source 1 represents an emitting source of electromagnetic radiation or a source of visually perceptible radiant energy (including "visible" light in the electromagnetic spectrum), but may include a broad range or combination of electromagnetic or radiant energies, including x-rays, ultraviolet light, infrared energy, microwaves, the radio spectrum, etc. Light source 1 may include any conventional suitable lighting element source, such as a filament-based or incandescent lamp, a fluorescent lamp, an arclight or gas discharge type light, a light-emitting diode (LED), or other suitable conventional light source. Light source 1 may include a single element or multiple (more than one) lighting elements.

[0050] Highly uniform light is particularly beneficial in many vehicle signage applications (e.g., brake lights, tail lights, daytime running lights (DRLs), turn signals, backup lights, etc.). In certain vehicle signage applications, lighting assemblies capable of producing output light patterns that are both highly uniform and highly luminous are particularly advantageous. For example, certain federal regulations require DRLs to produce highly luminous light patterns, and customers often require that such patterns be produced with high uniformity.

[0051] In FIG. 1, a cross section of a light emitting panel 100 is shown. The light emitting panel 100 may include a cover lens or a lenticular body and may be part of an automotive assembly or lighting device. The light emitting panel 100 includes an optically transmissive medium 30 (hereinafter "substrate") having an anti-fog diffusive coating 10 and a seal coat 20. The seal coat 20 may include a separate layer formed with the substrate 30, or may already be included as an integral part of the optically transmissive medium 30 from the manufacturer. The optically transmissive medium 30 includes a polymer or glassy composition with optically transmissive properties, allowing the beam 11 from the light source 1 to pass through the substrate 30.

[0052] In one embodiment, the optically transmissive medium 30 may comprise a polycarbonate (PC) material or a polymethyl methacrylate (PMMA) material. The optically transmissive medium 30 may include a hard coat, seal coat, or protective layer within the constituent or outer layers of the substrate 30. The anti-fog diffusive coating 10 includes a unique formulation that provides both light-planarizing and anti-fog properties. The formulation is applied to the side of the optically transmissive medium 30 and comprises an essential portion of the light-emitting panel 100. The anti-fog diffusive coating 10 may be applied by means of, but not limited to, spraying, manual or mechanical application, or dipping. In one embodiment, the anti-fog diffusive coating 10 includes an applied body having a thickness (T) of approximately 12 microns to 15 microns (0.012 to 0.015 mm). In an alternative embodiment, the anti-fog diffusive coating 10 may be applied to a thickness (T) value in the range of 8 to 12 microns (0.008 to 0.012 mm) to achieve acceptable results.

[0053] The beam 11 emitted from the light source 1 undergoes a light planarization process while propagating the incident light through the anti-fog diffusing coating formulation 10, providing a balanced, uniform luminous intensity result that meets the goals of the present invention of uniformity and high luminous intensity. The uniform luminous intensity value is consistently within 10% variation along the light output side of the light emitting panel, as measured by known existing methods. To determine the uniformity measurement, the luminous intensity value can be measured from multiple reference positions along the exterior side of the light emitting panel.

[0054] The anti-fog function prevents fogging and unwanted moisture buildup along the surface of the anti-fog diffusive coating 10 by hiding water droplets from view. The primary contribution of the formulation that enables the anti-fog diffusive coating 10's anti-fog function is moisture hiding. While the anti-fog diffusive coating 10 promotes water repellency through its polyurethane-based resin formulation, it primarily acts to hide water droplets from view rather than by absorbing, dispersing, or removing moisture. Hybrid formulation coatings can perform two functions, including a light-planarizing component and an anti-fog component, which are inter-incorporated into the anti-fog diffusive coating 10. Alternatively, a separate coating formulation applied with a secondary coating formulation having an anti-fog component may be used to achieve equivalent results through separate coating layer processes.

[0055] The light-flattening function diffuses light penetration and eliminates hot spots while improving white light intensity. To reduce gloss and provide light-flattening functionality, the anti-fog diffusing coating formulation 10 includes a silica-based matting agent or matting particles added at a concentration of 5-9% by volume. In one embodiment, acceptable results are achieved by mixing the silica-based matting agent or matting particles in a size range of 4-12 microns (0.004-0.012 mm). However, in other embodiments, more suitable results are achieved by mixing the silica-based matting agent or matting particles in a size range of 6-9.5 microns (0.006 mm-0.0095 mm).

[0056] In one embodiment, the anti-fog diffusive coating 10 may be applied to a thickness T in the range of 8 to 15 microns (0.008 to 0.015 mm). In another embodiment, to achieve more desirable luminosity levels required by customers, the anti-fog diffusive coating 10 is typically applied to a thickness T of 12 to 15 microns (0.012 to 0.015 mm).

