MXPA00001028A - Thin light managing system for directing and distributing light from one or more light sources and method for making optics structures for use in the system - Google Patents

Abstract

A rear signal lamp (10) of an automotive vehicle comprising a lamp housing (14) and a curved cover lens (22) for enclosing a thin light managing system (12). The thin light managing system (12) includes a plurality of backlight light-emitting diodes (28) mounted in a light mounting substrate (30) and secured to the lamp housing (14). A control module (34) operatively connected to the light-emitting diodes (28) for controlling the operation and illumination of the light-emitting diodes (28). A reflector matrix (36) having a plurality of reflector cones (38) corresponding to each of the light-emitting diodes (28) in the mounting substrate (30) and a hybrid optics panel (40) having a direct lensing section (42) covering the reflector matrix (36) and light-emitting diodes (28) and a double redirecting light pipe section (44) surrounding the lensing section (42). A single light-emitting diode (28) is coupled along spaced apart quadrants (98, 100, 102, 104) of the redirecting light pipe (44). Each single light-emitting diode (28) emits light to the respective quadrant of the optics panel (40) which is reflected and redirected from one or more lens facets to illuminate the front surface of the panel. The direct lensing section (42) and redirecting light pipe (44) illuminate distinct area on the curved cover lens (22).

Description

SYSTEM. OF LIGHT CONTROL ATTENUATED TO DIRECT AND DISTRIBUTE THE LIGHT FROM ONE OR MORE SOURCES OF LIGHT AND METHOD FOR DEVELOPING USEFUL OPTICAL STRUCTURES IN THE SYSTEM Field of the Invention The subject invention relates to an attenuated light control system, and more particularly, to an attenuated light control system for the change of direction and redistribution of light from one or more light sources.

BACKGROUND OF THE INVENTION Conventional light control systems for the headlights, side lights and tail lights of an automotive vehicle typically include a recessed bulb filament in a reflector housing behind a cover lens. The light emitted from the bulb filament is reflected from the reflector housing externally through the cover lens to form a beam or a flat light image. The cover lens forms the light in the desired model, ie the beam of the headlights focusing or side model or rear signal. However, reflector and lighting systems.

REF. : 32541 conventional bulb has disadvantages in terms of design and size of flexibility. The bulb and the reflector require a significant amplitude and depth to acquire the desired focus and light dispersion through the cover lens, thus, limiting the capacity of the flow path and contour of the light system. Other systems have been developed to provide alternatives to the conventional reflector and filament filament system using a light conductor and aligner to direct light to a reflective emitter which has a plurality of lens facets to change the direction of light in the desired trajectory and model. These systems are exemplified in U.S. Patents 5,434,754 to Li et al., Issued July 18, 1995 and 5,197,792 to Jiao et al., Issued March 30, 1993. However, there is still a need for an attenuated light control system. effective, which provides the flexibility of coupling a variety of light emission arrangements for direct illumination and redirected lighting by combining the use of direct lens formation and light optical conductors that have facet change facets to achieve a desired model and light distribution.

Brief Description of The Invention The present subject matter relates, in part, to a system for the change of direction and / or redistribution of light from one or more light sources to provide the flexibility of the lighting design and to couple the constraints of the packaging. of lighting. The system employs an access of unit cells whereby one or more light sources, preferably light emitting diodes, or LEDs, are coupled with an "optical structure." A plurality of unit cells, which can be either of a variety of lenses or light conductors, which can be coupled in a variety of arrangements to achieve the desired intensity and light distribution patterns.The lens formation unit cells employ a lens-forming structure by which the incident light from the unit cells is transmitted directly through it, usually after being reconditioned in some ways Fresnel includes examples of concave or convex lens structures A single dual surface lens element employing spherical surfaces and Cylindrical, a specially adjusted Fresnel lens element, and a combination of the Fresnel lens element / support are described to achieve the best distribution desired lightings. The light conductor unit cells include a light transmission structure that changes the direction and redistributes the incident light therein, typically employing direction change facets and light coupling optics formed on one surface of the structure. The system is particularly advantageously adapted to the applications of the signal lamp of a vehicle. For example, the requirements of the intensity distribution of the signal lamp in the United States are defined by the Federal Motor Vehicle Safety Standard ("FMVSS") No. 108. The FMVSS 108 is consistent with other regional standards and unique customer requirements. Cell units can be constructed, configured and oriented to meet any of these requirements to provide substantially any configuration, shape, or size of the signal lamp in a mechanically robust structure. In addition, the design and flexibility of the packaging provided by the present system can provide the opportunity to improve the configurations of the conventional vehicle signal lamp. The system is particularly thin. It can be used in packaging configurations ranging from around 25-50 mm. The flexibility provided by the unit cell seems to simplify packaging in vehicles and allows variations in lighting and packaging design, for example, signal lamps with curved surfaces. The system is cost effective due to the lighting design that simplifies the access of the unit cells; each unit cell constitutes an optical design element which can be advantageously varied and configured with other design elements for an effective cost achieving a desired intensity distribution of light. Developed light sources, such as LEDs, are cold, consume less energy, and are more reliable and durable than conventional filament light elements. In addition, the LEDs instantly reach virtually the full light intensity, considering that conventional filament light elements take a finite period of time to reach full intensity. A car traveling at highway speeds will travel a significant distance for the time it takes for the filament element to reach full intensity. Therefore, when signal lamps, such as brake lights, are incorporated into the vehicle, the LEDs provide safety advantages because they can release the "brake signal" more quickly than the signal lamps employing the lighting elements with base in the conventional filament. The light control system employs unit cells capable of improving designs such as logos, decals, or writing. In addition, the access of the unit cell allows the creation of unique illuminated appearances, or models, not possible or practical with the associated conventional and optical light sources. A variety of different types of unit cells can be combined to obtain a desired design and intensity distribution: - or to meet the packaging constraints. The resulting optical structure, which may comprise a variety of shapes and optical surfaces, is preferably formed of an optical grade plastic material.

