DESC:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENT RULES, 2003
COMPLETE SPECIFICATION
(See Section 10 & Rule 13)

TITLE OF THE INVENTION:
A LIGHTING DEVICE

APPLICANT(S):
VARROC ENGINEERING LIMITED
An Indian Entity Having Address As:
L-4, MIDC Waluj, Aurangabad-431136, Maharashtra, India

The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[0001] The present application claims priority from Indian provisional application having application number 202421075779 and filed on 7th day of October 2024.
TECHNICAL FIELD
[0002] The present disclosure relates to the field of automotive systems and, in particular, relates to a lighting device for a vehicle.
BACKGROUND
[0003] This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure that are described or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements in this background section are to be read in this light, and not as admissions of prior art. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
[0004] The modern automotive lighting industry has evolved beyond simply providing road illumination and conventional signaling functions. Today's vehicle lighting systems incorporate advanced features such as animation effects during system activation and deactivation, as well as personalized message displays. These enhanced capabilities are typically achieved through the use of light emitting diodes (LEDs) arranged in pixelated segments.
[0005] Pixel execution in automobile lighting systems allows for the creation of customized lighting effects and intricate light patterns. This technology enables the display of animations and communication of specific information through the lighting system, enhancing both the aesthetic appeal and safety features of vehicles. The implementation of pixel-based lighting is particularly relevant in tail lamps, where it can be used to execute various animation patterns.
[0006] Conventional tail lamp designs often utilize a configuration where light rays from LEDs travel through two light tunnels placed at a gap before reaching the transparent or translucent part of the pixel opening. Some existing designs employ a light blade and multicolor bezel technology to achieve pixel patterns in mid-range automobiles. However, these conventional approaches frequently encounter issues with light leakage between pixel openings and gap between the two light tunnels, resulting in undesirable visual effects.
[0007] The problem of light leakage in traditional tail lamps occurs when light from one pixel inadvertently illuminates adjacent pixels, compromising the clarity and definition of the intended lighting pattern. This issue can detract from the overall appearance and effectiveness of the lighting system, particularly during the execution of complex animation sequences or when displaying specific information.
[0008] While high-end technologies such as organic light emitting diodes (OLEDs) and optical resin-based concepts can potentially address the light leakage problem, these solutions tend to be costly. The expense associated with these advanced technologies often makes them impractical for widespread implementation, especially in mid-range or budget-friendly vehicle models.
[0009] Another challenge in pixel-based automotive lighting is achieving uniform light distribution and maintaining consistent brightness across all pixels. Variations in illumination intensity between different segments of the lighting array can result in an uneven or disjointed appearance, diminishing the visual impact of the intended lighting effects. Furthermore, the integration of pixel-based lighting systems into existing vehicle designs presents additional hurdles. Considerations such as power consumption, heat management, and durability in various environmental conditions all factors into the complexity of developing effective and reliable pixel-executed tail lamps.
[0010] In light of the foregoing discussion, there exists a need for an improved lighting device which can address at least one of the above discussed requirements.
SUMMARY
[0011] Before the present system and method and its components are summarized, it is to be understood that this disclosure is not limited to the system and its arrangement as described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. The present disclosure overcomes one or more shortcomings of the prior art and provides additional advantages discussed throughout the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the versions or embodiments only and is not intended to limit the scope of the present disclosure. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in detecting or limiting the scope of the claimed subject matter.
[0012] In an example aspect, a lighting device is disclosed. The lighting device includes a housing. The housing includes a printed circuit board (PCB) mounted in a rear portion inside the housing. The PCB includes a plurality of light emitting diodes (LEDs). The plurality of LEDs is configured to emit light. One or more brackets are positioned in front of the PCB. The one or more brackets are configured to channel the light emitted from the plurality of LEDs. A bezel is positioned in front of the one or more brackets. The bezel includes an opaque region including a plurality of openings. The opaque region includes a plurality of splines protruding around each of the plurality of openings. A dispersive element is filled in each of the plurality of openings of the opaque region. The one or more brackets and the plurality of splines of the bezel are configured to prevent light leakage between adjacent openings of the plurality of openings.
[0013] In an embodiment, the bezel is manufactured using a two-shot injection moulding process.
[0014] In another embodiment, the two-shot injection moulding process includes a first moulding step configured to fill the dispersive element in the plurality of openings. A plurality of first inlets is provided to inject a 2K mould with the dispersive element.
[0015] In yet another embodiment, the two-shot injection moulding process further includes a second moulding process. The second moulding process is configured to inject an opaque material through a plurality of second inlets to form the opaque region of the bezel.
[0016] In yet another embodiment, the dispersive element includes a plurality of vertical ribs, and a plurality of horizontal ribs arranged in a grid-like pattern.
[0017] In yet another embodiment, the dispersive element is configured to uniformly scatter the light within each opening from the plurality of openings.
[0018] In yet another embodiment, the plurality of horizontal ribs protrudes perpendicularly from the plurality of vertical ribs.
[0019] In yet another embodiment, the plurality of splines extends along a periphery of each opening of the plurality of opening.
[0020] In yet another embodiment, each of the plurality of LEDs is mounted on the PCB in a matrix configuration and each of the plurality of LEDs is equidistantly spaced from each other.
