CN116981599A

CN116981599A - Illuminated sign assembly and method of manufacture

Info

Publication number: CN116981599A
Application number: CN202280021028.6A
Authority: CN
Inventors: 达利伯·塔拉斯; 杨尼克·高达德
Original assignee: SRG Global Liria SL
Current assignee: SRG Global Liria SL
Priority date: 2021-05-07
Filing date: 2022-05-06
Publication date: 2023-10-31

Abstract

An illuminated sign assembly comprising: a multi-component outer lens having an outer surface and an inner surface, the multi-component outer lens further comprising an outer visible region to be illuminated; an inner lens having an outer surface and an inner surface; a printed circuit board assembly; a heat sink; a housing for the inner lens and the outer lens; and at least one light source, wherein the at least one light source is offset from an external visible region to be illuminated. A method of manufacturing an illuminated sign assembly, comprising: injection molding the multi-part outer lens; providing an inner lens; providing a housing for the inner lens and the outer lens; providing at least one light source; and assembling the inner and outer lenses and the at least one light source within the housing to obtain the illuminated sign assembly.

Description

Illuminated sign assembly and method of manufacture

Cross Reference to Related Applications

The present application claims the benefits of U.S. provisional application No. 63/185,964 filed on day 5 and 7 of 2021 and U.S. non-provisional application No. 17/738,064 filed on day 3 and 7 of 2022 and also filed on day 5 and 6 of 2022. The disclosures of the above-identified applications are incorporated herein by reference in their entirety.

Technical Field

The present disclosure relates to illuminated displays, and more particularly to illuminated sign assemblies and methods of their manufacture.

Background

The logo is used to display brand information or other logos on a product such as, but not limited to, a vehicle. The illumination of the sign may enhance the visual appearance of the sign, illuminate the sign in dark conditions, and/or otherwise draw attention to the sign. A typical light source produces light that radiates outward from the light source. However, when the sign is illuminated using a light source, a radial illumination mode may not be required. Accordingly, there is a need for an illuminated sign assembly having improved uniformity and brightness and a method of making the same.

The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

Disclosure of Invention

According to one aspect of the present disclosure, an illuminated sign assembly is presented. In one exemplary implementation, the illuminated sign component includes: a multi-component outer lens having an outer surface and an inner surface, the multi-component outer lens further comprising an outer visible region to be illuminated; an inner lens having an outer surface and an inner surface; a printed circuit board assembly; a heat sink; a housing for the inner lens and the outer lens; and at least one light source, wherein the at least one light source is offset from an external visible region to be illuminated. According to another aspect of the present disclosure, a vehicle body component including an illuminated sign assembly and similar methods of manufacture are presented.

In some implementations, the multi-component outer lens is a multi-shot molded lens. In some implementations, the material for the multi-shot molded lens includes at least black Polymethylmethacrylate (PMMA) and light transmissive PMMA. In some implementations, the light source is a Light Emitting Diode (LED) assembly having one or more LED lamps. In some implementations, when the outer visible region to be illuminated includes a circular region, the light source is radially centered on each circle offset from the outer visible region to be illuminated. In some implementations, when the outer visible region to be illuminated includes a circular region, the light source includes at least one light source radially offset from a center of each circle offset from the outer visible region to be illuminated. In some implementations, the at least one light source radially offset from the center of each circle includes two light sources radially offset from the center of each circle in opposite directions. In some implementations, each circle defines a central elongated or elliptical aperture, and wherein the two light sources are in directly opposite directions radially along a central longer axis of the respective central aperture.

In some implementations, a reflective coating is applied to at least a portion of the inner surface of the outer lens. In some implementations, at least a portion of the inner surface of the outer lens or the outer surface of the inner lens is granular or textured. In some implementations, the multi-component outer lens has at least one set of alternating solid structures and open structures, wherein the amount of light transferred from the light source to the area to be illuminated is not substantially affected by any of the alternating structures. In some implementations, the multi-component outer lens is an alternating solid circular region and an open circular region. In some implementations, alternating solid circular regions and open circular regions are interlocked. In some implementations, the plane or surface of the entry point of the light source is not stepped or staggered relative to the area to be illuminated.

According to another aspect of the present disclosure, a method of manufacturing an illuminated sign assembly is presented. In one exemplary implementation, the method includes: molding a multi-part outer lens having an outer surface and an inner surface, the multi-part outer lens further comprising an outer visible region to be illuminated; providing an inner lens having an outer surface and an inner surface; providing a housing for the inner lens and the outer lens; providing at least one light source, wherein the at least one light source is offset from an external visible region to be illuminated; and assembling the inner and outer lenses and the at least one light source within the housing to obtain the illuminated sign assembly.