According to another aspect of the present invention, the plastic optical structures can be formed by a unique injection compression casting technique. One or more molded parts define an injection cavity and each molded part may include a movable surface portion for compressing the material within the molded part. Each compressible molded part is preferably independently controlled to apply a specific amount of force, to compress a specific distance, and compress for a specific duration of time. A casting assembly, therefore, the present invention, comprises one or more of the independently controlled compressible mold parts, capable of molding optical structures having complicated geometries, including thick and thin portions in the same relative area and significant transitions of a geometry to the next, with real and exact surfaces. Accordingly, the complicated optical structures of the present invention can be produced economically, even for the high volumes required for the automotive industry, with greater accuracy. Thus, the optical system of the present invention represents a commercially viable improvement in lighting technology.

Brief Description of the Drawings Other advantages of the present invention will be readily appreciated as they will come to be better understood by reference to the following detailed description when considered in connection with the accompanying drawings in which: Figure 1 is a view in schematic perspective of a rear signal lamp of a vehicle employing an attenuated light control system including aspects of the present invention; Figure 2 is a perspective view of a double directional light direction change section of an attenuated light system including aspects of the present invention; Figure 3 is a partial cross-section taken along line 3-3 of Figure 2; Figure 4 is an enlarged and partially rotated view of an area A in Figure 2; Figure 5 is a perspective view of a hybrid optical panel of an attenuated light control system that includes aspects of the present invention; Figure 6 is a partial cross-sectional view of an extraction section of an optical panel including aspects of the present invention that illustrate the light extraction facets of varying inclinations; Figure 7 is a partial plan view of an extraction section of an optical panel including aspects of the present invention illustrating the facets of light extraction of varying slopes; Figure 8 is a perspective view of an alternative embodiment of a hybrid optical panel including aspects of the present invention which illustrates four alternative light couplings for the panel; Figure 9 is a perspective view of a single direction change optical panel employing light sources and optical light coupling on a side edge thereof; Figure 10 is a planar view of a dual surface lens element that can be employed in the attenuated light control system that includes aspects of the present invention; Figure 11 is a cross-sectional view taken along line 11-11 of Figure 10; Figure 12 is a cross-sectional view taken along line 12-12 of Figure 10; Figure 13 is a perspective view of a coupled Fresnel lens element which can be employed in an attenuated light control system that includes aspects of the present invention; Figure 14 is a cross section of the coupled Fresnel lens element taken along line 14-14 of Figure 13; Figure 15 is a perspective view of a Fresnel lens support lens element which can be employed in the attenuated light control system that includes aspects of the present invention; Figure 16 is a cross section of the lens element of the Fresnel lens holder taken along line 16-16 of Figure 15; and Figure 17 is a partial cross-sectional view of an arrangement of the ejection recess for forming an optical element including aspects of the present invention.

Detailed Description of the Drawings For convenience in the following description, various directional or other spatial references are made with respect to the orientation of the structure (s) shown in the drawings. It is understood, however, that the references, include, such as upper, lower, envelope, background, frontal, opposite, left, right, vertical, horizontal, lateral, or longitudinal, without limitation, are only made for convenience and they must not necessarily be elaborated to limit the invention described therein. Although the attenuated light control system of the present invention can be used advantageously in any application where a thin profile of the lighting structure is important, where design flexibility is important, and / or where a surface can be illuminated, the present invention is shown in Figure 1 for purposes of illustration as regards its advantageous use within a rear signal lamp of a vehicle. The attenuated light control system of the present invention finds the particular request within the vehicle signal lamps due to the benefits provided by the thin profile of the system, the flexibility of the design as regards the possible shapes of surface of the illuminated surfaces as well as the flexibility in the lighting designs, the reliability, durability and improved quality of the lighting provided by the system, and the reduced energy consumption of the present system. With reference to the Figures, where similar numbers indicate corresponding or similar parts throughout the various views, a rear signal lamp for a vehicle is generally shown with the reference number 10 in Figure 1. The signal lamp 10 includes an attenuated light control system 12 including aspects of the present invention. The signal lamp 10 further includes a lamp housing 14, preferably composed of a molded plastic, having a rear wall 16 and a peripheral edge wall 18 extending transversely from the rear wall 16 and a plurality of mountable fasteners 20 for mounting the elements of the lighting structure in the housing 14. The signal lamp 10 also preferably includes a cover lens 22 having a curved front surface 24 and a peripheral edge 26. The cover lens 22 is preferably composed of a plastic molded and includes portions which are substantially translucent and which can also be colored. The cover lens 22 can be conventionally designed for a rear signal lamp of a vehicle. The light control system 12 is housed in a cover formed between the accommodation lamp 14 and the cover lens 22, and the entire lamp 10 can be mounted to the rear of a vehicle. The light control system 12 illustrated in the Figures includes a plurality of LEDs emitting backlighting light (LEDs) 28 which are mounted on an LED mounting substrate 30 that forms an array of LEDs. In addition to providing an LED mounting structure, the substrate 30 can also function to transmit power to the LED array and to conduct the heat outside of the LED array. The specific structure shown is similar to a product manufactured by Hewlett-Packard Company and sold under the trade name Snap LED, which is the preferred LED array and substrate. In the embodiment shown, the mounting substrate LED 30 is formed in a staggered step design to couple the curvature of the signal lamp 10. It is noted that the rear wall 16 of the accommodation lamp 14 preferably includes a support section of the lamp. corresponding stepped shape 32 for coupling the mounting substrate in a stepped manner 30. The stepped support section 32 creates the intimate contact between the LED substrate 30 and the plastic housing 14 to more efficiently conduct the heat away from the LEDs 28This improves the thermal characteristics of the system which results in an improved LED performance. The signal lamp system 10 can also generally include an LED electronic control module designated with the number 34. The LED electronic control module 34 includes related electronic and packaging components that are configured to operate the LEDs 28 in a manner required or desired This operation can invert the LEDs on or off or control the intensity of the LEDs for a desired lighting signal. The operation can also control individual LEDs or groups of LEDs to achieve a particular design or appearance objective. In addition, the control module 34 can be used to control the current amount of current to the LEDs as a function of environmental operating conditions in order to ensure proper operation and reliability under certain operating conditions of effort or to maximize efficiency and performance under more normal operating conditions. The electronic control module 34 can be configured in different ways to mount the module 34 within the lamp housing 14, as shown in Figure 1, or to mount the module 34 outside the lamp housing 14, as dictated by the requirements and restrictions of manufacturing requirements and limitations of packaging space. The substrate of the LED assembly 30 has the plurality of LEDs 28 mounted thereon coupled with a matrix reflector 36 having a plurality of reflector cones 38 corresponding in number and position to each of the LEDs 28 mounted on the substrate LED assembly 30. The light control system 12 additionally includes a hybrid optical panel 40, the details of which will be described later. The hybrid optical panel 40 shown in Figures 1 and 5 includes a direct lens-forming section 42, which has a generally elliptical shape, and a double steering-light-changing section 44, which surrounds the lens-forming section. 42 to form a contoured solid body corresponding to the curved front surface 24 of the cover lens 22. The hybrid optical panel 40 preferably formed of an acrylic / PMMA molding, but may, alternatively, be formed of a polycarbonate. The preferred pouring process for forming the hybrid optical panel 40 will be described in detail hereinafter. Disposed in each of the four corners of the hybrid optical panel 40 are the individual LEDs 46, each of which is coupled with a quadrant of the double direction-change light-conducting section 44 of the optical panel 40. The light emitted by each one of the corners of LEDs, or diodes 46 are coupled in their respective quadrant of the double directional light-changing section 44, and the light is changed in direction and redistributed so that the light emitted from the LEDs 46 in the corners are emitted from the front surface of the panel 40 as a generally greater surface illumination. Although it is preferred to use the LEDs as a light source, other light sources can be used as, for example, fiber optic or gas discharge light sources. The combination of an individual LED, or other appropriate light source, with a particular optical structure, is a change-of-direction light conducting structure or one or more direct transmission lenses, known as a unit cell.