[0021] In yet another embodiment, each opening of the plurality of openings forms a pixel when illuminated by at least one LED of the plurality of LEDs.
[0022] In yet another embodiment, the one or more brackets includes a first bracket and a second bracket. The first bracket is positioned between the PCB and the second bracket. The second bracket is positioned between the first bracket and the bezel. A gap is provided between the first bracket and the second bracket. The gap between the first bracket and the second bracket is between 1 mm and 1.5 mm.
[0023] In yet another embodiment, the plurality of splines connects to the second bracket from the one or more brackets to cover a remaining periphery of each opening of the plurality of openings.
[0024] In yet another embodiment, the lighting device includes a lens coupled to the housing.
[0025] In yet another embodiment, the lens is coupled to the housing using at least one of a screw, hot welding, snap-fit, or any combination thereof.
[0026] In yet another embodiment, the lighting device includes a first polarizer array and a second polarizer array. The first polarizer array is positioned between the PCB and the one or more brackets. The second polarizer array is positioned between the bezel and the lens. The first polarizer array and the second polarizer array are configured to reduce the light leakage to form alternating regions of orthogonal polarization states.
[0027] In yet another embodiment, the dispersive element filled in each of the plurality of openings of the opaque region is configured to have a scattering structure in the middle of each of the plurality of openings.
[0028] In yet another embodiment, the first bracket is a white bracket and the second bracket is a black bracket. The white bracket is configured to increase a pixel brightness. The black bracket is configured to arrest the light leakage.
[0029] In yet another embodiment, at least one of the first bracket and the second bracket has a low refractive index. The at least one of the first bracket and the second bracket is filled with a high refractive index material.
[0030] In yet another embodiment, the lighting device further includes at least one dampening element disposed along the periphery of the housing to reduce vibration transfer to components of the lighting device.
[0031] In yet another embodiment, the bezel is coupled to the housing using at least one of a screw, a snap-fit, a press-fit, or any combination thereof.
[0032] In yet another embodiment, the lighting device is configured to be used in a vehicle. The lighting device corresponds to a headlight, a taillight, or any lighting device mounted on the vehicle exterior or interior region.
[0033] In another example aspect, a vehicle is disclosed. The vehicle includes one or more lighting devices. Each of the one or more lighting device includes a housing. The housing includes a printed circuit board (PCB) mounted in a rear portion inside the housing. The PCB includes a plurality of light emitting diodes (LEDs). The plurality of LEDs is configured to emit light. One or more brackets are positioned in front of the PCB. The one or more brackets are configured to channel the light emitted from the plurality of LEDs. A bezel is positioned in front of the one or more brackets. The bezel includes an opaque region including a plurality of openings. The opaque region includes a plurality of splines protruding around each of the plurality of openings. A dispersive element is filled in each of the plurality of openings of the opaque region. The one or more brackets and the plurality of splines of the bezel are configured to prevent light leakage between adjacent openings of the plurality of openings.
BRIEF DESCRIPTION OF FIGURES
[0034] Having thus described the disclosure in general terms, references will now be made to the accompanying figures, wherein:
[0035] Figure 1a and Figure 1b illustrate a first lighting device of a prior art, in accordance with various embodiments of the present disclosure;
[0036] Figure 2a illustrates a top view of a second lighting device of a prior art, in accordance with various embodiments of the present disclosure;
[0037] Figure 2b illustrates a side sectional view of the second lighting device of Figure 2a, in accordance with various embodiments of the present disclosure;
[0038] Figure 3 illustrates a schematic view of a third lighting device of a prior art, in accordance with various embodiments of the present disclosure;
[0039] Figure 4 illustrates a schematic view of a fourth lighting device of a prior art, in accordance with various embodiments of the present disclosure;
[0040] Figure 5 illustrates a schematic view of a fifth lighting device of a prior art, in accordance with various embodiments of the present disclosure;
[0041] Figure 6 illustrates a sectional view of a lighting device, in accordance with various embodiments of the present disclosure;
[0042] Figure 7 illustrates a detailed sectional view of components in the lighting device, in accordance with various embodiments of the present disclosure;
[0043] Figure 8 illustrates sectional view of one or more brackets and a plurality of LEDs, in accordance with various embodiments of the present disclosure;
[0044] Figure 9 illustrates the sectional view of the one or more bracket and the plurality of LEDs, in accordance with various embodiments of the present disclosure;
[0045] Figure 10 illustrates an exploded view of the lighting device components, in accordance with various embodiments of the present disclosure;
[0046] Figure 11 illustrates a detailed view of a dispersive element, in accordance with various embodiments of the present disclosure;
[0047] Figure 12 illustrates a top view of the plurality of LEDs and a plurality of openings, in accordance with various embodiments of the present disclosure;
[0048] Figure 13 illustrates the top view of the plurality of LEDs and the plurality of openings, in accordance with various embodiments of the present disclosure;
[0049] Figure 14 illustrates an isometric view of the plurality of openings, in accordance with various embodiments of the present disclosure;
[0050] Figure 15a and Figure 15b illustrates injection molding configurations to fill a dispersive element with plurality of first inlets, in accordance with various embodiments of the present disclosure;
[0051] Figure 16a and Figure 16b illustrates an orthogonal view of an opaque region with plurality of second inlets, in accordance with various embodiments of the present disclosure;
[0052] Figure 17a and Figure 17b illustrates a front and a rear orthogonal view of a bezel, in accordance with various embodiments of the present disclosure;
[0053] Figure 18 illustrates a sectional view of the plurality of LEDs, one or more brackets, and the bezel, in accordance with various embodiments of the present disclosure;
[0054] Figure 19 illustrates a sectional view of the lighting device with a first polarizer array and a second polarizer array, in accordance with various embodiments of the present disclosure;
[0055] Figure 20 illustrates the sectional view of the lighting device with the first polarizer array and the second polarizer array, in accordance with various embodiments of the present disclosure;
[0056] Figure 21 illustrates an exploded view of the bezel and the one or more brackets, in accordance with various embodiments of the present disclosure;
[0057] Figure 22 illustrates a polarization array with alternating polarization states, in accordance with various embodiments of the present disclosure;
[0058] Figure 23 illustrates pixel patterns demonstrating illumination capabilities, in accordance with various embodiments of the present disclosure; and
[0059] Figure 24 illustrates the pixel patterns demonstrating illumination capabilities, in accordance with various embodiments of the present disclosure.
