Lamp system having an optic with two sub-layers of different refractive indices

Abstract

A lamp system (100) including an optic layer (200) with a first optic sub-layer (201) comprising a first optic material having a first refractive index and a second optic sub-layer (201) comprising a second optic material having a second refractive index. The first optic sub-layer (201) is positioned adjacent to and in contact with the second optic sub-layer (202). The first refractive index is different than the second refractive index. A light source layer (300) includes a light source material and at least one light source (320). The optic layer (200) is positioned to receive light emitted from within the light source layer (300).

Description

LAMP IN PRESS OPTICAL SYSTEMTECHNICAL FIELD

[0001] The present application relates generally to a lamp system. More specifically, the present application relates to a lamp system that can be installed on a vehicle.BACKGROUND

[0002] Vehicles often include lamp assemblies to provide illumination. For example, lamp assemblies may be used as low beam headlights, high beam headlights, and / or daytime running lights. Also, lamp assemblies are often used in vehicles for decorative purposes. It is often desirable for lamp assemblies for vehicles to have a minimal depth. However, existing lamp assemblies often include light-emitting devices that are separate from and not integrated with the optics of the lamp assembly, which may increase a thickness of the lamp assembly.

[0003] The inventor has identified numerous deficiencies and problems with the existing technologies in this field. Through applied effort, ingenuity, and innovation, many of these identified deficiencies and problems have been solved by developing solutions that are structured in accordance with the embodiments of the present disclosure, many examples of which are described in detail herein.BRIEF SUMMARY

[0004] In general, embodiments of the present disclosure provided herein include systems, methods, and apparatuses to provide for improved lamp systems.

[0005] In various aspects, a lamp system includes an optic layer. The optic layer may include a first optic sub-layer comprising a first optic material having a first refractive index and a second optic sub-layer comprising a second optic material having a second refractive index. The first optic sub-layer may be positioned adjacent to and in contact with the second optic sub-layer. The first refractive index may be different than the second refractive index. A light source layer may include a light source material and at least one light source. The optic layer may be positioned to receive light emitted from within the light source layer.1077979 / 634524LEGAL02 / 46336458vl

[0006] In various examples, the light source layer, the first optic sub-layer, and the second optic sub-layer are positioned in a stacked configuration.

[0007] In various examples, the at least one light source is embedded within the light source material.

[0008] In various examples, one or more of the first optic material, the second optic material, or the light source material are transparent or semi-transparent polymers.

[0009] In various examples, the first refractive index or the second refractive index is at least 1.1.

[0010] In various examples, at least a portion of structure of the first optic sub-layer and at least a portion of the second optic sub-layer are defined by a single mould of an injection moulding system.

[0011] In various examples, the lamp system comprises a plurality of layers comprising at least the optic layer and the light source layer. There may be no gaps between each of the plurality of layers.

[0012] In various examples, the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a decoration layer. The decoration layer may be positioned adjacent to and in contact with at least one of the light source layer or the optic layer. The decoration layer may be configured to change a property of light emitted from the light source layer.

[0013] In various examples, the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a decoration layer. The decoration layer may be positioned adjacent to and in contact with the light source layer, the light source layer may be positioned between the decoration layer and the optic layer, and the light emitted from the at least one light source of the light source layer may be directed towards the decoration layer and subsequently reflected from the decoration layer and to the optic layer.

[0014] In various examples, the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a decoration layer. The decoration layer may be positioned adjacent to and in contact with the optic layer, the optic layer may be positioned between the decoration layer and the light source layer, and the light emitted from the at least one light source of the light source layer may be2077979 / 634524LEGAL02 / 46336458vldirected towards the optic layer, through the decoration layer, subsequently reflected from the decoration layer and back through the optic layer.

[0015] In various examples, the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a protection layer. The protection layer may be positioned on an exterior of the lamp system and configured to provide chemical, climatic, or mechanical resistance to the lamp system.

[0016] In various examples, the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a decoration layer. The decoration layer may comprise a plurality of zones, a first zone of the plurality of zones may be transparent, and a second zone of the plurality of zones may be semi-transparent or opaque.

[0017] In various examples, the second zone of the plurality of zones is opaque.

[0018] In various examples, the first zone and the second zone are alternatingly arranged to collimate light emitted from the light source layer.

[0019] In various aspects, a method of manufacturing a lamp system is provided. The lamp system may include an optic layer. The optic layer may include a first optic sublayer comprising a first optic material having a first refractive index and a second optic sub-layer comprising a second optic material having a second refractive index. The first optic sub-layer may be positioned adjacent to and in contact with the second optic sublayer. The first refractive index may be different than the second refractive index. A light source layer may include a light source material and at least one light source. The optic layer may be positioned to receive light emitted from within the light source layer. The method may include injecting a first optic material into a mould to form the first optic sub-layer and injecting a second optic material into the mould and onto the first optic sub-layer to form the second optic sub-layer. The first optic material may have a first refractive index when cured and the second optic material may have a second refractive index when cured. The first refractive index may be different than the second refractive index.