The LED mounting substrate 30 and the matrix reflector 36 are positioned directly behind the direct lens-forming section 42 of the optical panel 40. The lens-forming section 42 may comprise a plurality, or array, of individual lenses 48 which corresponds in number and position with the reflector cones 38 and the LEDs 28. The light emitted from the LEDs 28 passes directly through the lenses 48 of the lens forming section 42 to be emitted from the surface of the optical panel 40 in a first predetermined model. The details of the operation of a simplified double direction change unit cell with reference to the exemplified unit cell shown in Figures 2-4 will be explained. Figure 2 generally illustrates a double direction change light conductor 50 comprising two unit cells 52 and 54, wherein the unit cell 52 comprises the left half of the light conducting section 50, and the unit cell 54 comprises the right half of the light conducting section 50. Each unit cell 52, 54 has been associated with the LEDs 56 and 58, respectively, placed on an optical coupling lens 60, 62 formed in each respective unit cell 52. , 54. With reference to the unit cell 54 for purposes of illustration, the unit cell 54 includes a first light direction change structure 64, also known as an "internal total reflection or TIR" section, and a second light direction change structure 66, also known as an extraction section. For clarity in Figure 2, the reference line WN "separates the first light direction change structure 64 from the second light direction change structure 66. The first and second light direction change structures 64 and 66 are preferably formed integrally with each other The first light direction changing structure, or TIR section 64, has a generally elongated vertical wedge shape structure with a plurality of facet defining steps formed along the length of the the marginal outer surface thereof The stages defining the facet define the facet changes of light direction 68 separated by the planar sections 70 of variable length.Referring to Figure 3, the second structure of light direction change, or extraction section 66, has a panel structure having a generally elongated laterally extending wedge-shaped cross section, a second plurality of e.g. Lids defining the facet are formed along the angular outer surface of the wedge. The second stages defining the facet also define the light direction change facets 72 separated by planar sections 74 of variable length. The light conductor 50 further includes a front surface 76 that preferably has a generally flat illumination surface to each unit cell 52, 54. Similarly, the unit cell 52 also includes a first light direction changing structure 78 having light direction change facets 80 separated by straight flat sections 82 of varying lengths and a second light direction changing structure 84 having light direction change facets 86 separated by straight flat sections 88 of varying length. Figure 4 shows an elongated area indicated as A of the unit cell 54 of Figure 2. Referring to Figure 4, the light direction change facets 68 of the first light direction change structure 64 preferably they have a shape defined by the flat central portion 90 extending in a generally parallel relationship with respect to the lateral edge of the light direction changing facet 68 and surrounded on either side by the curved portions 92, 94, which preferably define the portions of arches. The curved portions 92, 94 preferably define the portions of the various arcs, but can define the portions of a common circular arc. This shape of each of the light direction change facets 68 expands the light reflected from it in a desired manner to be described later. The direction change facets 72 of the second light direction changing structure 66 are also preferably formed in a similar manner. Accordingly, as shown in Figure 2, the LED 58 emits light in the optical coupling lens 62. of the unit cell 54. The optical coupling lens 62 is preferably a Fresnel lens with constant focal length when aligning the light from the LED 58. The cone of light emitted by the LED 58 is transmitted by the optical coupling lens 62. in the first light direction changing structure 64. A portion of the light of the LED 58 is schematically represented by the lines defined with arrows. The light transmitted through the first light direction change structure 64 until contact with a plurality of direction change facets 68 formed along the outer edge edge of the light direction change structure 64. Large part of the light which is in contact with the planar sections 70 before being in contact with a facet of change of direction 68 is transmitted by the total internal reflection again of the first light direction change structure 64. Accordingly, the structure 64 is a body that transmits light effectively. As represented by the arrows, light contacting a direction change facet 68 is vertically expanded and changed direction laterally along a second predetermined pattern for address change facet 68 in the second change structure of light direction, or extraction section 66. The operation of a structure similar to the first light direction change structures has a plurality of flat direction change facets which is described in US Patent No. 5,434,754 for Li and collaborators The light reflected laterally by one of the direction change facets 68 of the first direction change structure 64 in the second light direction change structure 66 is transmitted through the second light direction change structure 66 to which finds one of the pluralities of the extraction facets 72 whereby the light is expanded horizontally and again changes direction laterally, i.e. extracted, along a second pattern predetermined by the facet 72 across the surface of front illumination 76 of the light conductor 50. Much of the light transmitted through the second light direction changing structure 66 which makes contact with the flat sections 74 or the illumination surface 76 before contacting a facet of extraction 72 is directed by the total interior reflection again of the light direction changing structure 66. Accordingly, the second structure of ac The direction of light 66 is a body that transmits light efficiently, and thus, the light of a single LED 58 can be changed in direction and redistributed to emit as a generally greater surface illumination from the illumination surface 76 of the light conductor 50. The unit cell 52 is essentially a mirror image of the unit cell 54, and thus, the light emitted from the LED 56 is changed in direction and redistributed to the front illumination surface 76 similarly as shown in FIG. described above for unit cell 54. The expansion of light on the reflection from a facet of light direction change is caused by the shape of the curved-straight-curved surface described above of the same facet as shown in FIG. Figure 4. It can be seen that the amount of light expansion can be controlled by the amount of the facet surface that is curved and by the radius of curvature of the curved portions. ace. If the facet is not curved at all, the reflected light will be redirected with no substantial expansion. For any given facet, the proportion of the facet surface which constitutes the flat portion, the proportion which constitutes the curved portions, and the radius of curvature of the curved portions may vary from facet to facet, depending on the result of the extension. of desired light. The curved portions or flat portions may be omitted, ie, the facet may be completely flat or completely curved. The curve may be concave or convex, depending on whether light expansion or light focus is desired. The shape, size, number, and orientation of all facets can be varied so that the facets interact to achieve the desired lighting effect more effectively. The facets of change of direction 68 and 72 can also change the direction by beating the light by means of total internal reflection. If, however, the amount of reflection provided by the total of the internal reflection is insufficient, some or all of the facets can be coated with a reflective coating such as aluminum deposited in a vacuum. For the application of the vehicle signal lamp described therein, it is preferable that the facets of the second light direction changing structures 66 and 84 are coated with a reflective material. Again, the double direction change light conductor 50 shown in Figure 2 is essentially symmetrical about a vertical center line, ie, the unit cell 52 is essentially an equal image of the unit cell 54. It will be