In some implementations, the injection molding of the multi-part outer lens is a multi-shot molding process. In some implementations, the multi-shot molding process includes performing a first injection molding injection to form a first opaque portion of the multi-part outer lens, and performing a second injection molding injection before or after the first injection molding injection to form a second translucent or transparent portion of the multi-part outer lens. In some implementations, the materials for the first injection molding shot and the second injection molding shot include at least black PMMA and light transmissive PMMA, respectively. In some implementations, the method further includes providing and assembling a printed circuit board assembly and a heat sink within the housing for control/power and thermal management of the at least one light source.

Further areas of applicability of the teachings of the present disclosure will become apparent from the detailed description, claims and drawings provided hereinafter, wherein like reference numerals refer to like features throughout the several views of the drawings. It should be appreciated that the detailed description, including the disclosed embodiments and figures recited therein, is merely exemplary in nature and is intended for purposes of illustration only and is not intended to limit the scope of the disclosure, its application or uses. Accordingly, variations that do not depart from the gist of the disclosure are intended to be within the scope of the disclosure.

Drawings

The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a cross-sectional side view of a portion of a first exemplary illuminated sign assembly illuminated using a lower portion of its internal optics according to some implementations of the present disclosure;

FIG. 2 is a cross-sectional side view of a portion of a second exemplary illuminated sign assembly illuminated using an upper portion of its internal optics according to some implementations of the present disclosure;

FIG. 3 is a cross-sectional side view of a third exemplary illuminated sign assembly illuminated using both a lower portion and an upper portion of its internal optics according to some implementations of the present disclosure;

FIG. 4 is a cross-sectional top view of a portion of a fourth exemplary illuminated sign assembly having illuminated and non-illuminated regions corresponding to solid and open optical rings according to some implementations of the present disclosure;

FIG. 5 is a cross-sectional top view of a portion of a fifth exemplary illuminated sign assembly having a different light source configuration according to some implementations of the present disclosure;

6A-6B are front and cross-sectional (A-A') views of a portion of a sixth exemplary illuminated sign assembly according to some implementations of the present disclosure; and is also provided with

Fig. 7 is a flow chart of an exemplary method of manufacturing an illuminated sign assembly according to some implementations of the present disclosure.

Although each of the figures shows a particular embodiment for purposes of illustration clarity, other embodiments may omit, add, reorder, or modify any of the elements shown in the figures. For purposes of illustrating the clear examples, one or more of the drawings may be described with reference to one or more other drawings. However, in other embodiments, the particular arrangement shown in one or more of the other figures need not be used.

Detailed Description

As previously discussed, the logo is used to display brand information or other logos on a product, such as but not limited to a vehicle. The illumination of the sign may enhance the visual appearance of the sign, illuminate the sign in dark conditions, and/or otherwise draw attention to the sign. A typical light source produces light that radiates outward from the light source. However, when the sign is illuminated using a light source, a radial illumination mode may not be required. Accordingly, there is a need for an illuminated sign assembly having improved uniformity and brightness and a method of making the same. Accordingly, improved illuminated sign assemblies and methods of their manufacture are presented herein. The illuminated sign assemblies provide improved uniformity and brightness, and their method of manufacture is simple and efficient. Potential benefits include improved visual aesthetics and/or reduced manufacturing costs.

Referring now to fig. 1-3, cross-sectional side views of various examples of illuminated marker assemblies according to some implementations of the present disclosure are shown. More specifically, fig. 1 is a cross-sectional side view of a portion of a first exemplary illuminated sign assembly 100 using a lower portion of its internal optics for illumination, and fig. 2 is a cross-sectional side view of a portion of a second exemplary illuminated sign assembly 200 using an upper portion of its internal optics for illumination, while fig. 3 is a cross-sectional side view of a third exemplary illuminated sign assembly 300 (i.e., a combination of portions 100 and 200, reference numerals 100a, 100b, 200a and 200 b) using both a lower portion and an upper portion of its internal optics for illumination. The illuminated sign component generally includes: a multi-component outer lens 104 having an outer surface 104a and an inner surface 104b, the multi-component outer lens further comprising an outer visible region 140 to be illuminated; an inner lens 112 having an outer surface 112a and an inner surface 112 b; a Printed Circuit Board (PCB) assembly 132; a Heat Sink (HS) 136; a housing 124 for the inner lens 112 and the outer lens 104; and at least one light source 128, wherein the at least one light source is offset from an outer visible region 140 to be illuminated. In some implementations, the multi-part outer lens is a multi-shot (e.g., two shot or 2K) injection molded lens formed of two different materials 108a, 108 b. In some implementations, the material for the multi-shot molded lens includes at least black (e.g., opaque) polymethyl methacrylate (PMMA) and light transmissive (e.g., transparent or translucent) PMMA for the materials 108a, 108b, respectively.