[0020] In various examples, the method includes positioning the at least one light source into the mould and injecting the light source material into the mould onto the at3077979 / 634524LEGAL02 / 46336458vlleast one light source to form the light source layer and embed the at least one light source within the light source material.

[0021] In various examples, the method includes injecting a decoration material into the mould and onto the light source layer to form a decoration layer. The at least one light source may be positioned such that light emitted from the at least one light source is directed towards the decoration layer, and the decoration layer may be configured to reflect the light that is received from the at least one light source towards the optic layer.

[0022] In various examples, the method includes injecting a decoration material into the mould and onto the optic layer to form a decoration layer. The at least one light source may be positioned such that the light emitted from the at least one light source is directed towards the optic layer, through the decoration layer, subsequently reflected from the decoration layer and back through the optic layer. The decoration layer may be configured to reflect the light that is received from the at least one light source towards the optic layer.

[0023] In various examples, the method includes injecting a decoration material into the mould and onto the optic layer to form a decoration layer. The decoration material may be a transparent or semi-transparent material. The method may include incorporating an opaque zone onto the decoration layer.

[0024] In various examples, incorporating the opaque zone onto the decoration layer comprises altematingly arranging a plurality of opaque zones with a plurality of transparent or semi-transparent zones of the decoration material.

[0025] The above summary is provided merely for purposes of summarizing some example embodiments to provide a basic understanding of some aspects of the present disclosure. Accordingly, it will be appreciated that the above-described embodiments are merely examples and should not be construed to narrow the scope or spirit of the present disclosure in any way. It will be appreciated that the scope of the present disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.4077979 / 634524LEGAL02 / 46336458vlBRIEF DESCRIPTION OF THE DRAWINGS

[0026] Having thus described certain example embodiments of the present disclosure in general terms above, non-limiting and non-exhaustive embodiments of the subject disclosure are described with reference to the following figures, which are not necessarily drawn to scale and wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. The components illustrated in the figures may or may not be present in certain embodiments described herein. Some embodiments may include fewer (or more) components than those shown in the figures.

[0027] FIGS. 1-17 provide schematic views of at least a portion of a lamp system, in accordance with different example embodiments.

[0028] FIG. 18 provides a flowchart of a method of manufacturing a lamp system, in accordance with an example embodiment.DETAILED DESCRIPTION

[0029] One or more embodiments are now more fully described with reference to the accompanying drawings, wherein like reference numerals are used to refer to like elements throughout and in which some, but not all embodiments of the inventions are shown. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. It is evident, however, that the various embodiments can be practiced without these specific details. It should be understood that some, but not all embodiments are shown and described herein. Indeed, the embodiments may be embodied in many different forms, and accordingly this disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements.

[0030] As used herein, the term “exemplary” means serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion. In addition, while a particular feature may be disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the5077979 / 634524LEGAL02 / 46336458vlother implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes” and “including” and variants thereof are used in either the detailed description or the claims, these terms are intended to be inclusive in a manner similar to the term “comprising.”

[0031] As used herein, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form.

[0032] As used herein, the terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein.

[0033] As used herein, the term “positioned directly on” refers to a first component being positioned on a second component such that they make contact. Similarly, as used herein, the term “positioned directly between” refers to a first component being positioned between a second component and a third component such that the first component makes contact with both the second component and the third component. In contrast, a first component that is “positioned between” a second component and a third component may or may not have contact with the second component and the third component. Additionally, a first component that is “positioned between” a second component and a third component is positioned such that there may be other intervening components between the second component and the third component other than the first component.

[0034] As used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within manufacturing or engineering tolerances. For example, terms of approximation may refer to being within a five percent margin of error.6077979 / 634524LEGAL02 / 46336458vl

[0035] Referring now to FIG. 1 , a schematic view of at least a portion of a lamp system 100 is provided, in accordance with an example embodiment. The lamp system 100 may include a plurality of layers. As will be discussed further, the plurality of layers may comprise an optic layer 200, a light source layer 300, a decoration layer 400, a protection layer 500, or a combination thereof. At least some of the plurality of layers, such as the optic layer 200, the light source layer 300, the decoration layer 400, and / or the protection layer 500, may have at least a portion that is transparent or semitransparent. At least some of the plurality of layers may be opaque, reflective, or diffusing. At least some of the plurality of layers may comprise portions or zones that are transparent while other portions or zones are semi-transparent, opaque, reflective, or diffusing. At least some of the plurality of layers may comprise portions or zones that are semi-transparent while other portions or zones are opaque, reflective, or diffusing. At least some of the plurality of layers may comprise or consist of a material such as glass, polymethyl methacrylate (PMMA), polyurethane, polyurethane reactive, polycarbonate, silicon, or a combination thereof. At least some of the plurality of layers, such as the decoration layer 400, may be reflective and may comprise or consist of a reflective material, such as a metal, such as aluminum, chrome, or indium. At least some of the plurality of layers, such as the decoration layer 400 may be opaque and have a colored material, such as a white, red, or blue colored material.