appreciated, however, that symmetry is not necessary. For example, the inclination and orientation of each of the unit jails 52 and 54 can be varied substantially to adjust packing constraints and maintain a thin system. In addition, the first address change structure 78 of the unit cell 52 can have a different number of address change facets 80 located in different positions of the facets 68 of the first light direction change structure 64 of the cell of unit 54. In addition, the second light direction changing structures 66 and 84 of the unit cells 54 and 52, respectively, may have numbers, lengths, and arrangements of different direction change facets formed thereon. Also, the cells of the unit 52 and 54 shown in Figure 2 have second light direction changing structures 84, 66, respectively, which are symmetrical from the top to the base. This is also not necessary in the present invention. As shown, for example, in Figures 1 and 5, the shape, size, number, and orientation of the facets along the second structure for the change of light direction can be varied in both horizontal and vertical directions . The facets of the IRR and extraction sections act reciprocally, the last facets of reception, change of direction, and redistribution of the received light, change of direction, and redistributed by the trainer to more effectively achieve surface illumination relatively greater from a minimum number of light sources. This is the ability to vary the shape, size, number, and orientation of the address change facets in the light direction change structures which provide the attenuated light control system of the present invention with the flexibility to flatten a variety of lighting design requirements and packaging constraints. It should also be appreciated that the first light direction changing structures 64, 78 may include one or more LEDs 56, 58 coupled with the lenses 60, 62 corresponding to the distal end of the structures 64, 78 to increase the intensity of illumination to the unit cells 52, 54 and panel 50. Hybrid optical panel 40 is shown in more detail in Figure 5. Panel 40 includes a lens-forming section 42 and a dual direction-change light-conducting section 44. The double direction change light steering section 44 shown in Figure 5 includes a first quadrant 98., a second quadrant 100, a third quadrant 102, and a fourth quadrant 104, which together surround the lens forming section 42. The first quadrant 98 includes a first light direction changing structure 106 having a plurality of facets of light direction change 108, a second light direction change structure 110 having a plurality of direction change facets 112, and a front light surface 114. Similarly, the second quadrant 100 includes a first and second light direction structures. light direction change 116, 118 and a front lighting surface 120, the third quadrant 102 includes a first and second light direction changing structures 122, 124 and the front lighting surface 126, and the fourth quadrant 104 includes a first and second light direction changing structures 128, 130 and the front lighting surface 132. In addition, each of the second 100, third 102 and fourth quadrants rto 104 include facets similar to those shown in the first quadrant 98. As can be seen from Figure 5, the size, shape, orientation, and number of address change facets in the first and second address change structures Light of the four quadrants 98, 100, 102, and 104, are widely variable to accommodate a wide variety of lighting design requirements and packaging limitations. For example, the extraction facets 112 may be oriented for light direction change in a non-normal direction to the illumination surface 114. Accordingly, the light output may be directed along an axis of the vehicle as defined in FIG. FMVSS 108. As shown in Figure 6, a cross-section exemplifying a portion of a light removal section which can be used in one of the quadrants of Figure 5 is generally shown with the number 134 and includes three facets of change of direction, light extraction, 136, 138, 140 and a portion of illumination surface 142. Each extraction facet 136, 138, 140 are oriented at a different angle, or inclination,? i,? 2,? 3 , respectively, with respect to a normal one to the illumination surface 142. The extraction face 136 is oriented at an angle? i = 45 ° with respect to one normal to the illumination surface 142. For this orientation, the incident light , represented by the arrow labeled Ii, will be reflected, as represented by the arrow labeled Ri, in a preferred direction cii, approximately equal to 90 °, which is substantially normal to the illumination surface 142. The extraction facet 138 is oriented at an angle? - <; 45 ° with respect to one normal to the illumination surface 142. For this orientation, the incident light, represented by the arrow labeled I2, will be reflected, as represented by the arrow labeled R2, in a preferred direction a2 which is smaller than 90 ° _ with respect to the illumination surface 142. Finally, the extraction face 140 is oriented at an angle? 3 > 45 ° with respect to one normal to the illumination surface 142. For this orientation, the incident light, represented by the arrow labeled I3, will be reflected, as represented by the arrow labeled R3, in a preferred direction a3 which is larger than 90 ° with respect to the illumination surface 142. If the orientation of the extraction facet is such that it can not operate by total internal reflection, it may be necessary to apply a reflective coating to the surface of the direction change surface as discussed previously. As can be seen, for example, of Figure 5, the extraction facets formed on the back surfaces of the second light direction changing structures 110, 118, 124, and 130 define generally parallel lines of the facets that are they extend transversely through the posterior surfaces. As shown in Figure 7, a portion is generally shown with the number 144 exemplifying a back surface of a second light direction changing structure, or extraction section, may include extraction facets 146, 148, 150, generally for define a line 152 of the facets. The orientation of the facets with respect to the line, ie, the inclination, can be varied to adjust the preferred direction of the light reflected by the facets of the plane provided in Figure 6. For example, the facet 146 is oriented at an angle , or inclination, ßi, of 90 ° which is normal to line 152 and parallel to the vertical or V direction and reflects light without deflection along direction V, facet 140 is oriented at an angle, ß2 which is less than 90 ° with respect to line 152 and the light changes direction towards the negative direction V, and facet 150 is oriented at an angle, ß which is greater than 90 ° with respect to line 152 to change from I direct the light towards the positive V direction. While the illumination surface of each individual quadrant, or unit cell, of the dual address change light steering section 44 is preferably, but not necessarily, a flat surface, the four planar surfaces of the quadrants are not necessarily coplanar between yes. The individual quadrants, or unit cells, may be arranged at angles relative to each other to accommodate the requirements of the curved illumination surface and / or curved packaging constraints. The inclination and slope facet and angular orientation of the light removal section can be varied to achieve non-rectangular light distribution models, adjusted from thin light control structures whose shapes are adjusted to specify, packaging limitations often not flat. For example, such a structure can be provided behind a signal lamp cover of a vehicle that is curved and has a thickness of only 30 mm behind the cover. In the embodiment of the unit cells 52 and 54 shown in Figure 2, the optical coupling 60, 62 comprises a Fresnel lens preferably formed in the upper corner of each cell unit 52, 54 to direct, form, and align the light emitted by the LEDs 56 and 58 in the first light direction changing structures 78 and 64, respectively. As shown in Figure 8, however, a variety of light coupling accesses can be taken to direct light from a light source in a light direction change structure. It is not always necessary to align the directed light source to a light direction change structure. The light must be conditioned for the interaction of the light transmitted within the structure of change of direction or structures with the facets of change of direction that achieve the desired intensity and distribution of light more effectively.