[0057] Using known modeling techniques (such as Lambertian scattering model phases, specular scattering model phases, Gegenbauer scattering model phases, Gaussian models, or other medium-material-dependent models) derived from optical practice, consistent and reproducible intensity levels can be achieved with measurable characteristics when the appropriate model is applied to each medium (transparent, opaque, milky white, granular transparent, or granular reflective). Note that luminous intensity results are generally a function of the wavelength of the light source, the measured angle of incidence from the light source, measurements along the perimeter span at each angle of incidence, and the thickness of the optically transmissive medium. A uniform light intensity value is one that consistently varies within 10% along the light output side of a light-emitting panel, as measured by known existing methods. To determine the uniformity measurement, light intensity values ​​can be measured from multiple reference locations along the exterior side of the light-emitting panel.

[0058] The seal coat 20 provides a protective top coat against weathering, contaminants, and degradation. The seal coat 20 is preferably a polyurethane-based material, or may be another sealing material. The seal coat 20 is applied directly or indirectly along the sides of the optically transmissive medium 30 and may overlap other intermediate components (i.e., mask pattern layers). The seal coat 20 may be applied by any means, including, but not limited to, spraying, hand or machine application, or dipping.

[0059] The anti-fog diffusive coating 10 includes a chemical formulation that provides anti-fog functionality (moisture masking material) and light-planarizing functionality (light-planarizing technology) in a single application material. Some details of this formulation have been previously disclosed and shared above. The anti-fog diffusive coating 10 includes a composition formed from a polyurethane-based resin and a planarizing additive (preferably 6-9.5 micron (0.006-0.0095 mm) finely divided silica or glass-based particles suspended in a white wavelength pigment) that incorporates light-planarizing properties to promote diffusion and provide matte finish. In an alternative embodiment, the matting agent or matting particles may include polyethylene, polypropylene, PTFE, carnauba, or amide-based waxes in the coating or pigments included in the anti-fog diffusive coating 10. Alternatively, the planarizing additive may include talc or cornstarch to achieve similar performance effects, although such construction materials are not recommended due to their softness and lack of durability.

[0060] 1, 2, and 4, the LED light source 1 transmits a beam 11 directly through the anti-fog diffusing coating 10 and the respective light emitting panel embodiment, which results in a uniform light pattern effect as seen by the observer P that is consistent with photometric characteristics measurable by and derived from known applied modeling techniques as described above.

[0061] FIG. 2 shows a cross section of a light-emitting panel 200 including the elements of FIG. 1. The light-emitting panel 200 can be incorporated into a cover lens or lenticular body and can be part of an automotive assembly or lighting device. FIG. 2 includes a mask coat 40 and shows that bleed gaps 8 are formed within the surface pattern area of ​​the mask coat 40 after an ablation process on the mask coat 40. The mask coat 40 can be applied to the optically transmissive medium 30 by any means, including, but not limited to, spraying, manual or mechanical application, or dipping. In one embodiment, the mask coat 40 can be applied to a thickness (T) value of approximately 12 microns to 15 microns (0.012 to 0.015 mm) for best results. For alternative embodiments, the mask coat 40 can be applied at a thickness (T) value based on other laser ablation resolution settings tailored to time-performance results. Developmental testing has shown that this critical application thickness for the mask coat 40 is essential to effectively block bleed light from passing through the optically transparent medium 30 and to avoid gray shadows or undesirable spurious color casts that obscure the appearance upon viewing.

[0062] The LED light source 1 transmits a light beam 11 directly through the anti-fog diffusing coating 10 and substrate 30, resulting in an illumination effect from the formed bleed gap 8 as seen by an observer P. The illumination effect is consistent with luminous intensity measurements obtained using known applied modeling techniques as described previously in this specification. The uniform light intensity values ​​are consistently within 10% variation along the light output side of the light emitting panel as measured by known existing methods. To determine the uniformity measurement, light intensity values ​​can be measured from multiple reference locations along the exterior side of the light emitting panel.

[0063] An ablation process is the removal of material from a deposit or layer of the mask coat 40 by an excited wavelength or high intensity light beam process, such as, but not limited to, a laser (light amplification by stimulated emission of radiation). The ablation process is not limited to laser-based material removal means, but may also be other material-destructive-removal processes, such as mechanical abrasion, ultrasonic, thermal, ultraviolet wavelength, or vibration processes. In one embodiment, the ablation applies a pattern removal resolution of approximately 0.3 mm at 0.3 mm intervals. In alternative embodiments, laser ablation can apply fine or coarse resolution patterns of ablation, depending on the wavelength of the applied laser.

