Optical waveguide structures

Details Optical waveguide structures Optical waveguide structures

1998-07-02

2001-05-29

Spyrou, Cassandra (Department: 2872)

Illumination

Light fiber, rod, or pipe

C362S035000, C362S558000, C362S581000

Reexamination Certificate

active

06238074

ABSTRACT:

BACKGROUND
The invention relates to distributed lighting systems.
Distributed lighting systems distribute light from one or more light sources in central or strategic locations to one or more remote locations. A distributed lighting system promises several advantages over conventional lighting techniques, including low power consumption, extended life, heat reduction where the light is emitted, and increased design flexibility.
SUMMARY
The invention provides a distributed lighting system (DLS) for use, for example, in an automobile. Issues associated with incorporating a distributed lighting system into an automobile are discussed by Hulse, Lane, and Woodward in “Three Specific Design Issues Associated with Automotive Distributed Lighting Systems: Size, Efficiency and Reliability,” SAE Technical Paper Series, Paper No. 960492, which was presented at the SAE International Congress and Exposition, Detroit, Mich., Feb. 26-29, 1996, and Hulse and Mullican in “Analysis of Waveguide Geometries at Bends and Branches for the Directing of Light,” SAE Technical Paper Series, Paper No. 981189, which are incorporated herein by reference.
A practical distributed lighting system for an automobile must address size, efficiency, and reliability issues. To this end, an implementation of the invention employs focus-less optics components, such as collector elements and waveguides. These components are inexpensive to manufacture, since they can be formed from plastic (acrylic, for example) in an injection molding process. In addition, they have high collecting efficiency and are very compact. For example, a collector element may be smaller than one cubic inch (16.4 cubic centimeters). Components that must handle high heat levels (e.g., components are placed in proximity to the light source) may require a ventilation system or may include portions formed from heat resistant materials, such as glass or Pyrex™.
The three most demanding lighting functions in automotive illumination systems are headlamp high beams, headlamp low beams, and stop lights. These functions may be implemented using a centralized light source having waveguide outputs that transmit the light to the appropriate output points on the vehicle (i.e., the headlamps and stop lights) and form beam patterns at each output location. However, inefficiencies in the light distribution components may make such a configuration impractical. One solution to this problem is to form a hybrid lighting subsystem by combining a conventional optical system, such as a headlamp, with components that receive light from the headlamp and transmit the light through waveguides or fiber optics to provide other lighting functions throughout the vehicle.
Four hybrid lighting subsystems, each including a high intensity discharge (HID) source, should provide enough light for an entire automobile. Less efficient systems may require additional HID sources. The HID source acts as a primary light source for a particular lighting function, such as a headlamp. In addition, the HID acts as a light source for other lighting functions throughout the vehicle. Light sources other than a HID source, such as high intensity infrared (HIR), halogen, cartridge bulbs, printed circuit (PC) bulbs, and other gas discharge and incandescent bulbs, may be used. The hybrid subsystem may employ focus-less optics (FLO) to receive and transmit light from the light source. Focus-less optics components include optical waveguides and collector elements, such as are described below and in U.S. application Ser. Nos. 08/697,930 (“Distributed Lighting System”, filed Sep. 3, 1996) and 08/791,683 (“Optical Waveguide Elements for a Distributed Lighting System”, filed Jan. 30, 1997), both which are incorporated herein by reference. A hybrid tail light subsystem may be used to provide stop lights, turn signals, backup lights, and a center high-mounted stop light (CHMSL).
A vehicle distributed lighting system may include hybrid headlamp subsystems, turn signal subsystems, and hybrid tail light subsystems. The hybrid headlamp subsystems may provide primary forward illumination for the vehicle. The headlamp subsystems may be light sources for other exterior lights, such as front turn signals of the subsystems and side markers, as well as interior lights, such as dashboard lights and dome lights. These other lights may be connected to the headlamp subsystems by optical waveguides. Similarly, the tail light subsystems provide light for rear turn signals and a center high mounted stop light. The subsystems of the DLS are interconnected so that the light source of one subsystem serves as a redundant light source for another subsystem.
The DLS may incorporate different types of optical waveguide structures to distribute light throughout the vehicle, including joints, elements with epoxy coatings, pinched end collector portions, integrated installation snaps, integrated input optics and integrated output lenses. The DLS may also include waveguide structures to provide illumination to portions of the vehicle interior, including cup holders, assist grips, storage pockets step-up boards and running boards.
In one aspect, generally, an optical waveguide structure for distributing light from a light source includes a cylindrical sleeve configured to accommodate and receive light from a light source. The sleeve includes a central axis. A waveguide collar is formed from a solid, planar block of material. The block of material has a central portion configured to accommodate and surround the sleeve. The first and second output arms extend in a plane away from the central portion. The plane is substantially perpendicular to the central axis.
Embodiments may include one or more of the following features. The sleeve may be configured to confine a portion of light from the light source through internal reflection and to transmit the light away from the light source in the direction of the central axis. The sleeve may be longer in the direction of the central axis than a thickness of the central portion in that direction. The sleeve may have rim portions that are positioned to define gaps, the gaps being configured to accommodate locking tabs of a lamp base.
An integral lens portion may be formed at an end of the first arm. The first and second arms may be optical waveguides that are positioned on a surface of the waveguide collar. The waveguides may extend across the surface of the waveguide collar and beyond an edge of the waveguide collar. The first and second arms may be optical waveguides that protrude above a top surface and below a bottom surface of the waveguide collar.
In another aspect, a waveguide collar for distributing light from a light source includes a solid, planar block of material. The block of material has a central portion that accommodates a light source. The central portion surrounds the light source in a plane. First and second output arms extend in the plane away from the central portion. The thickness of the central portion in a direction perpendicular to the plane is less than a thickness of the output arms in the direction perpendicular to the plane.
Embodiments may include one or more of the following features. A cylindrical sleeve may accommodate and receive light from a light source. The sleeve may be positioned within the central portion.
In another aspect, a waveguide collar for distributing light from a light source includes a solid, planar block of material. The block of material has a hub defining an interior portion configured to accommodate a light source. The hub has side surfaces on an exterior portion. Alignment notches are positioned on the side surfaces. The notches are configured to receive an alignment tab of a waveguide. Rim portions extend around the interior portion of the hub. The rim portions are positioned to define gaps that accommodate locking tabs of a lamp base.
In another aspect, a waveguide collar for distributing light from a light source includes a solid, planar block of material. The block of material has a central portion that accommodates a light source. The

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