Referring now to fig. 4-5 and with continued reference to fig. 1-3, a cross-sectional top view of a portion of a fourth exemplary illuminated sign assembly 400 having illuminated and non-illuminated regions corresponding to solid and open optical rings and a portion of a fifth exemplary illuminated sign assembly 500 having a different light source configuration is shown, according to some implementations of the present disclosure. In one exemplary implementation, the light source 128 is a Light Emitting Diode (LED) assembly having one or more LED lamps controlled by a PCB assembly 132 and having thermal management regulated via a Heat Sink (HS) 136. A reflective coating may be applied to at least a portion of the inner surface 104b of the outer lens 104, such as in a portion through which light is not transmitted, as shown. In some implementations, at least a portion of the inner surface 104b of the outer lens and/or the outer surface 112a of the inner lens 112 is granular or textured (see 120). Such graining or texturing of these surfaces may create lighting effects, such as by diffusion of light alternately passing therethrough.

Referring now to fig. 6A-6B and with continued reference to the previous figures, a front view and a cross-sectional (A-A') view of a portion of a sixth exemplary illuminated sign assembly 600 according to some implementations of the present disclosure are shown, when the outer visible region to be illuminated includes a circular region 604, the light sources include at least one light source 616A and/or 616B radially offset from the center of each circle 604 that is offset from the outer visible region to be illuminated (i.e., via the central aperture 608), while still achieving the necessary illumination quality requirements. The outer visible region to be illuminated may also include non-central holes 612a and/or 612b as shown. In such implementations, the at least one light source radially offset from the center of each circle 604 includes two light sources 616a, 616b radially offset from the center of each circle in opposite directions. In some implementations, the two light sources 616A, 616b are radially offset relative to the central elongated or oblong aperture 608 as shown in fig. 6A in diametrically opposite directions along the elongated length (e.g., along the central axis of the circumference) and parallel to the elongated length.

These light sources 616a, 616b may be fixed/attached or integrated into the back or rear surface of the illuminated sign assembly 600. For example, each light source 616a, 616b may be an LED recessed in the back of the illuminated flag assembly 600 in a respective recessed region 620a, 620b as shown, such that the overall profile of the illuminated flag assembly 600 remains flat or low profile. In some implementations, the multi-component outer lens 104 has at least one set of alternating solid structures and open structures, wherein the amount of light delivered from the light source to the region to be illuminated 140 is not substantially affected by any of the alternating structures (e.g., particularly if the alternating structures are superimposed). In some implementations, the multi-component outer lens is an alternating solid circular region and an open circular region (see fig. 4). In some implementations, alternating solid circular regions and open circular regions are interlocked (see fig. 6). In some implementations, the plane or surface of the entry point of the light source is not stepped or staggered relative to the area to be illuminated.

In some implementations, the illuminated sign assembly is part of (e.g., attached to or integrated in) an automobile or body part. Non-limiting examples of such body components include grille assemblies, bumpers, side moldings, and rear elements (hatches, trunk lid trim, etc.). While exterior body components are specifically discussed, it should be understood that these systems and methods (see below) may be applied to other automotive components, such as interior vehicle components.

Referring now to FIG. 7, a flowchart of an exemplary method 700 of manufacturing an illuminated sign component (e.g., component 100/200/300) is shown, according to some embodiments of the present application. At 704, injection molding of a multi-part outer lens having an outer surface and an inner surface is performed, the multi-part outer lens further comprising an outer visible region to be illuminated. This may include, for example, a multi-shot molding process, such as performing a first injection molding at 704a to form a first opaque portion of the multi-part outer lens, and performing a second injection molding 704b before or after the first injection molding 704a to form a second translucent or transparent portion of the multi-part outer lens. As previously discussed, the materials for the first and second injection injections include at least black PMMA and light transmissive PMMA, respectively, but it should be appreciated that other suitable materials may be utilized.