[0060] It should be noted that the accompanying figures are intended to present illustrations of exemplary embodiments of the present disclosure. These figures are not intended to limit the scope of the present disclosure. It should also be noted that accompanying figures are not necessarily drawn to scale.
DETAILED DESCRIPTION
[0061] Reference will now be made in more detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout the specification. In this regard, the present embodiments may have different forms and should not be construed as being limited to the descriptions set forth herein. Accordingly, the embodiments are merely described below, by referring to the figures, to explain aspects of embodiments of the present description. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items. Throughout the present disclosure, the expression "at least one of a, b and c" indicates only a, only b, only c, both a and b, both a and c, both b and c, all of a, b, and c, or variations thereof.
[0062] The subject matter of the present disclosure may include various modifications and various embodiments, and example embodiments will be illustrated in the drawings and described in more detail in the detailed description. Effects and features of the subject matter of the present disclosure, and implementation methods therefor will become clear with reference to the embodiments described herein below together with the drawings. The subject matter of the present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
[0063] Hereinafter, embodiments of the present disclosure will be described in more detail with reference to the accompanying drawings. The same or corresponding elements will be denoted by the same reference numerals, and thus, redundant description thereof will not be repeated.
[0064] It will be understood that although the terms "first," "second," etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another.
[0065] An expression used in the singular may also encompasses the expression of the plural, unless it has a clearly different meaning in the context.
[0066] In the following embodiments, it is to be understood that the terms such as "including," "includes," "having," "comprises," and "comprising," are intended to indicate the existence of the features or elements disclosed in the specification, and are not intended to preclude the possibility that one or more other features or elements may exist or may be added.
[0067] An objective of the present disclosure is to provide a lighting device (200). Another objective of the present disclosure is to achieve uniform light distribution across a pixel array while maintaining clear definition between individual pixels. Yet another objective of the present disclosure is to create a cost-effective solution for implementing pixel patterns and animations. Yet another objective of the present disclosure is to develop the lighting device (200) that can execute dynamic lighting patterns and animations with minimal light leakage. Yet another objective of the present disclosure is to develop a modular pixel structure that facilitates the creation of various lighting patterns. Yet another objective of the present disclosure is to incorporate a bezel that uniformly scatters light within each pixel opening without any leakage.
[0068] Figure 1a and Figure 1b illustrate a first lighting device (100a) of a prior art, in accordance with various embodiments of the present disclosure. Figure 2a illustrates a top view of a second lighting device (100b) of a prior art, in accordance with various embodiments of the present disclosure. Figure 2b illustrates a side sectional view of the second lighting device (100b) of Figure 2a, in accordance with various embodiments of the present disclosure. Figure 3 illustrates a schematic view of a third lighting device (500a) of the prior art, in accordance with various embodiments of the present disclosure. Figure 4 illustrates a schematic view of a fourth lighting device (500b) of the prior art, in accordance with various embodiments of the present disclosure. Figure 5 illustrates a schematic view of a fifth lighting device (500c) of the prior art, in accordance with various embodiments of the present disclosure.
[0069] Conventional lighting devices for vehicles, such as taillights, often face challenges in controlling light distribution and preventing light leakage between pixel segments. The lighting devices (100a, 100b, 500a, 500b, 500c) of the prior art may utilize various approaches to create pixel patterns and animations, but these approaches often have limitations.
[0070] One approach for pixel execution in the lighting devices (100a, 100b, 500a, 500b, 500c) of the prior art involves using digital organic light emitting diodes (OLEDs). While OLEDs can provide precise light control, this technology tends to be costly, making it less suitable for widespread implementation in mid-range vehicles.
[0071] Another method employs optical resin-based concepts to create pixel patterns in the lighting devices (100a, 100b, 500a, 500b, 500c). Although this approach can achieve good light control, it also tends to be an expensive solution, limiting its application in more affordable vehicle models.
[0072] Some of the lighting devices (100a, 100b, 500a, 500b, 500c) use a combination of light blades and multi-color bezels to execute pixel patterns. However, these configurations often struggle with light leakage between pixel openings, resulting in reduced visual clarity and definition of the intended light patterns.