[0064] 3A and 3B show product sample depictions of what is depicted from the embodiment of FIG. 2, from hidden to lit appearances, respectively, showing what an observer P can see along the light-emitting panel 200 when unlit (FIG. 3A), versus what can be seen through the bleed gaps 8 of the mask coat 40 in the associated bleed areas 88 when the light-emitting panel 200 is actively lit (FIG. 3B). The bleed areas 88 may represent sections of multiple bleed gaps 8 that may represent various pattern configurations.

[0065] FIG. 3A shows how light-emitting panel 200 may appear to observer P in an unlit state. In the unlit state, occlusion sections 77 along the panel surface conceal and obscure the forming pattern and bleed gaps 8, which are obscured from view in mask coat 40 when the panel remains unlit. FIG. 3B shows light-emitting panel 200 in an illuminated state, along with bleed area 88 patterns and bleed gaps 88, which reveal the pattern features from their hidden ghost state and become discernible to observer P from mask coat 40 when illuminated. While mask coat 40 preferably represents a light-blocking composition, mask coat 40 is not limited to light-blocking properties and may, in various embodiments, be opaque or include iridescent materials to enhance lighting effects or adjust light transmission as desired.

[0066] Figure 4 shows a cross section of a light emitting panel 400 similar to the element of Figure 2. However, the embodiment of Figure 4 includes the variation that the mask coat 40 and the seal coat 20 have interchangeable layer positions. The light emitting panel 400 can be incorporated into a cover lens or lenticular body and can be part of an automotive assembly or lighting device. In the embodiment of Figure 4, the seal coat 20 is superimposed on the mask coat 40.

[0067] Figures 5, 6, 7, 8, 9, 10, 11, and 12 illustrate various embodiments with a good pattern 42 of bleed gaps 8 obtained by applying laser ablation to a mask coat 40. As various exemplary embodiments show, many non-limiting pattern effects can be achieved by using the ablation process to modify actual graphic examples of fine gradations, dots, geometric shapes, or superimposed patterns 42 to provide strong diffusion with additional style, some decorative features, or lighting effects. While the resolution of the created pattern 42 varies depending on the embodiment, in one embodiment, the pattern bleed areas 88 of the bleed gaps 9 are created with a resolution of 0.3 mm and spaced 0.3 mm apart. The alternative embodiment of Figure 12 illustrates a non-limiting example in which a laser ablation pattern includes a combination of a smoked optically transmissive medium 30 and a mask coat 40, and a sample is created on a surface panel 200. Other examples of pixel patterns that can be created along the surface panel 200 may be observable in an unlit state and in a backlit state, as shown in Figures 10 and 11, respectively.

[0068] The balance between light diffusion characteristics and white light luminosity can be altered by the above-mentioned light intensity measurements and the achievable luminosity effect aspects, which are proportional to certain variables and factors (as a function of light source wavelength, incident angle measurements from the light source, measurements along the circumferential span at each incident angle, thickness and type of light-transmitting medium: transparent medium, opaque medium, milky white medium, granular transparent medium, and granular reflective medium). Some of the listed factors are based on the type of light-transmitting medium 30 (e.g., transparent, opaque, milky white, granular transparent, granular reflective) with various medium thicknesses, with special treatments applied, or with measured incident refraction angles, or with operating temperatures measured under Gaussian, specular, Lambertian, or Gegenbauer scattering model blending approaches.

[0069] Figures 13-15 illustrate various embodiments of an optically transmissive medium 30 and the overall resulting effects. The optically transmissive medium 30 may include, but is not limited to, imprints, surface etching, bubbles, cracks, molding additives, tints, smoke, colorants, or optical effects. As a non-limiting example, Figure 13 illustrates a patterned feature in the substrate 30 to enhance the optical effect or light dispersion. Figure 14 illustrates bubbles, texture dispersions, or buried features 16 within the substrate 30. Figure 15 illustrates a wave or surface etching pattern 24 in the substrate 30 to further enhance the optically transmissive effect.

[0070] FIG. 16 illustratively illustrates an embodiment of the present invention and describes a process or method 1000 for fabricating a light diffusion panel system. Accordingly, in the method 1000, a substrate or optically transmissive medium 30 may form an embodiment of a light-emitting panel. For example, two blocks shown consecutively in various method embodiments may actually be performed substantially simultaneously. Also, associated blocks may be performed in reverse order depending on the functionality involved. It should also be noted that each block of a block or flowchart diagram, and combinations of blocks in a block or flowchart diagram, may be realized by both manual and automated systems that perform the specified functions through operations or that implement a combination of special-purpose hardware and control instructions.