Although not shown as a separate step, it should be understood that the multi-part outer lens may be removed from the mold after the injection molding process. At 708, an inner lens having an outer surface and an inner surface is provided. At 712, a housing for the inner lens and the outer lens is provided. At 716, at least one light source is provided that is offset from the external visible region to be illuminated. Finally, at 724, the inner and outer lenses and at least one light source are assembled within the housing to obtain an illuminated sign assembly (e.g., assemblies 100 and/or 200). At optional intermediate step 720, a PCB assembly and heat sink may be provided and also assembled within the housing for control/power supply and thermal management of the at least one light source. The method 700 then ends or returns to 704 for one or more additional manufacturing cycles.

The exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope to those skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that the exemplary embodiments may be embodied in many different forms without the specific details and should not be construed as limiting the scope of the disclosure. In some exemplary embodiments, well-known programs, well-known device structures, and well-known techniques have not been described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The term "and/or" includes any and all combinations of one or more of the associated listed items. The terms "comprises," "comprising," "includes," and "including" are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein should not be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as being performed in that order. It should also be understood that additional or alternative steps may be employed.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

The foregoing description of the embodiments has been presented for purposes of illustration and description. But are not intended to be exhaustive or limiting of the present disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable if appropriate and can be used in selected embodiments, even if not specifically shown or described. This too can be varied in a number of ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. An illuminated sign assembly (100, 200, 300, 600) comprising:

a multi-component outer lens (104) having an outer surface (104 a) and an inner surface (104 b), further comprising an outer visible region (140) to be illuminated;

an inner lens (112) having an outer surface (112 a) and an inner surface (112 b);

a printed circuit board assembly (132);

a heat sink (136);

a housing (124) for the inner lens and the outer lens; and

at least one light source (128), wherein the at least one light source is offset from the external visible region to be illuminated.

2. The illuminated sign assembly of claim 1, wherein the multi-component outer lens is a multi-shot molded lens.

3. The illuminated sign assembly of claim 2, wherein the material (108 a, 108 b) for the multi-shot molded lens comprises at least black polymethyl methacrylate (PMMA) and light transmissive PMMA.

4. The illuminated sign assembly of any preceding claim, wherein the light source is a Light Emitting Diode (LED) assembly (500) having one or more LED lamps.

5. The illuminated sign assembly (400, 600) of any preceding claim, wherein when the outer visible region to be illuminated comprises a circular region, the light sources are radially centered on each circle offset from the outer visible region to be illuminated.

6. The illuminated sign assembly (600) of any preceding claim, wherein when the outer visible region to be illuminated comprises a circular region, the light source comprises at least one light source (616 a, 616 b) radially offset from a center of each circle (604) offset from the outer visible region to be illuminated.

7. The illuminated sign assembly of claim 6, wherein the at least one light source radially offset from the center of each circle comprises two light sources (616 a, 616 b) radially offset from the center of each circle in opposite directions.

8. The illuminated sign assembly of claim 7, wherein each circle defines a central elongated or elliptical aperture (608), and wherein the two light sources are radially offset in diametrically opposite directions along a central longer axis of the respective central aperture.

9. The illuminated sign assembly of any preceding claim, wherein at least one of: (i) A reflective coating is applied to at least a portion of the inner surface of the outer lens and (ii) at least a portion of the inner surface of the outer lens or the outer surface of the inner lens is granular or textured (120).

10. The illuminated sign assembly of any preceding claim, wherein the multi-component outer lens has at least one set of alternating solid structures and open structures, wherein an amount of light passing from the light source to the area to be illuminated is not substantially affected by any alternating structures.

11. The illuminated sign assembly of claim 10, wherein the multi-component outer lens is an alternating solid circular area and an open circular area.

12. The illuminated sign assembly (600) of claim 11, wherein the alternating solid circular regions and open circular regions are interlocked.

13. The illuminated sign assembly (600) of any preceding claim, wherein a plane or surface of an entry point of the light source is not stepped or staggered with respect to the area to be illuminated.

14. A body component comprising an illuminated sign assembly according to any preceding claim.

15. A method (700) of manufacturing an illuminated sign assembly according to any preceding claim, the method comprising: -injection molding (704) the multi-part outer lens; providing (708) the inner lens; -providing (712) the housing; -providing (716) the at least one light source; and assembling (720) the inner and outer lenses and the at least one light source within the housing to obtain the illuminated sign assembly.