Examples of different light coupling accesses are shown in Figure 8. A hybrid optical panel generally shown with no. 154 in Figure 8 has four double direction change quadrants, or unit cells, 156, 158, 160, 162 and a centrally located lens forming section 164. The coupling 166 of the first address change structure 168 of FIG. the unit cell 156 does not include any external coupling structure. The light receiving surface may comprise a Fresnel lens as shown in Fl 2, or another type of lens structure, such as a concave or convex lens, as determined by the lighting requirements. Alternatively, the coupling 166 may comprise only a flat, light receiving surface that has no particular light conditioning structure formed therein. The coupling 170 of the unit cell 158 includes a reflector cone 172 for collection and direction of light emitted from a light source in the first direction change structure 174. A lens structure, such as Fresnel, concave or convex , it can be used in the interface 176 of the reflector cone 172 and in the first address change structure 174. The coupling 178 of the unit cell 162 includes the address change structure 180. The light emitted by the incoming light source to the light receiving surface 182 and reflected from the reflection surface 184 in the first address change structure 186 of the quadrant, or unit cell 162. A lens structure, such as a Fresnel lens, concave, or convex, it can be employed in either or both of the light receiving surface 182 and of the address change structure interface 180 and the first address change structure 186. The reflection surface 184 can reflecting light by total internal reflection, or a reflective coating, such as vacuum-deposited aluminum, can be applied to surface 184. Coupling 188 of unit cell 160 combines a reflector cone 190 with a light direction change structure 192 The light emitted by a light source and collected and directed by the reflector cone 190 enters the direction change structure 192 on the receiving surface 194 and is reflected by the reflection surface 196 in the first direction change structure 198. of the quadrant, or unit cell 160. The reflection surface 196 may operate by total internal reflection or, alternatively, may be coated with a reflective coating to improve reflectivity thereof. A lens structure, such as a Fresnel lens, concave, convex, may be employed in the light receiving surface 194, or in the interface of the direction change structure 192 with the first address change structure 198. As can be seen , the optical and light coupling structure can be constructed and arranged to couple a variety of light source positions and incident angles. In addition, although the optical and light coupling structures shown in Figure 8 couple the light sources that generally emit light within a plane defined by the panel 154, it can be seen that the coupling and optical structure can be configured to accommodate the sources of light outside the plane. The flexibility of the light coupling allows the overall flexibility of the packaging and installation of the system. A light conducting section for the change of light direction may comprise more or less two light direction change structures. For example, as shown in Figure 9, the light direction change light conductor shown with the no. 200 includes only a single light direction change structure 202 and bordered by a plurality of edge mount LEDs 204 coupled with corresponding reflector cones 206. The illuminating edge A change of direction light conductor can also take other forms such as directing the light emitted from a light source to the edge of the panel without the use of reflector cones or using reflector cones combined with fiber optic cables or other combinations of light formation. lenses and / or light conductors. The optical panel 154 shown in Figure 8 includes a lens forming section 164 having a series of individual lenses 208 for coupling with a backlight matrix, preferably comprises a corresponding number of LEDs mounted in a similarly oriented array. As can be appreciated by comparing Figures 5 and 8, the orientation and number of individual lenses in the lens forming section can be varied and the overall shape of the lens forming section can also be varied. Alternatively, as shown in Figures 2 and 9, a direct emitting lens training section can be omitted altogether.