[0071] In block 1010, an optically transmissive medium or substrate 30 of a polymeric material is provided. In block 1020, an anti-fog diffusive coating formulation 10 is applied along the side of the optically transmissive medium or substrate 30. In non-limiting embodiments, the side can be the exterior side, interior side, or front side of the substrate 30. In block 1030, a light-shielding or opaque mask (optical modification mask) 40 can be applied over the hard coat layer 20 or the side of the optically transmissive medium or substrate 30. In block 1032, an ablation process can be performed on the light-shielding or opaque mask (optical modification mask) 40.

[0072] At block 1034, a light source may be activated from the interior side 3 of the optically transmissive medium or substrate 30. The light source is configured to transmit a light beam 11 through the light-blocking or opaque mask 40 and the plurality of bleed gaps 8 to the exterior side 5 of the optically transmissive medium or substrate 30. At block 1036, the activated light source 1 may be configured to transmit the light beam 11 through the plurality of bleed gaps 8 and to be visible to a viewer P at the exterior side 5 of the optically transmissive medium or substrate 30 with a predetermined diffusivity and light intensity value based on the measured anti-fog diffusive coating formulation 10.

[0073] In block 1038, deactivation of light source 1 may be configured to present obscured sections 77 to observer P by obscuring visibility through a plurality of bleed gaps 8 in the exterior side 5 of light transmissive medium or substrate 30. Obscured sections 77 may present a hidden view or different impression of the associated light emitting panel through the observable obscured sections 77 or bleed gaps 8 in an unlit state versus an lit state.

[0074] FIG. 17 illustrates another embodiment of the present invention and describes a process or method 2000 for making a light-transmitting panel system. Accordingly, in method 2000, a substrate or light-transmitting medium 30 may form an embodiment of a light-emitting panel. For example, two blocks shown in succession in various method embodiments may actually be performed substantially simultaneously. Also, associated blocks may be performed in reverse order, depending on the functionality involved. It should also be noted that each block of a block or flowchart diagram, and combinations of blocks in a block or flowchart diagram, may be realized by both manual and automated systems that perform the specified functions through operations or that implement a combination of special-purpose hardware and control instructions.

[0075] In block 2010, an optically transmissive medium or substrate 30 of a polymeric material is provided. In block 2020, an anti-fog diffusive coating formulation 10 is applied along the side of the optically transmissive medium or substrate 30. In non-limiting embodiments, the side can be the exterior side, the interior side, or the front side of the substrate 30. In block 2030, a light-blocking or opaque mask (optical modification mask) 40 can be applied across the side of the optically transmissive medium or substrate 30. In block 2032, an ablation process can be performed on the light-blocking or opaque mask (optical modification mask) 40 to form a bleed gap 8.

[0076] At block 2034, light source 1 may be activated. Light source 1 may be configured to transmit light beam 11 through outer side 5 and inner side 3 of light-transmitting medium or substrate 30 by way of light-blocking or opaque mask 40 and multiple bleed gaps 8. At block 2036, the activated light may be configured to transmit light beam 11 through multiple bleed gaps 8 and appear to observer P at outer side 5 of light-transmitting medium or substrate 30 with predetermined diffusivity and light intensity values ​​based on the measured anti-fog diffusive coating formulation 10.

[0077] In block 2038, the shielding sections 77 may be configured such that deactivation of the light sources or lack of light transmitting through the substrate 30 hides visibility through the plurality of bleed gaps 8 on the exterior side 5 of the substrate 30 as observably measured by the observer P, thereby presenting the shielding sections 77 to the observer P. The shielding sections 77 may present a hidden view or different impression of the associated light-emitting panel (panel lens or cover panel) through the observable shielding sections 77 or bleed gaps 8 in an unlit state versus an lit state.

[0078] Methods 1000 and 2000 show sample embodiments of a fabrication process using a light diffusion panel with hidden and illuminated features while providing a strong luminous effect that meets predetermined light intensity and diffused light values ​​or regulatory measurement requirements, thus providing high quality and good lighting performance while meeting market acceptance at low manufacturing costs.

[0079] The above-described aspects and examples, as shown and described herein, should be understood to be non-limiting. Unless otherwise stated, the dimensions and shapes of the various structures shown herein are not intended to limit the invention, as other dimensions or shapes are possible. Multiple structural components may be provided by a single, integrated structure. Alternatively, a single, integrated structure may be divided into separate components.

