LIGHT FOR VEHICLES

• US 20080253140A1
• Filed: 03/19/2008
• Published: 10/16/2008
• Est. Priority Date: 03/19/2007
• Status: Active Grant

• Current Assignee: Innotec, Corp.
• Original Assignee: Interlum, LLC
• Inventors: Veenstra, Thomas J., Judge, Michael K., Fleischmann, Eric L., DeVries, Nick J.
• Granted Patent: US 7,712,933 B2
• Time in Patent Office: Days
• US Class Current: 362/487
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• CPC Class Codes: B60Q 3/217 Doors, e.g. door sills; Steps
• CPC Class Codes: B60R 2013/016 integrating other functions or accessories
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: G02B 6/006 to produce indicia, symbols, texts or the like
• CPC Class Codes: G02B 6/0091 of the light source relative to the light guide G02B6/0021 takes precedence
• CPC Class Codes: H05K 3/284 for encapsulating mounted components H05K1/185 takes precedence
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.

Abstract

A light for motor vehicles and the like includes one or more LEDs that are embedded in a polymer material. The light may be positioned on an exposed surface of the vehicle, and the encapsulation of the LEDs and other electrical components provides a waterproof assembly that is substantially impervious to ambient conditions. The light may include a light source and a light guide that are disposed in a watertight housing.

Claims

1. A light assembly for vehicles, comprising:

a vehicle component configured to form a portion of a motor vehicle;

an outer member defining opposed inner and outer surfaces, the outer member comprising a sheet of material having a first area that transmits at least a substantial portion of light incident on the sheet through the sheet, and a second area that transmits substantially less light relative to the first area, such that the first and second areas together define a predetermined pattern;

a light guide disposed adjacent the inner surface of the outer member, the light guide defining a light-receiving portion, wherein the light guide is made of a light-transmitting material that internally reflects a substantial portion of light introduced into the light guide at the light-receiving portion;

a light source mechanically connected to the light guide adjacent the light-receiving portion, the light source including an electrically conductive circuit and at least one LED connected to the circuit, the light source further including a thermoplastic polymer body encapsulating the one LED and at least a substantial portion of the circuit;

a base member fixed to the outer member to define therewith a watertight cavity, and wherein the light guide and the light source are disposed within the watertight cavity.

2. The light assembly of claim 1, wherein:

the outer member comprises a sheet of material having a substantially uniform thickness.

3. The light assembly of claim 2, wherein:

the inner and outer surfaces of the outer member are substantially planar.

4. The light assembly of claim 3, wherein:

the outer member has a thickness of about 1.0-2.0 mm.

5. The light assembly of claim 4, wherein:

the outer member comprises a layer of polymer material.

6. The light assembly of claim 1, wherein:

the base member comprises a substantially planar inner surface; and

the light guide comprises a sheet of polymer material having substantially planar first and second opposed surfaces disposed adjacent the inner surface of the outer member and the inner surface of the base member, respectively.

7. The light assembly of claim 6, wherein:

the first and second surfaces of the light guide are in direct contact with the inner surface of the outer member and the inner surface of the base member, respectively.

8. The light assembly of claim 6, wherein:

the light guide has a thickness of about 2.0 mm to about 5.0 mm.

9. The light assembly of claim 1, wherein:

the light guide includes a body portion and an integrally-formed first connector; and

wherein;

the thermoplastic polymer body of the light source includes an integrally-formed second connector engaging the first connector and mechanically interconnecting the light guide and the light source.

10. The light assembly of claim 9, wherein:

a selected one of the first and second connectors comprises a protrusion, and the other of the first and second connectors comprises an indentation, and wherein the protrusion is received in the indentation.

11. The light assembly of claim 10, wherein:

the protrusion includes a first portion extending in a first direction, and a second portion extending in a second direction that is transverse to the first direction.

12. The light assembly of claim 11, wherein:

the protrusion is T-shaped.

13. The light assembly of claim 12, wherein:

the protrusion includes planar opposite side surfaces, and a peripheral edge surface extending between the opposite side surfaces, and wherein the peripheral edge surface is perpendicular to the opposite side surfaces.

14. The light assembly of claim 1, wherein:

the base member defines a peripheral outer edge; and

the outer member defines a peripheral outer edge that is about the same size and shape as the peripheral outer edge of the base member.

15. The light assembly of claim 14, wherein:

the base member defines a generally planar outer surface, the outer surface of the base member and the outer surface of the outer member defining a thickness that is less than about 5.0 mm.

16. The light assembly of claim 15, wherein:

the vehicle component includes a generally planar web portion having an opening therethrough, and wherein;

the outer member extends across said opening.

17. The light assembly of claim 16, wherein:

the web portion of the vehicle component comprises an upper surface portion adjacent a peripheral edge of the opening, and wherein;

the upper surfaces of the vehicle component and the outer surface of the base member define a dimension therebetween of about 5.0 mm or less.

18. The light assembly of claim 1, wherein:

the light guide comprises a sheet of polymer material defining a first thickness; and

wherein;

the body of the light source includes upper and lower side faces defining a second thickness therebetween that is approximately the same as the first thickness.