[0036] As used herein, the terms transparent, semi-transparent, and opaque may refer to a “total transmittance” of the material. The total transmittance of the material may be measured using a spectrophotometer, which is an instrument that quantifies the amount of light passing through a sample of the material. The total transmittance may be calculated by dividing the intensity of transmitted light through the sample of the material by the intensity of the incident light that was transmitted through the sample of the material, and multiplied by 100 to express as a “percent transmittance”. An opaque material may have a percent transmittance of less than 30 percent, a semi-transparent material may have a percent transmittance of at least 30 percent and less than 80 percent, and a transparent material may have a percent transmittance of at least 80 percent.

[0037] In various examples, the plurality of layers are arranged in a stacked configuration. As used herein, the term “stacked configuration” refers to an arrangement7077979 / 634524LEGAL02 / 46336458vlwhere layers are placed on top of each other. The stacked configuration may result in no gaps or minimal gapping (e.g., less than a 10 micron gap) existing between adjacent layers of the plurality of layers. As will become apparent in view of the present disclosure and as will be explained further, the stacked configuration with at least minimal gapping may be accomplished with a multi-shot injection moulding process. Arranging the layers in a stacked configuration with no or minimal gapping may prevent the undesired bending of light beams as the light travels through the air that exists within the gaps.

[0038] In various examples, the lamp system 100 is manufactured using a multi-shot injection moulding process. For example, the material for a first layer of the plurality of layers may be injected into a first mould cavity to form the first layer, which may be an optic layer 200, a light source layer 300, a decoration layer 400, and / or the protection layer 500. Subsequently, the first layer may be transferred to a second mould cavity, which can be accomplished using a rotary platen, a robotic arm, or any other specialized equipment. Once the first layer is positioned within the second mould cavity, material for a second layer of the plurality of layers may be injected into the second mould cavity, and overmoulded onto or combined with the first material. This process repeats until all moulded layers of the lamp system 100 are formed. Additional layers may be applied as a film or a coating. Manufacturing the lamp system 100 with a multi-shot injection moulding process may allow for a more complex design, improved functionality, and aesthetic appeal.

[0039] In various examples, the lamp system 100 may include an optic layer 200 and a light source layer 300. The optic layer 200 may include a first optic sub-layer 201 and a second optic sub-layer 202. The first optic sub-layer 201 may comprise or consist of a first optic material having a first refractive index. The second optic sub-layer 202 may comprise or consist of a second optic material having a second refractive index. As used herein, the term “refractive index” refers to a dimensionless number that is equal to a ratio between the speed of light in a vacuum and the speed of light through a material, such as the first optic material or the second optic material.

[0040] In various examples, the first refractive index is different than the second refractive index. For example, the first refractive index may be different than the second refractive index by at least 2 percent, such as at least 5 percent, such as by at least 108077979 / 634524LEGAL02 / 46336458vlpercent, such as by at least 30 percent, such as by at least 50 percent, such as by at least 70 percent. One of the first refractive index or the second refractive index may be less than 1.1 and the other of the first refractive index or the second refractive index may be at least 1.1. One of the first refractive index or the second refractive index may be at least 1.2, such as at least 1.3 and up to 1.9, such as up to 1.8. Configuring the first refractive index to be different than the second refractive index may achieve an optical influence on light passing through the optical layer from a light source 320 in the lamp system 100.

[0041] In various examples, the first optic sub-layer 201 may be positioned adjacent to and in contact with the second optic sub-layer 202. The light source layer 300 may be positioned adjacent to and in contact with the first optic sub-layer 201. The optic layer 200 may be positioned to receive light emitted from within the light source layer 300.

[0042] In various examples, an intermediate surface 150 may be defined between adjacent layers of the plurality of layers. For example, an intermediate surface 150 may be defined between the first optic sub-layer 201 and the second optic sub-layer 202. At least one of the intermediate surfaces 150 may have a portion that is non-orthogonal relative to a direction of a light beam that passes through the intermediate surface 150. For example, at least one of the intermediate surfaces 150 may have a non-planar geometry and / or a planar geometry that is non-orthogonal (e.g., tilts) relative to a direction of a light beam that passes through the intermediate surface 150. As depicted, the intermediate surface 150 between the first optic sub-layer 201 and the second optic sub-layer 202 has a non-planar geometry. The non-planar geometry may include concave and / or convex portions. As will be appreciated, the geometries shown in the figures is for indicative and illustrative purposes, and may not be optically accurate. The non-planar geometry may form a textured surface at the intermediate surface 150.