[0080] Also, while a feature of the invention may be described with respect to only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments. As will also be understood from the above, the fabrication of the unique structures described herein and their operation also constitute methods in accordance with the present invention.

[0081] Light-emitting panel 100 200 400 LED light source 1 Inner surface position 3 External position 5 Light Beam 11 Anti-fog light diffusion coating 10 Seal Coat Composition 20 Substrate - Light Transparent Media 30 Mask Coat 40 Creation pattern 42 Embedded Optical Features 15 Surface optical features 22 Etched Pattern Optical Elements 24 surface 38 Internal buried features 16 Bleed Gap 8 Breed Area 88 Shielded Section 77 Light-emitting lighting device unit 70 Method for making a luminous diffusion panel system 1000 2000

Claims

1. a polymer panel of a light-transmitting medium; a seal coat layer pre-applied to or already incorporated into said polymer panel; a mask coat in contact with the seal coat layer; an anti-fog diffusive coating formulation in contact with the polymer panel; Equipped with the mask coat includes a pattern having a plurality of bleed gaps formed therein; the plurality of bleed gaps are configured to allow light to pass through the bleed gaps; A light-emitting panel having light-diffusing properties associated with a lighting or signage system for an automobile.

2. The polymer panel comprises polycarbonate (PC) or polymethyl methacrylate (PMMA); The light-emitting panel according to claim 1 .

3. the mask coat is about 12 to 15 microns thick; The light-emitting panel according to claim 1 .

4. a bleed area defined by a plurality of said bleed gaps configured to form a plurality of patterns by an ablation process; The light-emitting panel according to claim 1 .

5. the anti-fog diffusive coating formulation has a thickness of about 8 to 15 microns; The light-emitting panel according to claim 1 .

6. another seal coat layer covers the mask coat and the plurality of bleed gaps along the polymer panel; The light-emitting panel according to claim 1 .

7. the seal coat layer covers the polymer panel below the mask coat and the plurality of bleed gaps; The light-emitting panel according to claim 1 .

8. The seal coat layer is a polyurethane-based material. The light-emitting panel according to claim 1 .

9. the light emitting panel is configured to generate uniform light along the pattern when activated by a light source, with no visible hot spots to a viewer; The light-emitting panel according to claim 1 .

10. The pattern includes a ghost effect feature, the ghost effect feature is configured to cause a bleed area feature to appear to an observer, presenting a visible impression when the associated light-emitting unit is turned on and a different impression when the associated light-emitting unit is turned off; The light-emitting panel according to claim 1 .

11. configured such that emitted light transmitted through the light-emitting panel undergoes a light-flattening process after propagating incident light through an anti-fogging diffusing coating formulation; The light-emitting panel according to claim 1 .

12. The anti-fog diffusing coating formulation comprises a silica-based matting agent or matting particles in a concentration of 5-9% by volume. The light-emitting panel according to claim 1 .

13. further comprising a composition configured to diffuse light passing therethrough and eliminate hot spots; The light-emitting panel according to claim 1 .

14. The lenticular body forms part of the automotive system. The light-emitting panel according to claim 1 .

15. an intense white diffused light configured to provide a uniform light output value that varies within 10% along the circumferential span of the light emitting panel as measured by a known process; The light-emitting panel according to claim 1 .

16. configured such that when light activation is applied to the light-emitting panel from a "ghost effect" state, an intense white diffused light is produced to the observer; The light-emitting panel according to claim 1 .

17. a polymer substrate that is optically transparent; a hybrid coating in contact with the polymer substrate, the hybrid coating performing anti-fog and light planarizing functions in an integrated layer configured to provide a predetermined luminous intensity value and a predetermined light diffusion value to an observer; a mask coat of a light-blocking composition applied to an outer surface of the polymer substrate opposite to the inner surface; a plurality of bleed gaps formed in the mask coat by laser ablation, the plurality of bleed gaps configured to receive a plurality of beams of diffused light transmitted through the hybrid coating; A powered vehicle that uses a light-emitting panel equipped with

18. the hybrid coating in contact with the polymer substrate has a thickness of about 0.008 mm to 0.015 mm; 18. The motor vehicle of claim 17.

19. the mask coat composition is about 0.012 mm to 0.015 mm thick; 18. The motor vehicle of claim 17.

20. providing a polymer panel of light-transmitting substrate; applying an anti-fog diffusive coating to the polymer panel; superimposing a mask coat onto the seal coat layer of the polymer panel; ablating the mask coat by a laser process to form a pattern of bleed gaps; A method for manufacturing a light emitting panel for an automobile, comprising:

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