[0073] Bracket-based systems in the lighting devices (100a, 100b, 500a, 500b, 500c) may be used to channel light from LEDs to pixel openings. When used alone, these systems can have difficulty achieving uniform light distribution across the pixel array. Combining brackets with overlaid bezels may improve light distribution to some extent but can still allow light leakage between adjacent pixel chambers.
[0074] The lighting devices (100a, 100b, 500a, 500b, 500c) of the prior art utilizing only bezel structures for pixel definition may perform adequately when all LEDs are illuminated simultaneously. However, these systems often experience significant light leakage when executing dynamic lighting patterns or animations where only select pixels are illuminated at any given time.
[0075] The limitations of these conventional approaches highlight a need for improved lighting devices that can provide better control over light distribution, reduce inter-pixel light leakage, and maintain cost-effectiveness for implementation in a wide range of vehicle models.
[0076] Figure 6 illustrates a sectional view of the lighting device (200), in accordance with various embodiments of the present disclosure. Figure 7 illustrates a detailed sectional view (600) of components in the lighting device (200), in accordance with various embodiments of the present disclosure. Figure 8 illustrates a sectional view (700) of one or more brackets (208) and a plurality of light emitting diodes (LEDs) (206), in accordance with various embodiments of the present disclosure. Figure 9 illustrates the sectional view (700) of the one or more brackets (208) and the plurality of LEDs (206), in accordance with various embodiments of the present disclosure. Figure 10 illustrates an exploded view of the lighting device (200), in accordance with various embodiments of the present disclosure.
[0077] In an example aspect, the lighting device (200) includes a housing (202) that includes and supports various components. The housing (202) encloses a printed circuit board (PCB) (204) mounted in a rear portion of the housing (202). The PCB (204) includes the plurality of LEDs (206) configured to emit light. Further, the one or more brackets (208) are positioned in front of the PCB (204) and configured to channel the light emitted from the plurality of LEDs (206).
[0078] In another example aspect, a bezel (210) is positioned in front of the one or more brackets (208). The bezel (210) includes an opaque region (214) with a plurality of openings (228). The opaque region (214) includes a plurality of splines (220) protruding around each of the plurality of openings (228). A dispersive element (212) is filled in each of the plurality of openings (228) of the opaque region (214). The one or more brackets (208) and the plurality of splines (220) of the bezel (210) are configured to prevent light leakage between adjacent openings of the plurality of openings (228).
[0079] In an example implementation, a lens (222) is coupled to the housing (202). The lens (222) may be coupled to the housing (202) using at least one of a screw, hot welding, snap-fit, or any combination thereof. The lighting device (200) further includes at least one dampening element (234) disposed along the periphery of the housing (202) to reduce vibration transfer to components of the lighting device (200).
[0080] In another example implementation, the one or more brackets (208), and the bezel (210) within the lighting device (200). The dispersive element (212) in each of the plurality of openings (228) of the opaque region (214) is configured to have a scattering structure in the middle of each of the plurality of openings (228). This configuration allows for uniform scattering of light within each opening.
[0081] In some embodiments, the one or more brackets (208) and the plurality of splines (220) work together to channel light and prevent light leakage between adjacent openings. The plurality of splines (220) extends along a periphery of each opening of the plurality of openings (228), connecting to the one or more brackets (208) to cover the remaining periphery of each opening.
[0082] In an embodiment, the bezel (210) is coupled to the housing (202). The bezel (210) may be coupled to the housing (202) using at least one of a screw, a snap-fit, a press-fit, or any combination thereof.
[0083] In an example, the lighting device (200) is configured to be used in a vehicle. The lighting device (200) may correspond to a headlight, a taillight, or any lighting device mounted on the vehicle exterior or interior region. This versatile design allows for application in various automotive lighting scenarios while maintaining controlled light distribution and minimizing light leakage between pixel segments.
[0084] In another example implementation, the lighting device (200) may include a thermal management system. Further, the thermal management system may include a heat sink embedded behind the PCB (204) to efficiently dissipate heat generated by the plurality of LEDs (206). The thermal management system may be configured to maintain optimal operating temperatures for the plurality of LEDs (206), potentially extending their lifespan and ensuring consistent performance.
[0085] Furthermore, the lighting device (200) may include a control unit. Further, the control unit may be configured to manage various functions. The control unit may include a microprocessor, memory, and communication interfaces. It may be configured to control the brightness of each of the plurality of LEDs (206), allowing for dynamic adjustment of light output. The control unit may also manage the turn-on and turn-off functions of the plurality of LEDs (206), enabling precise timing and sequencing of illumination patterns. In some aspects, the control unit may interface with external systems, such as a vehicle's onboard computer, to synchronize lighting effects with other vehicle functions or respond to user inputs. The control unit may utilize pulse-width modulation (PWM) techniques to adjust LED brightness levels, providing smooth dimming capabilities and energy-efficient operation. Additionally, the control unit may incorporate temperature sensors to monitor the heat sink and LEDs, adjusting power output as needed to prevent overheating and maintain optimal performance of the lighting device.