The type of optics used for the individual lenses of the lens training section can also be varied. Individual lenses can be concave, convex, Fresnel, or other types of lenses. In the embodiment illustrated in Figure 8, the lenses 208 are Fresnel lenses. It is not necessary that all the lenses of a particular lens training section are of the same type of lens, that is, that the type of lens can be varied within the lens forming section. Furthermore, it is not necessary that all individual direct emission lenses are grouped into a single contiguous lens formation section. • Direct emission lenses can extend along the hybrid optical panel as individual lenses or subgroups of lenses. In a direct lens forming section or sections, the light is transmitted substantially directly through the optical structure without a significant change of direction. In addition, the amount of light expansion occurring in the direct lens-forming section (s) is relatively small when compared to the substantial expansion which can take place in a double-directional beam-changing section as described previously. Thus, it can be readily appreciated that the intensity of the light emitted from the direct lens-forming section will normally be substantially greater than the intensity of light emitted from a direction-changing light-conducting section. In a vehicle signal lamp application of an attenuated light control system of the present invention, as shown in Figure 1. The relatively high intensity direct lens forming section 42 can be used to illuminate a portion of advance / stop as shown with the number 43 of the cover lens of the signal lamp 22, and the relatively low intensity direction change light conducting section 44 surrounding the lens forming section 42 can be used to illuminate a portion of ordinary light as shown with no. 45 of the cover lens of the signal lamp 22. A particularly advantageous direct emission lens structure for use in the lens forming section of a hybrid optical panel is shown in Figures 10-12. A lens element like it is shown with the no. 210, called as a dual surface lens, includes a partial spherical surface 212 embedded within and imposed on a partial cylindrical surface 214. The lens 210 is preferably molded of a plastic material of appropriate optical quality. As shown in Figure 10, the dual surface lens 210 is preferably square in plan view. The lens 210 is preferably coupled with a square reflector cone 216, as shown in Figures 11 and 12, which has a reflective internal surface 218, and an LED 220 is centered within an entrance aperture 222 of the reflector cone 216. The surface receiving light from the lens 210 in the outlet aperture 224 of the cone 216 is preferably planar. In the preferred embodiment, the apertures of the inlet and outlet reflector cone 222, 224 are 3.7 and 10.8 m square, respectively, and the length of the cone 216 is 10 mm. Each lens 210 is preferably oriented within a hybrid optical panel so that the axis of the cylindrical surface 214 is horizontal. The construction of the dual surface of light direction change horizontally or vertically. The change of direction design can be varied by changing the structure of the lens 210, for example by varying the radius of curvature of either or both of the spherical 212 and cylindrical portions 214 of the lens 210. In the preferred embodiment, the radius of curvature of the spherical portion 212 is 16.8 mm and the radius of curvature of cylindrical portion 214 is 11.9 mm. Another lens structure for the advantageous direct emission for use in the lens forming section of a hybrid optical panel is shown in Figures 13 and 14. A Fresnel lens element of adjusted variable focal length having 2: 1 of height for the wide aspect ratio shown with the no. 226. Lens 226 includes a circular central portion 228, which comprises a portion of a sphere, and a plurality of concentric rings that progress externally from the portion 228. In the illustrated embodiment, the lens has four rings 230, 232, 234, 236. The upper surface of the lens 226 has a a rotationally symmetrical profile, and each facet, defined by a single ring, has a different focal length. The focal length of a ring of the lens 226 is preferably provided by the equation: 1- initiation "i" (Ipa ro li ni cio ^ ^ stop) Where: f = focal length in a given Fresnel ring, defined by the radius r; finido = focal length in the spherical central facet; fparo = focal length in the outer Fresnel ring; rBar = radius of the outer Fresnel ring, and n = exponential interpolation factor.