[0043] In various examples, and as depicted in FIG. 1, a light beam may enter the first optic sub-layer 201 orthogonally relative to an entry surface 101 of the first optic sub-layer 201. The light beam may exit the first optic sub-layer 201 through a portion of the intermediate surface 150 that is non-orthogonal relative to the direction of the light beam, which may influence the direction of the light so that it bends (e.g., bends upward as depicted on the page) as it exits the first optic sub-layer 201 and enters the second optic sub-layer 202 because of the different refractive indexes of the first optic sub-layer9077979 / 634524LEGAL02 / 46336458vl201 and the second optic sub-layer 202. The light may travel through the second optic sub-layer 202 and be bent again (e.g., bent downwards as depicted on the page) as it travels through an exterior surface 199 of the lamp system 100 because of a difference in refractive indexes of the second optic sub-layer 202 and the air surrounding the lamp system 100.

[0044] In various example, the entry surface 101 and / or the exterior surface 199 may include portions that are non-orthogonal relative to the direction of light beams passing through the surfaces to achieve optical influence within the plurality of layers. The entry surface 101 and / or the exterior surface 199 may be planar, as depicted, but may have influence on the final light direction because of a difference of refractive indexes. The entry surface 101 may be upstream from the exterior surface 199. As used herein, the terms “upstream” and “downstream” refer to a direction that a light beam travels. For example, a light beam will travel from an upstream location to a downstream location.

[0045] Referring now to FIGS. 2-5, schematic views of at least portions of lamp systems are provided, in accordance with four different example embodiments. In various examples, the lamp system 100 comprises a decoration layer 400. The decoration layer 400 may comprise or consist of a decoration material The decoration layer 400 may be positioned adjacent to and in contact with at least one of the light source layer 300 or the optic layer 200. The decoration material may be applied on the light source layer 300 and / or the optic layer 200 with an injection moulding process. The decoration layer 400 may be configured as a film that is applied in the same injection moulding press that is used for processing other layers of the plurality of layers or applied separately in a postprocess.

[0046] In various examples, the decoration layer 400 is configured to affect or change at least one property of light emitted from the light source layer 300. For example, the decoration layer 400 may be configured to modify the photometric distribution of light emitted from the light source layer 300 to correspond with functional or aesthetic requirements of the plurality of layers. The at least one property of light affected or changed by the decoration layer 400 may be the color of the light. For example, the decoration layer 400 may change the color of the light to match the color of components surrounding the lamp system 100 (e.g., components of a vehicle that surround the lamp10077979 / 634524LEGAL02 / 46336458vlsystem 100). The at least one property of light affected or changed by the decoration layer 400 may be the color of light so that it changes depending on the viewing angle. The at least one property of light affected or changed by the decoration layer 400 may be an angle of the light such that the decoration layer 400 reflects light. The at least one property of light affected or changed by the decoration layer 400 may be to add a metallic effect to the light (e.g., polished, satin, or metallic colored). The decoration layer 400 may add patterning to the color by, for example, incorporating opaque zones 420 into the decoration layer 400. The decoration layer 400 may change the property of light to give the impression of a texture or a three-dimensional effect.

[0047] In various examples, and as depicted in FIG. 2, the decoration layer 400 may be configured to collimate or converge light received from the light source layer 300 to achieve photometric functional requirements. In various examples, and as depicted in FIG. 3, the decoration layer 400 may include a plurality of zones, at least one of the zones may have a transparency that is different than another one of the zones. For example, the decoration layer 400 may include a combination of transparent zones 425, semitransparent zones, and / or opaque zones 420. The decoration layer 400 may comprise opaque zones 420 and transparent zones 425, and be configured to collimate or converge light received from the light source layer 300 to achieve alignment with transparent zones 425 in the decoration layer 400, which may increase optical efficiency or increase the effect of hiding the illuminated area when unlit. The opaque zones 420 may be alternatingly arranged with the transparent zones 425 to collimate the light emitted from the light source layer 300. The opaque zones 420 may be incorporated onto the decoration layer 400 with a post-process such as painting the opaque zone 420 onto the decoration layer 400, incorporating the opaque zone 420 onto the decoration layer 400 with an etching or ablation process, such as a laser etching or ablation process, or incorporating the opaque zone 420 onto the decoration layer 400 by placing a printed film onto the decoration layer 400.