[0086] Now referring to Figure 11, which illustrates a detailed view of a dispersive element (212), in accordance with various embodiments of the present disclosure. The dispersive element (212) of the lighting device (200) includes a plurality of vertical ribs (216) and a plurality of horizontal ribs (218) arranged in a grid-like pattern. The plurality of vertical ribs (216) is positioned parallel to each other and extends in a vertical direction. The plurality of horizontal ribs (218) protrudes perpendicularly from the plurality of vertical ribs (216), creating a structured grid pattern within the dispersive element (212). Further, the arrangement of the plurality of vertical ribs (216) and the plurality of horizontal ribs (218) forms a scattering structure within the dispersive element (212). This scattering structure is concentrated in the middle of each opening of the plurality of openings (228) of the opaque region (214). The grid-like pattern created by the intersection of the plurality of vertical ribs (216) and the plurality of horizontal ribs (218) contributes to uniform light dispersion within each of the plurality of openings (228).
[0087] In an example embodiment, the dispersive element (212) uniformly scatters light within each opening of the plurality of openings (228). The perpendicular protrusion of the plurality of horizontal ribs (218) from the plurality of vertical ribs (216) creates multiple surfaces and angles for light interaction. This configuration enhances the dispersive properties of the element, promoting even distribution of light across the opening area. Further, the grid-like structure of the dispersive element (212) serves to break up incident light into multiple paths, reducing hot spots and shadows. This results in a more uniform illumination across each pixel formed by the openings of the opaque region (214).
[0088] Figure 12 illustrates a top view (800a) of the plurality of LEDs (206) and the plurality of openings (228), in accordance with various embodiments of the present disclosure. Figure 13 illustrates the top view (800) of the plurality of LEDs (206) and the plurality of openings (228), in accordance with various embodiments of the present disclosure. Figure 14 illustrates an isometric view (800b) of the plurality of openings (228), in accordance with various embodiments of the present disclosure.
[0089] In an embodiment, the plurality of LEDs (206) is arranged on the PCB (204) in a matrix configuration, with each of the plurality of LEDs (206) equidistantly spaced from adjacent LEDs (206). This uniform spacing ensures consistent light distribution across the lighting device (200).
[0090] In an embodiment, the plurality of openings (228) is arranged in a pattern that corresponds to the matrix configuration of the plurality of LEDs (206) on the PCB (204). Each opening of the plurality of openings (228) forms a pixel when illuminated by at least one LED of the plurality of LEDs (206). Further, the grid pattern of the plurality of openings (228) aligns with the matrix configuration of the plurality of LEDs (206), enabling precise control of light output for each pixel.
[0091] In yet another embodiment, the lighting device (200) incorporates multiple mini-LEDs coupled on the PCB (204) for illuminating each pixel. This configuration allows for enhanced control over pixel brightness and uniformity. The arrangement of multiple mini-LEDs per pixel provides redundancy and enables fine-tuning of light output for each opening of the plurality of openings (228).
[0092] In an implementation, the matrix configuration of the plurality of LEDs (206) on the PCB (204), combined with the corresponding arrangement of the plurality of openings (228), creates a modular pixel structure within the lighting device (200). This structure facilitates the creation of various lighting patterns and animations by selectively activating specific LEDs (206) to illuminate corresponding openings (228).
[0093] Now referring to Figure 15a and Figure 15b, which illustrate injection molding configurations to fill the dispersive element (212) with a plurality of first inlets (224), in accordance with various embodiments of the present disclosure. The lighting device (200) includes the bezel (210) that is manufactured using a two-shot injection molding process. As shown in Figure 15a, which shows a top view of the molding setup for the dispersive element (212). The figure depicts a plurality of first inlets (224) arranged in a linear configuration. The plurality of first inlets (224) serve as injection points for the material that forms the dispersive element (212). Furthermore, as shown in Figure 15b, which provides a cross-sectional view of the same molding setup. The plurality of first inlets (224) are visible along the top surface of the mold. Below the plurality of first inlets (224), a plurality of channels (236) is arranged in a uniform pattern. The plurality of channels (236) corresponds to the structure of the dispersive element (212) and facilitates the flow of injected material.
[0094] In an embodiment, the first molding step of the two-shot injection molding process involves injecting material through the plurality of first inlets (224) to fill the dispersive element (212) in the plurality of openings (228) of the bezel (210). The placement of the plurality of first inlets (224) allows for even distribution of the injected material across the mold, ensuring uniform filling of the dispersive element (212) in each of the plurality of openings (228). Further, the plurality of channels (236) visible in Figure 15a and Figure 15b guide the flow of injected material, creating the internal structure of the dispersive element (212). This structure contributes to the light-scattering properties of the dispersive element (212), promoting uniform light distribution within each opening of the bezel (210). Moreover, the two-shot injection molding process enables the creation of the bezel (210) with the dispersive elements (212), combining different materials and properties in a single component. This manufacturing method allows for precise control over the formation of the dispersive element (212) within the bezel (210) structure.
[0095] Now referring to Figure 16a and Figure 16b, which illustrate an orthogonal view of the opaque region (214) with a plurality of second inlets (226), in accordance with various embodiments of the present disclosure. The lighting device (200) includes the opaque region (214) that is manufactured using the two-shot injection molding process. As shown in Figure 16a, which shows a top view of the molding setup for the opaque region (214). The figure depicts the plurality of second inlets (226) arranged around the perimeter of openings in the opaque region (214). The plurality of second inlets (226) serve as injection points for an opaque material that forms the opaque region (214). Further, as shown in Figure 16b, which provides a cross-sectional view of the same molding setup. The plurality of second inlets (226) are visible along the edges of the openings in the opaque region (214). The plurality of second inlets (226) are positioned to allow for even distribution of the injected opaque material across the mold.
