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

• US 6,398,988 B1
• Filed: 03/22/2000
• Issued: 06/04/2002
• Est. Priority Date: 08/07/1997
• Status: Expired due to Fees

• Current Assignee: Decoma International Corporation
• Original Assignee: Decoma International Corporation
• Inventors: Jenkins, David, Garcia, Kevin, Hirmer, Gerhard F., Pagano, Robert, Passera, Robert, Griffin, Joseph A.
• Primary Examiner(s): Vargot, Mathieu D.
• Application Number:
  US09/532,540
• Time in Patent Office: 804 Days
• Field of Search: 264/1.1, 264/1.9, 264/2.2, 264/2.5, 264/2.7, 264/328.7, 264/40.1, 264/40.5, 362/31, 425/808
• US Class Current: 264/2.2
• CPC Class Codes: B29C 45/561 Injection-compression moulding
• CPC Class Codes: B29D 11/00 Producing optical elements, e.g. lenses or prisms grinding or polishing of optical elements B24B; constructional form of optical elements G02B; optical parts of spectacles G02C7/00
• CPC Class Codes: B29L 2011/0016 Lenses
• CPC Class Codes: B29L 2011/005 Fresnel lenses
• CPC Class Codes: B29L 2011/0091 Reflex reflectors
• CPC Class Codes: B60Q 1/2607 comprising at least two indicating lamps
• CPC Class Codes: B60Q 1/2665 on rear-view mirrors lighting devices for vehicle interior on or for rear-view mirrors B60Q3/258
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/239 plate-shaped
• CPC Class Codes: F21S 43/245 emitting light from one or more of its major surfaces
• CPC Class Codes: F21S 43/249 with two or more light sources being coupled into the light guide
• CPC Class Codes: G02B 6/0018 Redirecting means on the surface of the light guide
• CPC Class Codes: G02B 6/003 Lens or lenticular sheet or layer
• CPC Class Codes: G02B 6/0038 Linear indentations or grooves, e.g. arc-shaped grooves or meandering grooves, extending over the full length or width of the light guide
• CPC Class Codes: G02B 6/0048 with stepwise taper
• CPC Class Codes: G02B 6/0068 Arrangements of plural sources, e.g. multi-colour light sources
• CPC Class Codes: G02B 6/0073 Light emitting diode [LED]
• CPC Class Codes: G02B 6/0088 of the light guide or other optical sheets in the package
• CPC Class Codes: Y10S 425/808 Lens mold

Abstract

A rear signal lamp of an automotive vehicle comprising a lamp housing and a curved cover lens for enclosing a thin light managing system. The thin light managing systems includes a plurality of backlight light-emitting diodes mounted in a light mounting substrate and secured to the lamp housing. A control module operatively connected to the light-emitting diodes for controlling the operation and illumination of the light-emitting diodes. A reflector matrix having a plurality of reflector cones corresponding to each of the light-emitting diodes in the mounting substrate and a hybrid optics panel having a direct lensing section covering the reflector matrix and light-emitting diodes and a double redirecting light pipe section surrounding the lensing section. A single light-emitting diodes is coupled along spaced apart quadrants of the redirecting light pipe. Each single light-emitting diodes emits light to the respective quadrant of the optics panel which is reflected and redirected from one or more lens facets to illuminated the front surface of the panel. The direct lensing section and redirecting light pipe illuminate distinct area on the curved cover lens.

Claims

1. A method of injection molding a hybrid optics panel in a mold assembly to form first and second redirecting light pipe sections, a flat illumination surface, and a contoured lensing section on the panel, said method including the steps of:

forming a mold cavity defined by a fixed mold portion, a facet forming portion, an edge facet forming portion, an inner moveable portion, an outer moveable portion, and a top portion;

injecting a molten material into the mold cavity;

moving the inner moveable portion against the molten material to form the contoured lensing section on the panel;

moving the outer moveable portion against the molten material independent of said movement of the inner moveable portion to form the flat illumination surface on the panel; and

applying a predetermined amount of pressure to the mold cavity to urge the molten material against the edge facet forming portion to form at least one facet on the first redirecting light pipe section of the panel and against the facet forming portion to form at least one facet on the second redirecting light pipe section of the panel opposite the flat illumination surface.

2. The method as set forth in claim 1 further including the step of controlling the amount of pressure applied to the mold cavity.

3. The method as set forth in claim 2 further including the step of controlling the duration of time the pressure is applied to the mold cavity.

4. The method as set forth in claim 3 further including the step of independently controlling the displacement of each of the inner and outer moveable portions.

5. The method as set forth in claim 1 wherein the step of moving the inner moveable portion against the molten material to form the contoured lensing section on the panel is further defined as moving the inner moveable portion to form at least one of a concave lens, a convex lens, a Fresnel lens, a dual surface lens element, a tailored Fresnel lens element, and a Fresnel-pillow lens element.

6. The method as set forth in claim 1 wherein the step of applying a predetermined amount of pressure to the mold cavity is further defined as urging the molten material against the top portion to form at least one coupling optic structure on the panel.

7. The method as set forth in claim 1 wherein the step of applying a predetermined amount of pressure to the mold cavity is further defined as eliminating gaps in the molten material such that the molten material substantially fills the mold cavity.

8. The method as set forth in claim 1 wherein the step of applying a predetermined amount of pressure to the mold cavity is further defined as reducing sag of the molten material.

9. The method as set forth in claim 1 wherein the step of applying a predetermined amount of pressure to the mold cavity is further defined urging the molten material against the edge facet forming portion to form a plurality of facets on the first redirecting light pipe section of the panel and against the facet forming portion to form a plurality of facets on the second redirecting light pipe section of the panel opposite the flat illumination surface.

10. The method as set forth in claim 9 wherein the step of applying a predetermined amount of pressure to the mold cavity is further defined urging the molten material against the edge facet forming portion to form a plurality of facets separated by a plurality of flat sections on the first redirecting light pipe section of the panel and against the facet forming portion to form a plurality of facets separated by a plurality of flat sections on the second redirecting light pipe section of the panel opposite the flat illumination surface.

11. The method as set forth in claim 1 wherein the step of injecting a molten material into the mold cavity is further defined as injecting an acrylic-based molten material.

12. The method as set forth in claim 11 wherein the step of injecting an acrylic-based molten material is further defined as injecting an acrylic-based molten material comprising poly(methyl methacrylate).