[0048] In various examples, and as depicted in FIG. 4, the decoration layer 400 may be configured to spread the light received from the light source layer 300 to achieve photometric functional, aesthetic or homogeneity preferences or requirements. In various11077979 / 634524LEGAL02 / 46336458vlexamples, and as depicted in FIG. 5, the decoration layer 400 may be configured to change the dominant direction of light to achieve photometric functional requirements.

[0049] Referring now to FIG. 6, a schematic view of at least a portion of a lamp system 100 is provided, in accordance with an example embodiment. In various examples, the plurality of layers of the lamp system 100 comprises a light source layer 300. The light source layer 300 may comprise or consist of a light source material and at least one light source 320. Each light source 320 may be embedded within the light source material. Electrical connections between light sources 320 may be embedded within the light source material. The light sources 320 may be configured as a film or a moulded insert that may be embedded within the light source material or positioned on a surface of the light source material. The light sources 320 may be a matrix of light sources 320, such as a matrix of light emitting diodes (LEDs) that are each attached to a frame or a substrate, or embedded within a film that can be embedded within the light source material.

[0050] In various example, the at least one light source 320, such as a matrix of light sources 320, are placed into an injection moulding press and liquid light source material may be injected into the press to embed each light source 320 in the light source material, once cooled and hardened.

[0051] In various examples, the light source material of the light source layer 300 has a different refractive index than an adjacent layer of the plurality of layers. For example, the light source layer 300 may be adjacent to the optic layer 200, such as adjacent to the first optic sub-layer 201 of the optic layer 200. The refractive index of the light source material may be different than the refractive index of the material of the adjacent layer by at least 2 percent, such as at least 5 percent, such as by at least 10 percent, such as by at least 30 percent, such as by at least 50 percent, such as by at least 70 percent. One of the refractive index of the light source material or the refractive index of the adjacent layer may be less than 1.1 and the other o of the refractive index of the light source material or the refractive index of the adjacent layer may be at least 1.1. One of the refractive index of the light source material or the refractive index of the adjacent layer may be at least 1.2, such as at least 1.3, and up to 1.9, such as up to 1.8. Configuring the refractive index of the light source material to be different from the refractive index of the adjacent layer12077979 / 634524LEGAL02 / 46336458vlmay achieve an optical influence on light passing through the light source layer 300 to the adjacent layer.

[0052] In various examples, the optic layer 200 is positioned to receive light emitted from within the light source layer 300. For example, and as depicted in FIG. 6, the light sources 320 emit light in a direction towards the optic layer 200 so that the optic layer 200 receives light from the light sources 320. As another example, and as depicted in FIGS. 16 and 17, and as will be explained further, the light sources 320 may emit light in a direction away from the optic layer 200, but the light may be reflected back towards the optic layer 200 by, for example, a decoration layer 400, so that the optic layer 200 receives the reflected light from the light source layer 300.

[0053] Referring now to FIG. 7, a schematic view of at least a portion of a lamp system 100 is provided, in accordance with an example embodiment. In various examples, the plurality of layers of the lamp system 100 comprise a protection layer 500. The protection layer 500 may comprise or consist of a protection material. The protection layer 500 may be an outer-most layer of the plurality of layers. For example, the protection layer 500 may define the exterior surface 199 of the lamp system 100. The protection layer 500 may be configured to provide protection to the other layers of the plurality of layers of the lamp system 100. For example, the protection layer 500 may provide protection from ultraviolet light exposure, mechanical wear (e.g., external scratching or abrasion), physical impacts, chemical exposure, and / or weather or climate exposure (e.g., temperature, humidity, water, ice).

[0054] In various examples, the protection material of the protection layer 500 has a different refractive index than an adjacent layer of the plurality of layers. The protection layer 500 may be adjacent to the decoration layer 400, as depicted in FIG. 7 and 9, adjacent to the optic layer 200, as depicted in FIGS. 10, 11, 12, 14, 16, or adjacent to the light source layer 300, as depicted in FIGS. 15 and 17. The refractive index of the protection material may be different than the refractive index of the material of the adjacent layer by at least 2 percent, such as at least 5 percent, such as by at least 10 percent, such as by at least 30 percent, such as by at least 50 percent, such as by at least 70 percent. One of the refractive indexes of the protection material or the refractive index of the adjacent layer may be less than 1.1 and the other o of the refractive index of13077979 / 634524LEGAL02 / 46336458vlthe protection material or the refractive index of the adjacent layer may be at least 1.1. One of the refractive indexes of the protection material or the refractive index of the adjacent layer may be at least 1.2, such as at least 1.3, and up to 1.9, such as up to 1.8. Configuring the refractive index of the protection material to be different from the refractive index of the adjacent layer may achieve an optical influence on light passing through the protection layer 500 to the adjacent layer.