[0096] In an exemplary embodiment, the second molding step of the two-shot injection molding process involves injecting the opaque material through the plurality of second inlets (226) to form the opaque region (214) of the bezel (210). The placement of the plurality of second inlets (226) allows for controlled flow of the opaque material, ensuring uniform filling and formation of the opaque region (214) around the dispersive element (212) which is previously molded. Further, the injection of the opaque material through the plurality of second inlets (226) creates a solid structure that surrounds and defines the plurality of openings (228) in the bezel (210). This process enables the integration of the opaque region (214) with the dispersive element (212) which is previously molded, resulting in the bezel (210) structure with distinct optical properties in different areas.
[0097] Now referring to Figure 17a and Figure 17b, which illustrate a front and a rear orthogonal view of the bezel (210), in accordance with various embodiments of the present disclosure. The bezel (210) includes the plurality of openings (228) arranged in a grid-like pattern. The plurality of openings (228) is distributed across the surface of the bezel (210) in parallel rows and columns, creating a uniform array. Further, each opening of the plurality of openings (228) is configured to form a pixel when illuminated by at least one light emitting diode (LED) of a plurality of LEDs (206). The plurality of LEDs (206) is mounted on the PCB (204) positioned behind the bezel (210). When activated, the light from the plurality of LEDs (206) passes through the corresponding opening of the plurality of openings (228), creating individual pixels of illumination.
[0098] In an embodiment, the opaque region (214) serves to define the boundaries of each pixel and prevent light bleed between adjacent openings. The plurality of splines (220) protrudes from the opaque region (214) around each of the plurality of openings (228). The plurality of splines (220) extends along the periphery of each opening of the plurality of openings (228), further enhancing light control and pixel definition. Furthermore, the arrangement of the plurality of openings (228) in the bezel (210) corresponds to the configuration of the plurality of LEDs (206) on the PCB (204). This alignment ensures that each opening is positioned to receive light from its corresponding LED of the plurality of LEDs (206), enabling precise control over individual pixel illumination within the lighting device (200).
[0099] In an example implementation, the bezel (210) may be manufactured using a variety of materials suitable for automotive lighting applications. In some aspects, the bezel (210) may be made from thermoplastic polymers such as polycarbonate, acrylonitrile butadiene styrene (ABS), or any combination thereof. These materials may provide a combination of durability, heat resistance, and optical clarity necessary for the bezel's function. For the opaque region (214) of the bezel (210), materials with light-blocking properties may be used. In some cases, this may involve adding pigments or fillers to the base polymer to achieve the desired opacity. The dispersive element (212) of the bezel may be made from a transparent or translucent material with light-scattering properties, such as a specially formulated acrylic or silicone compound.
[0100] Now referring to Figure 18, which illustrates a sectional view (900) of the plurality of LEDs (206), one or more brackets (208), and the bezel (210), in accordance with various embodiments of the present disclosure. The one or more brackets (208) are configured to channel the light emitted from the plurality of LEDs (206). The one or more brackets (208) include multiple channels or passages through which the light from the LEDs (206) can travel. Furthermore, the bezel (210) is positioned in front of the one or more brackets (208). The bezel (210) includes an angled or sloped surface with multiple openings arranged in a grid pattern. The bezel (210) works in conjunction with the one or more brackets (208) to direct and control the light output from the LEDs (206).
[0101] In addition, the components of the lighting device (200) are arranged in a layered configuration, with the PCB (204) at the rear, followed by the one or more brackets (208), and the bezel (210) at the front. This arrangement allows for controlled light distribution while preventing light leakage between adjacent openings in the bezel (210). Further, the one or more brackets (208) serve to channel and direct the light emitted by the plurality of LEDs (206) towards the corresponding opening of the plurality of openings (228) in the bezel (210). The channels or passages within the one or more brackets (208) help to collimate the light, reducing scatter and improving directionality. The bezel (210) further refines the light distribution. The angled or sloped surface of the bezel (210) helps to direct the light outward from the lighting device (200). The grid pattern of the plurality of openings (228) in the bezel (210) corresponds to the arrangement of the plurality of LEDs (206) on the PCB (204), ensuring that each of the plurality of LEDs (206) illuminates each of the plurality of openings (228).
[0102] Additionally, the combination of the one or more brackets (208) and the bezel (210) creates a series of light paths from each of the plurality of LEDs (206) to a corresponding opening in the bezel (210). This configuration minimizes light bleed between adjacent openings, resulting in well-defined pixels or light segments. Further, the layered structure of the lighting device (200) allows for precise control over the light emitted by each of the plurality of LEDs (206). The light travels from each of the plurality of LEDs (206) through the channels in the one or more brackets (208) and then through the corresponding opening of the plurality of openings (228) in the bezel (210). This controlled light path helps to maintain the integrity of each pixel or light segment, preventing unwanted light leakage or blending between adjacent areas.