19. The light assembly of claim 1, wherein:

the light guide and the polymer body of the light source both comprise and acrylic polymer material.

20. The light assembly of claim 1, wherein:

the base member comprises a central web having a peripheral edge, and a side wall extending transverse relative to the central web about the peripheral edge, and a flange extending transverse to the side wall, and wherein the flange is sealed to the vehicle component and forms a watertight joint between the vehicle component and the base member.

21. The light assembly of claim 20, wherein:

the central web has a substantially uniform thickness with generally planar upper and lower surfaces.

22. The light assembly of claim 20, wherein:

the central web defines an inner side, and includes;

a layer of reflective material disposed on the inner side of the central web.

23. The light assembly of claim 22, wherein:

the layer of reflective material comprises a first material defining a first reflectivity; and

the central web further comprises a second material defining a second reflectivity that is substantially lower than the first reflectivity.

24. The light assembly of claim 23, wherein:

the side wall and the flange are made of the second material.

25. A method of fabricating a lighting device, the method comprising the steps of:

providing an electrically-powered light source having a first connector;

providing a sheet of light-transmitting material having generally smooth opposite side surfaces that internally reflect light introduced into the sheet;

cutting the sheet to form a light guide having a peripheral edge and including a second connector; and

;

engaging the first and second connectors to connect the light source to the light guide.

26. The method of claim 25, wherein:

the sheet of light is cut utilizing a laser.

27. The method of claim 26, wherein:

providing an electrically-powered light source includes;

providing an electrical circuit element;

securing an LED to the electrical circuit element; and

encapsulating the LED and at least a portion of the electrical circuit element in a thermoplastic polymer material.

28. The method of claim 27, wherein:

engaging the first and second connectors includes causing the first and second connectors to slidably contact one another.

29. The method of claim 28, wherein:

the step of cutting the sheet includes forming one of a protrusion and a recess in the peripheral edge of the sheet; and

wherein;

encapsulating the LED includes forming a body surrounding the LED including the other of a protrusion and a recess.

30. The method of claim 25, including:

forming a plurality of surface irregularities on one of the opposite side surfaces of the light guide utilizing a laser.

31. The method of claim 30, wherein:

the surface irregularities form a predefined pattern.

32. The method of claim 25, including:

providing a base member defining a cavity; and

;

positioning the light source and light guide in the cavity.

33. The method of claim 32, wherein:

the light source is connected to the light guide before the light source and the light guide are positioned in the cavity.

34. The method of claim 32, including:

providing a cover member; and

;

sealing the cover member and the base member together such that the cavity is watertight.

35. The method of claim 34, wherein:

the cover member comprises a sheet of light-transmitting material having first and second opposite side surfaces; and

including;

applying a layer of light-blocking material to portions of the first side surface to form a predefined pattern that is illuminated by the light source.

36. The method of claim 25, wherein:

the first connector is one of a protrusion and recess; and

wherein;

cutting the sheet includes forming the other of a recess and a protrusion in the peripheral edge of the sheet.

37. The method of claim 36, wherein:

the first connector comprises a T-shaped protrusion; and

cutting the sheet includes forming a T-shaped recess in the peripheral edge of the sheet.

38. The method of claim 25, wherein:

providing an electrically-powered light source includes molding a thermoplastic body around at least one LED to encapsulate the LED within the thermoplastic body.

39. The method of claim 38, wherein:

the thermoplastic body is molded to include a pair of T-shaped protrusions;

a pair of corresponding T-shaped recesses are formed in the peripheral edge of the light guide.

40. The method of claim 39, wherein:

the light guide and the light source have substantially similar cross-sectional shapes.

41. A light assembly, comprising:

an electrically conductive circuit;

a plurality of LEDs mounted to the circuit;

a light-transmitting thermoplastic polymer body encapsulating the LEDs and at least a portion of the circuit and defining inner and outer side faces, wherein the polymer body includes smooth surface portions configured to internally reflect light from the LEDs, and irregular surface portions that disperse light from the LEDs such that the light from the LEDs escapes from the polymer body;

a layer of substantially opaque material disposed on the outer side face of the polymer body and covering selected portions of the outer side face and substantially blocking escape of light from the polymer body at the selected portions, the layer of substantially opaque material defining open areas on the outer side face of the polymer body, wherein the open areas are illuminated by light from the LEDs and form a lighted pattern.

42. The light assembly of claim 41, wherein:

the open areas are formed by openings through the layer of substantially opaque material.

43. The light assembly of claim 42, including:

at least one opaque member disposed in a selected one of the openings through the layer of substantially opaque material and defining a gap between the opaque member and the edge of the one opening through which light can escape.

44. The light assembly of claim 42, including:

a light-transmitting member extending over at least one of the openings and closing off the opening.

45. The light assembly of claim 44, wherein:

the light-transmitting member includes a polymer body portion and a layer of light-transmitting material disposed on the body portion, wherein the layer of light-transmitting material has an appearance that is substantially similar to chrome when the LEDs are turned off.

46. The light assembly of claim 41, including:

a timer that turns off the LEDs after a preselected period of time.