[0055] In various examples, the protection layer 500 may be applied with an injection molding process. In some examples, the protection layer 500 may be configured as a film that is applied in the same injection moulding press that is used for processing other layers of the plurality of layers or applied separately in a post-process. For example, the protection layer 500 may be a polyurethane reactive (PUR) layer that is applied in the same injection moulding press that is used for processing the other layers of the plurality of layers. The protection layer 500 may be a protective paint or lacquer that is applied as a post-process.

[0056] Referring now to FIG. 8, a schematic view of at least a portion of a lamp system 100 is provided, in accordance with an example embodiment. In various examples, a layer of the plurality of layers that is not a devoted protection layer 500 may serve as the protection layer 500. For example, and as depicted in FIG. 8, the decoration layer 400 may provide the functionality of a decoration layer 400 and a protection layer 500. The decoration layer 400 may define an exterior surface 199 of the lamp system 100 and provide protection to the plurality of layers.

[0057] Referring now to FIGS. 9-11, schematic views of portions of lamp systems are provided, in accordance with three different example embodiments. In various examples, a layer of the plurality of layers that is not a devoted optic layer 200 may serve the function of or be configured as an optic layer 200. For example, and as depicted in FIG.9, the light source layer 300 may provide the functionality of or be configured as an optic layer 200, such as the first optic sub-layer 201 of the optic layer 200. As depicted in FIG.10, the protection layer 500 may provide the functionality of or be configured as an optic layer 200, such as the second optic sub-layer 202 of the optic layer 200. As depicted in FIG. 11, the protection layer 500 may provide the functionality of or be configured as an optic layer 200, such as a third optic sub-layer of the optic layer 200. The layer that is14077979 / 634524LEGAL02 / 46336458vlconfigured as both an optic layer 200 and a protection layer 500 may have a higher refractive index that the adjacent layer that is upstream from the layer.

[0058] Referring now to FIGS. 12-15, schematic views of portions of lamp systems are provided, in accordance with three different example embodiments. In various examples, the light source layer 300 may be positioned in front of the decoration layer 400. The emission direction of each light source 320 may be away from the decoration layer 400. As such, light emitted from each light source 320 may not travel directly towards the decoration layer 400 direction, but at least some of the light from each light source 320 may be reflected from other layers of the plurality of layers. For example, at least one of the intermediate surfaces 150 of the plurality of layers, such as an intermediate surface 150 between the first optic sub-layer 201 and the second optic sublayer 202, may comprise a total internal reflection (TIR) surface. The TIR surface may reflect a beam of light when the beam of light hits the surface at an angle that is less than a critical angle. As will be appreciated by those skilled in the art, the critical angle, in optics, is the greatest angle at which a beam of light, travelling in one transparent medium (e.g., the first optic sub-layer 201), can strike the boundary between that medium and a second of lower refractive index (e.g., the second optic sub-layer 202) without being totally reflected within the first medium. The TIR surface may cause a beam of light to reflect off the TIR surface such that an angle of incidence is equal to an angle of reflection. As such, at least some of the intermediate surfaces 150 may be configured as TIR surfaces that may cause light to be reflected back towards the decoration layer 400 that is behind the light sources 320.

[0059] Referring now to FIGS. 16-17, schematic views of portions of lamp systems are provided, in accordance with three different example embodiments. In various examples, the emission direction of each light source 320 is away from the exterior surface 199 of the lamp system 100. The optic layer 200 and the protection layer 500, when included, may be positioned to receive light that is emitted by the light source 320 but subsequently reflected from, for example, the decoration layer 400. The decoration layer 400 may comprise or consist of a reflective material, such as a metal (e.g., chrome, aluminum, indium, or a combination thereof). The decoration layer 400 may be configured to reflect at least 90 percent, such as at least 95 percent, such as at least 9915077979 / 634524LEGAL02 / 46336458vlpercent, such as at least 100 percent of the light it receives. The decoration layer 400 may be configured to diffuse and reflect light that it receives.

[0060] In various examples, the decoration layer 400 may be configured to reflect a predetermined wavelength to affect a color of the light reflected by the decoration layer 400. For example, the decoration layer 400 may comprise a colored material, such as a white colored polymer, a blue colored polymer, a red colored polymer, etc. Light reflected from the colored material would be of the respective wavelength associated with the color of the material. The reflected light may also be diffused by the decoration layer 400 to contribute to a homogeneity factor of light emitted by the lamp system 100.