[0103] Figure 19 illustrates a sectional view (1000a) of the lighting device (200) with a first polarizer array (230) and a second polarizer array (232), in accordance with various embodiments of the present disclosure. Figure 20 illustrates the sectional view (1000b) of the lighting device with the first polarizer array (230) and the second polarizer array (232), in accordance with various embodiments of the present disclosure.
[0104] In an embodiment, the first polarizer array (230) is located between the PCB (204) and the one or more brackets (208), while the second polarizer array (232) is positioned in front of the bezel (210). Further, the first polarizer array (230) and the second polarizer array (232) work in conjunction to control light distribution and reduce light leakage between adjacent openings. The first polarizer array (230) and the second polarizer array (232) are configured to form alternating regions of orthogonal polarization states. This configuration helps to minimize light bleed between adjacent pixels or light segments. Furthermore, the first polarizer array (230) acts to initially polarize the light emitted from the plurality of LEDs (206). As the light passes through the one or more brackets (208) and the bezel (210), the second polarizer array (232) further refines the light output. The orthogonal polarization states between adjacent regions in the first polarizer array (230) and the second polarizer array (232) blocks light that may have scattered or leaked from neighboring pixels, enhancing the overall contrast and definition of the lighting pattern.
[0105] Additionally, by incorporating the first polarizer array (230) and the second polarizer array (232), the lighting device (200) achieves improved control over light distribution. The first polarizer array (230) and the second polarizer array (232) contribute to reducing unwanted light leakage between adjacent openings, resulting in more precise and well-defined illumination patterns.
[0106] Now referring to Figure 21, which illustrates an exploded view (1100) of the bezel (210) and the one or more brackets (208), in accordance with various embodiments of the present disclosure. The bezel (210) is positioned in front of a first bracket (208a) and a second bracket (208b). The first bracket (208a) and the second bracket (208b) are arranged in a layered configuration, with the first bracket (208a) positioned between the PCB (204) and the second bracket (208b). The second bracket (208b) is positioned between the first bracket (208a) and the bezel (210). Further, a gap (X) is provided between the first bracket (208a) and the second bracket (208b). The gap (X) between the first bracket (208a) and the second bracket (208b) is between 1 mm and 1.5 mm. This gap (X) allows for precise control of light distribution while minimizing light leakage between adjacent openings of the plurality of openings (228).
[0107] In an embodiment, the first bracket (208a) is a white bracket and the second bracket (208b) is a black bracket. The white color of the first bracket (208a) increases pixel brightness by reflecting and diffusing light from the light emitting diodes (LEDs) (206). The black color of the second bracket (208b) arrests light leakage by absorbing stray light that may otherwise leak between adjacent openings of the plurality of openings (228).
[0108] In another embodiment, at least one of the first bracket (208a) and the second bracket (208b) has a low refractive index. Further, the at least one of the first bracket (208a) and the second bracket (208b) with the low refractive index is filled with a high refractive index material. This configuration creates a refractive index difference that contributes to improved light management within the lighting device (200).
[0109] In yet another example embodiment, the combination of the first bracket (208a) and the second bracket (208b), along with their specific material properties and arrangement, contributes to enhanced pixel brightness and reduced light leakage in the lighting device (200). The white first bracket (208a) increases light reflection and diffusion, while the black second bracket (208b) absorbs stray light. The refractive index difference between the bracket material and the filling material further improves light management within the device.
[0110] In another exemplary embodiment, the bezel (210) includes the plurality of splines (220) that connect to the second bracket (208b). The plurality of splines (220) cover a remaining periphery of each opening of the plurality of openings (228) in the bezel (210). This arrangement further enhances light control and prevents light leakage between adjacent openings.
[0111] In an example implementation, the one or more brackets (208) may be constructed from materials that offer structural stability and thermal management properties. In some implementations, the brackets may be made from engineering plastics such as polyamide (nylon), polybutylene terephthalate (PBT), or any combination thereof. In cases where different optical properties are desired for the first bracket (208a) and second bracket (208b), different materials or surface treatments may be applied. For instance, the white bracket may be made from a polymer with high reflectivity, while the black bracket may use a material or coating with light-absorbing properties.
[0112] Now referring to Figure 22, which illustrates a polarization array (300) with alternating polarization states, in accordance with various embodiments of the present disclosure. The polarization array (300) includes multiple rows of alternating polarization states arranged in a checkerboard-like configuration. A first polarization region (0) represents areas with a first polarization orientation. A second polarization region (90) represents areas with a second polarization orientation orthogonal to the first polarization orientation. The first polarization region (0) and the second polarization region (90) are arranged in an alternating pattern both horizontally and vertically.
[0113] In addition, each row in the polarization pattern begins with a first polarization region (0) followed by a second polarization region (90), and this alternating sequence continues across the row. The subsequent row begins with a second polarization region (90) followed by a first polarization region (0), creating an offset pattern between adjacent rows. Further, the orthogonal relationship between the first polarization region (0) and the second polarization region (90) helps to reduce light leakage between adjacent areas. Light that may scatter or leak from one region is blocked by the orthogonal polarization state of the neighboring region. This arrangement enhances the contrast and definition between illuminated and non-illuminated areas in the lighting device (200).