For the overall dimensions of the preferred embodiment of the lens are 30 mm X 15 mm and fine - 45 mm, fparo = 90 mm, and rparo = 15 mm and n = 2. The lens 226 is preferably coupled with a cone 238 having a rectangular cross-sectional shape and an LED 240 arranged in the entrance opening 242 of the cone 238. In the preferred embodiment, the cone 238 has a length of 20 mm. Another advantageous direct emission lens structure for use in the lens forming section of a hybrid optical panel is shown in Figures 15 and 16. A supporting Fresnel lens element 244 includes an internal alignment Fresnel surface 246 and a formed outer surface of the support lens 248. The Fresnel inner surface 246 is defined by a central spherically formed facet 250 and a plurality of Fresnel rings 252, having a constant focal length, progressing outwardly from the central facet 250. The faceted surface of the Fresnel inner surface 246 is rotationally symmetrical. The surface of the outer support lens 248 is defined by a series of support lenses 254. The outer Fresnel surface 248 aligns the incoming light and the support surface 248 expands the light. The profile of each individual support lens 254 is rotationally symmetrical and has a slightly hyperbolic shape. An asymmetric output distribution is created by altering the ratio of the horizontal to vertical aspect for each individual support lens. For the overall dimensions of the preferred embodiment of the support Fresnel lens element 240 is 30 mm by 15 mm. The internal surface of the Fresnel lens 246 has a focal length of 21.5 m. Each support lens 254 has an aperture of 3 mm by 1.5 mm and a profile that is slightly hyperbolic (conical constant of -1.25) with a radius of the apex of curvature of 3.1 mm. A reflector 256 has a length of 20 mm and an LED 258 is disposed in the inlet opening as previously described. In an application of the vehicle signal lamp of an attenuated light control system of the present invention, as shown in Figure 1, an injection casting arrangement for forming a hybrid optical panel according to the present invention it is generally indicated by the reference numeral 260 in Figure 17. What is shown in Figure 17 is about a quarter of one embodiment of a complete casting arrangement and a quarter of the hybrid optical panel formed therein. The hybrid optical panel formed by the injection casting arrangement 260 is generally designated by the reference numeral 262, a dial of a direction-changing light conducting section is generally indicated by the reference number 264 and a quarter of a section The central lens forming portion is generally indicated by the reference numeral 266. The illustrated pouring arrangement 260 includes a fixed molding portion 268, an outer movable molding portion 270, and an internal movable molding portion 272. The movable molding portion outer 270 and internal movable molding portion 272 are both independently movable with respect to fixed molding portion 268 and with respect to each other in the directions indicated by arrows "A" and "B", respectively. An upper portion 274 is also provided. The fixed molding portion 268 includes a facet of the surface forming surface 276 to form the light direction change facets of the desired number, shape, and orientation on the back side of the section. direction change light driver 264, to form a second, direction change or light removal structure. An edge face which forms the surface 278, formed in an end wall facing inwardly of the fixed molding portion 268, is formed to form the facet changes of light direction along an edge of the address change light conducting section 264 in the desired number, size, and orientation to form a first, direction change structure of light or IRR, to form a first structure of change of light direction. The injection casting arrangement 260 also includes an injection port 280 that preferably extends through the upper portion 274 and is preferably located in a relatively dense portion of the address change light section 264. The injection port 280 communicates with a pouring cavity defined by the fixed molding portion 268, the internal and external molding portions 272 and 270, and the upper portion 274. The finishing of a complete injection casting arrangement according to the present invention it will vary depending on the design formed of the thin optical structure of light control. One or more movable portions, such as the internal and external movable portions 272 and 270, may be included in the array. For example, a total injection casting arrangement for forming a complete hybrid optical panel, such as those shown in Figures 1, 5, and 8, will preferably include four quadrants, such as those shown in Figure 17, formed integrally with each other and also they will preferably include an injection port in each of the quadrants. On the other hand, a hybrid optical panel as shown in Figure 2 will preferably be formed using two emptying quadrants, as shown in Figure 17. An optical panel as shown in Figure 9 will be formed using a draining dial preferably , as shown in Figure 17, also without the inner movable portion 272. In operation, the outer movable molding portion 270 is applied against the non-faceted portion of the address change light steering section 264, or the front surface of lighting. Thus, a draining surface of the outer movable portion 270 will preferably be flat and smooth. The internal movable molding portion 272 is formed and oriented to form the lens forming portion 266 of the optical panel 262. Thus, a voiding surface of the internal movable molding portion 272 and / or molding surface 282 of the portion fixed molding 268 will be structured to form lens structures of the direct lens forming section 266, such as the concave, convex, or Fresnel lenses or one or more of the dual surface lens elements described above, the elements of adjusted Fresnel lens, or Fresnel lens elements of support. In addition, the emptying surface 284 of the upper portion 274 can be constructed and arranged to form the optical coupling structures appropriately located at the upper edge of the optical panel 262. Alternatively, or in addition, an end wall facing inwardly from the Fixed molding portion 268 can be constructed and arranged to form appropriately located optical coupling structures along a side edge of optical panel 262. Optical panel 262 is formed by a single and improved injection compression casting technique. The molten material is injected through the injection port 280 into the mold cavity defined by the fixed molding portion 268, the movable portions 270 and 272, and the upper portion 274. After the mold cavity is substantially filled with the molten material, and during the curing period of the material, a controlled amount of pressure can be applied to the outer and inner movable portions 270, 272 independently of one another. Not only can the amount of pressure be controlled, but the amount of displacement of each movable portion can also be controlled independently. The duration of the pressure applied to each movable molding portion is also preferably controlled independently. The pressure eliminates gaps in the molten material and causes the molten material to more accurately fill the formed surfaces of the pouring cavity. The pressure also eliminates buckling that can occur in the relatively denser portions of the molded part due to variations in curing time through the thickness of the part. Independent control of pressure and displacement, as well as the duration of application of pressure, of one or more movable molding portions that actually allow the injection casting of the articles, such as the hybrid optical panels of the present invention, which have complex geometries, including dense and thin sections in the same relative areas and drastic transitions of one geometry to the next as exemplified in the preferred embodiment of the present invention of Figure 1.