[0061] Referring to each of FIGS. 1-17, different combinations or order of layers of the plurality of layers can be incorporated into the lamp system 100. For example, the optic layer 200 may be positioned between, such as positioned directly between, a light source layer 300 and a decoration layer 400. A decoration layer 400 may be positioned between, such as positioned directly between, a first optic sub-layer 201 and a second optic sub-layer 202 of the optic layer 200. A decoration layer 400 may be positioned between, such as positioned directly between, a light source layer 300 and a protection layer 500. may be positioned between, such as positioned directly between, an optic layer 200. The plurality of layers may include a plurality of light source 320 layers. For example, a first light source layer 300 may include a light source 320 that emits light in a first direction and a second light source layer 300 may include a light source 320 that emits light in a second direction that is opposite the first direction. The plurality of layers may include a plurality of protection sub-layers. For example, a first protection sub-layer may be for ultraviolet protection and a second protection sub-layer may be for mechanical protection. The optic layer 200 may include a plurality of optic sub-layers, such as at least two, such as at least three, such as at least four, such as at least five optic sub-layers. The plurality of layers may include a plurality of decoration sub-layers. For example, a first decoration sub-layer may be configured to reflect light and a second decoration sub-layer may be configured to diffuse light.

[0062] Referring now to FIG. 18, a flowchart of a method 800 of manufacturing a lamp system 100 is provided, in accordance with an example embodiment. The lamp system 100 may be manufactured using a multi-shot injection moulding process. For16077979 / 634524LEGAL02 / 46336458vlexample, the method 800 may include a step 820 of injecting a first material into a mould to form a first layer. The first material may be a light source material that forms a light source layer 300 as the first layer, the first material may be an optic material that forms an optic layer 200 (e.g., a first optic sub-layer 201) as the first layer, the first material may be a decorative material that forms a decoration layer 400 as the first layer, or the first material may be a protection material that forms a protection layer 500 as the first layer. The method 800 may include a step 840 of injecting a second material into the mould and onto the first layer to form a second layer. The second material may be a light source material that forms a light source layer 300 as the second layer, the second material may be an optic material that forms an optic layer 200 (e.g., a second optic sublayer 202) as the second layer, the second material may be a decorative material that forms a decoration layer 400 as the second layer, or the second material may be a protection material that forms a protection layer 500 as the second layer.

[0063] In various examples, the first material is a light source material to form a light source layer 300 and the second material is an optic material to form an optic layer 200 (e.g., a first or second optic sub-layer 202, or vice-versa. The method 800 may include positioning at least one light source 320 into the mould prior to injecting the light source material into the mould.

[0064] In various examples, the first material is a decoration material to form a decoration layer 400 and the second material is a light source material to form a light source layer 300. The first material may be a protection layer 500 to form a protection layer 500 and the second material may be an optic material to form an optic layer 200. The first material may be an optic material to form an optic layer 200 and the second material may be a light source material to form a light source layer 300. The first material may be an optic material to form an optic layer 200 and the second material may be a decorative material to form a decorative layer.

[0065] In various examples, at least one of the plurality of layers may be or may comprise a film. For example, the decoration layer 400 may be a reflective film, a diffusing film, a colored film or may comprise a plurality of zones that each include an opaque or semi-transparent film. The protection layer 500 may be a protective film. In17077979 / 634524LEGAL02 / 46336458vlvarious examples, semi-transparent or opaque zones 420 may be formed in any of the plurality of layers with an etching or ablation process.

[0066] The lamp system 100 of the present disclosure has various benefits. For example, the lamp system 100 may be more compact than existing technologies, especially in the stack direction. The lamp system 100 of the present disclosure may allow for the light characteristics of the light emitted from the light source layer 300 to be tailored for lighting requirements and / or preferences. For example, a luminous flux may be increased or decreased by adjustment or addition of one or more of the discussed features of the lamp system 100 (e.g., adding or adjusting a curved surface of an optic layer 200, changing an angle and / or curvature of a TIR surface, adding a surface finish of a decorative layer or the exterior surface 199, incorporating opaque zones 420 as a collimator lens, etc ).Conclusion

[0067] The above descriptions of various embodiments of the subject disclosure and corresponding figures and what is described in the Abstract, are described herein for illustrative purposes, and are not intended to be exhaustive or to limit the disclosed embodiments to the precise forms disclosed. It is to be understood that one of ordinary skill in the art may recognize that other embodiments having modifications, permutations, combinations, and additions can be implemented for performing the same, similar, alternative, or substitute functions of the disclosed subject matter, and are therefore considered within the scope of this disclosure. Therefore, the disclosed subject matter should not be limited to any single embodiment described herein, but rather should be construed in breadth and scope in accordance with the appended claims below. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and / or functions, it should be appreciated that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and / or functions than those explicitly described above are also contemplated as may be18077979 / 634524LEGAL02 / 46336458vlset forth in some of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.19077979 / 634524LEGAL02 / 46336458vl

Claims

CLAIMSWhat is claimed is:

1. A lamp system comprising: an optic layer comprising: a first optic sub-layer comprising a first optic material having a first refractive index; and a second optic sub-layer comprising a second optic material having a second refractive index, wherein: the first optic sub-layer is positioned adjacent to and in contact with the second optic sub-layer, and the first refractive index is different than the second refractive index; and a light source layer comprising a light source material and at least one light source, wherein the optic layer is positioned to receive light emitted from within the light source layer.

2. The lamp system of claim 1, wherein the light source layer, the first optic sub-layer, and the second optic sub-layer are positioned in a stacked configuration.

3. The lamp system of claim 1, wherein the at least one light source is embedded within the light source material.

4. The lamp system of claim 1, wherein one or more of the first optic material, the second optic material, or the light source material are transparent or semi-transparent polymers.

5. The lamp system of claim 1, wherein the first refractive index or the second refractive index is at least 1.1.20077979 / 634524LEGAL02 / 46336458vl6. The lamp system of claim 1, wherein at least a portion of structure of the first optic sub-layer and at least a portion of the second optic sub-layer are defined by a single mould of an injection moulding system.

7. The lamp system of claim 1, wherein the lamp system comprises a plurality of layers comprising at least the optic layer and the light source layer, wherein there are no gaps between each of the plurality of layers.

8. The lamp system of claim 1, wherein the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a decoration layer, wherein the decoration layer is positioned adjacent to and in contact with at least one of the light source layer or the optic layer, wherein the decoration layer is configured to change a property of light emitted from the light source layer.

9. The lamp system of claim 1, wherein the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a decoration layer, wherein: the decoration layer is positioned adjacent to and in contact with the light source layer, the light source layer is positioned between the decoration layer and the optic layer, and the light emitted from the at least one light source of the light source layer is directed towards the decoration layer and subsequently reflected from the decoration layer and to the optic layer.

10. The lamp system of claim 1, wherein the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a decoration layer, wherein: the decoration layer is positioned adjacent to and in contact with the optic layer, the optic layer is positioned between the decoration layer and the light source layer, and21077979 / 634524LEGAL02 / 46336458vlthe light emitted from the at least one light source of the light source layer is directed towards the optic layer, through the decoration layer, subsequently reflected from the decoration layer and back through the optic layer.

11. The lamp system of claim 1, wherein the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a protection layer, wherein the protection layer is positioned on an exterior of the lamp system and configured to provide chemical, climatic, or mechanical resistance to the lamp system.

12. The lamp system of claim 1, wherein the lamp system comprises a plurality of layers comprising at least the optic layer, the light source layer, and a decoration layer, wherein: the decoration layer comprises a plurality of zones, a first zone of the plurality of zones is transparent, and a second zone of the plurality of zones is semi-transparent or opaque.

13. The lamp system of claim 12, wherein the second zone of the plurality of zones is opaque.

14. The lamp system of claim 13, wherein the first zone and the second zone are altematingly arranged to collimate light emitted from the light source layer.

15. A method of manufacturing a lamp system, the lamp system comprising: an optic layer comprising: a first optic sub-layer; and a second optic sub-layer that is positioned adjacent to and in contact with the second optic sub-layer; and a light source layer comprising a light source material and at least one light source, wherein the optic layer is positioned to receive light emitted from within the light source layer, and wherein the method comprises:22077979 / 634524LEGAL02 / 46336458vlinjecting a first optic material into a mould to form the first optic sublayer; and injecting a second optic material into the mould and onto the first optic sub-layer to form the second optic sub-layer, wherein: the first optic material has a first refractive index when cured and the second optic material has a second refractive index when cured, and the first refractive index is different than the second refractive index.

16. The method of claim 15, further comprising: positioning the at least one light source into the mould; and injecting the light source material into the mould onto the at least one light source to form the light source layer and embed the at least one light source within the light source material.

17. The method of claim 15, further comprising: injecting a decoration material into the mould and onto the light source layer to form a decoration layer, wherein: the at least one light source is positioned such that light emitted from the at least one light source is directed towards the decoration layer, and the decoration layer is configured to reflect the light that is received from the at least one light source towards the optic layer.

18. The method of claim 15, further comprising: injecting a decoration material into the mould and onto the optic layer to form a decoration layer, wherein: the at least one light source is positioned such that the light emitted from the at least one light source is directed towards the optic layer, through the23077979 / 634524LEGAL02 / 46336458vldecoration layer, subsequently reflected from the decoration layer and back through the optic layer, and the decoration layer is configured to reflect the light that is received from the at least one light source towards the optic layer.

19. The method of claim 15, further comprising: injecting a decoration material into the mould and onto the optic layer to form a decoration layer, wherein the decoration material is a transparent or semi-transparent material; and incorporating an opaque zone onto the decoration layer.

20. The method of claim 19, wherein the incorporating the opaque zone onto the decoration layer comprises altematingly arranging a plurality of opaque zones with a plurality of transparent or semi-transparent zones of the decoration material.24077979 / 634524LEGAL02 / 46336458vl

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