The invention has been described in an illustrative manner, and it will be understood that the terminology that has been used is desired to be in the nature of the words of the description rather than to limit it. Obviously, many modifications and variations of the present invention are possible in the clarity of the above teachings. Accordingly, it will be understood that within the scope of the appended claims the invention may be practiced on the other hand, which as specifically described.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is the conventional one for the manufacture of the objects or products to which it refers. Having described the invention as above, the contents of the following are claimed as properties:

Claims (24)

1. A hybrid optical panel for changing the direction of the light emitted from a light source to a lighting surface characterized in that: a double direction change conductor having a first light direction change structure and a second direction change structure of light forming an integral solid body having a front illumination surface; the first light direction changing structure forms a generally elongated wedge-shaped section having a plurality of spaced-apart facets to define a stepped outer edge for the change of direction of the light emitted from a generally co-planar light source to the front lighting surface; the second light direction changing structure forming a panel section having a generally elongated wedge-shaped cross section extending laterally and a plurality of facets spaced apart to define an outer surface in a stepped manner; and the facets of the second light direction change structure generally aligned transversely to the facets of the first light direction change structure to deflect the light reflected outwardly from the facets of the first light direction change structure to the front surface of lighting.

2. A hybrid optical panel according to claim 1, characterized in that the facets of one of the first and second light direction changing structures includes a central planar portion extending between the illuminating front surface and the outer surface and a portion thereof. curved adjacent to at least one side of the planar central portion to disperse the light emitted from the light source along a predetermined angular pattern.

3. A hybrid optical panel according to claim 2, characterized in that the facets of at least one of the first and second light direction change structures are separated by the planar sections.

4. A hybrid optical panel according to claim 3, characterized in that it additionally includes an optical coupling lens coupled to a distal end of the first light direction change structure to generally align the light emitted from the light source in the first structure of change of light direction.

5. A hybrid optical panel according to claim 4, characterized in that the panel includes a plurality of the first and second light direction changing structures for defining the unit cells to form a solid body optical panel.

6. A hybrid optical panel according to claim 5, characterized in that the unit cells forming the optical panel are coplanar.

7. A hybrid optical panel according to claim 5, characterized in that the unit cells forming the optical panel are not planar.

8. A hybrid optical panel according to any of the preceding claims in combination with a signal lamp assembly having a housing and a cover lens coupled to the housing to form a shell therebetween; the hybrid optical panel enclosed within the enclosure between the housing and the cover lens; And a second light source connected to the optical panel for emitting light in the direction change light conducting section, wherein the light of the second light source is changed direction through the conductive section of light of change of direction to illuminate a generally flat front surface of the optical panel.

9. A combination according to claim 8, characterized in that the address change light conducting section includes a plurality of integrally formed quadrants as a solid body optical panel.

10. A combination according to claim 8 or 9, characterized in that the hybrid optical panel includes a direct lens-forming section for transmitting light directly through the panel, the direct lens-forming section being integrally formed with a conductive section of direction change light; and the combination further comprises a first light source positioned between the housing and the hybrid optical panel for emitting light in the direct lens-forming section.

11. A combination according to claim 10, characterized in that it additionally includes a second light source associated with each of the quadrants of the direction change light conducting section to change direction of the light through the light conducting section and illuminate the front surface.

12. A combination according to claim 11, characterized in that each of the second light sources is coupled to one of the respective quadrants to emit the light generally coplana to the illumination surface area towards the facets of the first change structure of light direction.

13. A combination according to claim 12, characterized in that it additionally includes a plurality of the first light sources secured in a substrate assembly to define a series of light sources, the substrate assembly positioned between the housing the forming section of direct lenses.

14. A combination according to claim 12, characterized in that the direct lens forming section includes a series of individual lenses corresponding to the series of the first light sources.

15. A combination according to claim 14, characterized in that it additionally includes a matrix reflector positioned between the substrate assembly and the direct lens forming section; The matrix reflector has a plurality of corresponding reflector cones with a plurality of lenses and light sources to cut the light emitted from the first light sources in the lenses.

16. A combination according to claim 15, characterized in that the cover lens includes a curved front surface.

17. A combination according to claim 16, characterized in that the optical panel includes an optical panel of solid profiled body generally corresponding to the curved front surface of the cover lens.

18. A combination according to claim 17, characterized in that it additionally includes an electronic control module for controlling the operation of the first and second light sources.

19. A combination according to claim 18, characterized in that the first and second light sources include at least one light emitting diode.

20. A combination according to claim 19, characterized in that the hybrid optical panel is formed of molded acrylic / PMMA.

21. An injection casting method for a hybrid optical panel in a mold assembly to form a first and second direction change light conducting sections having at least one facet and a profiled lens forming section, the method is characterized because it includes the steps of: forming a mold cavity defined by a fixed mold portion, an internal movable portion, an external movable portion, and an upper portion; injecting a molten material into the mold cavity; moving the inner movable portion against the molten material to form the profiled lens formation section; moving the external movable portion against the molten material independent of the movement of the internal movable portion to form a flat lighting surface in the panel; And applying a predetermined amount of pressure to the mold cavity to bring the molten material against a portion that forms the edge facet to form the facets in the first light direction changing section of the panel and against a portion forming a facet to form the facets in the second conductive section of light change direction of the panel opposite the flat surface of illumination.

22. The method according to claim 21, characterized in that it additionally includes the step of controlling the amount of pressure applied to the mold cavity.

23. The method according to claim 22, characterized in that it additionally includes the step of controlling the time duration of the pressure applied to the mold cavity.

24. The method according to claim 23, characterized in that it additionally includes the step of independently controlling the displacement of each external and internal movable portion. SUMMARY OF THE INVENTION A rear signal lamp (10) of an automotive vehicle comprising a lamp housing (14) and a curved cover lens (22) for enclosing an attenuated light control system (12). The attenuated light control system (12) includes a plurality of light emitting diodes of the rear headlight (28) mounted in a mounting of the light substrate (30) and secured in the lamp housing (14). A control module (34) operatively connected to the light emitting diodes (28) to control the operation and illumination of the light emitting diodes (28). A matrix reflector (36) has a plurality of reflector cones (38) corresponding to each of the light emitting diodes (28) in the substrate assembly (30) and a hybrid optical panel (40) having a section of direct lens formation (42) covering the matrix reflector (36) and light emitting diodes (28) and a double direction change light conducting section (44) around the lens forming section (42). A light emitting diode (28) is coupled along spaced apart quadrants (98, 100, 102, 104) of the direction change light conductor (44). Each single light emitting diode (28) emits light to the respective dial of the optical panel (40) which is reflected and changed direction from one or more facets of the lens to illuminate the front surface of the panel. The direct lens training section (42) and the direction change light conductor (44) illuminate different areas on the curved cover lens (22).