[0114] In an example embodiment, the polarization array (300) shown in Figure 22 may be implemented using the first polarizer array (230) and the second polarizer array (232) described earlier. The first polarizer array (230) may initially polarize the light emitted from the light emitting diodes (206), while the second polarizer array (232) may further refine the light output, creating the alternating orthogonal polarization states that reduce light leakage between adjacent regions.
[0115] Figure 23 illustrates pixel patterns (400) demonstrating illumination capabilities, in accordance with various embodiments of the present disclosure. Figure 24 illustrates the pixel patterns (400) demonstrating illumination capabilities, in accordance with various embodiments of the present disclosure. As shown in Figure 23 and Figure 24, there is no light leakage in the lighting device (200).
[0116] The lighting device (200) as disclosed in the disclosure provides the following non-limiting advantages:
• The lighting device provides superior management of light distribution through the combination of one or more brackets, a bezel with an opaque region and splines, and a dispersive element.
• The lighting device offers a more affordable solution for implementing complex pixel patterns and animations in vehicle lighting systems.
• The dispersive element filled in each opening of the opaque region promotes uniform scattering of light within each pixel.
• The modular pixel structure, combined with the light leakage prevention features, allows for the execution of dynamic lighting patterns and animations with minimal interference between illuminated and non-illuminated pixels.
• The matrix configuration of LEDs on the PCB, coupled with the corresponding arrangement of openings in the bezel, provides a high degree of flexibility in creating various lighting patterns.
• The grid-like pattern of vertical and horizontal ribs in the dispersive element enhances light scattering within each pixel opening.
• The inclusion of dampening elements along the periphery of the housing reduces vibration transfer to the components of the lighting device.
• The two-shot injection molding process used to manufacture the bezel allows for precise integration of the dispersive element and opaque region.
• The lighting device is configured for use in various vehicle lighting applications, including headlights, taillights, and other exterior or interior lighting fixtures.
[0117] In light of the above-mentioned advantages and the technical advancements provided by the disclosed lighting device (200), the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the functioning of the lighting device (200) itself as the claimed steps and the constructional features of the lighting device (200) provide a technical solution to a technical problem.
[0118] It should be understood that embodiments described herein should be considered in a descriptive sense only and not for purposes of limitation. Descriptions of features or aspects within each embodiment should typically be considered as available for other similar features or aspects in other embodiments. While one or more embodiments have been described with reference to the figures, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the scope of the present disclosure as defined by the following claims, and equivalents thereof.
,CLAIMS:We Claim:
1. A lighting device (200), comprising:
a housing (202) comprises:
a printed circuit board (PCB) (204) mounted in a rear portion inside the housing (202), wherein the PCB (204) comprises a plurality of light emitting diodes (LEDs) (206), wherein the plurality of LEDs (206) is configured to emit light;
one or more brackets (208) positioned in front of the PCB (204), wherein the one or more brackets (208) configured to channel the light emitted from the plurality of LEDs (206); and
a bezel (210) positioned in front of the one or more brackets (208), wherein the bezel (210) comprises:
an opaque region (214) comprising a plurality of openings (228), wherein the opaque region (214) comprises a plurality of splines (220) protruding around each of the plurality of openings (228), and
a dispersive element (212) filled in each of the plurality of openings (228) of the opaque region (214), wherein the one or more brackets (208) and the plurality of splines (220) of the bezel (210) are configured to prevent light leakage between adjacent openings of the plurality of openings (228).
2. The lighting device (200) as claimed in claim 1, wherein the bezel (210) is manufactured using a two-shot injection molding process.
3. The lighting device (200) as claimed in claim 2, wherein the two-shot injection molding process comprises a first molding step configured to fill the dispersive element (212) in the plurality of openings (228), wherein a plurality of first inlets (224) is provided to inject a 2K mold with the dispersive element (212).
4. The lighting device (200) as claimed in claim 3, wherein the two-shot injection molding process further comprises a second molding process, wherein the second molding process is configured to inject an opaque material through a plurality of second inlets (226) to form the opaque region (214) of the bezel (210).
5. The lighting device (200) as claimed in claim 1, wherein the dispersive element (212) comprises a plurality of vertical ribs (216) and a plurality of horizontal ribs (218) arranged in a grid-like pattern.
6. The lighting device (200) as claimed in claim 1, wherein the dispersive element (212) is configured to uniformly scatter the light within each opening from the plurality of openings (228).
7. The lighting device (200) as claimed in claim 5, wherein the plurality of horizontal ribs (218) protrudes perpendicularly from the plurality of vertical ribs (216).
8. The lighting device (200) as claimed in claim 1, wherein the plurality of splines (220) extends along a periphery of each opening of the plurality of opening (228).
9. The lighting device (200) as claimed in claim 1, wherein each of the plurality of LEDs (206) is mounted on the PCB (204) in a matrix configuration and each of the plurality of LEDs (206) is equidistantly spaced from each other.
10. The lighting device (200) as claimed in claim 1, wherein each opening of the plurality of openings (228) forms a pixel when illuminated by at least one LED of the plurality of LEDs (206).
11. The lighting device (200) as claimed in claim 1, wherein the one or more brackets (208) comprises a first bracket (208a) and a second bracket (208b), wherein the first bracket (208a) is positioned between the PCB (204) and the second bracket (208b), wherein the second bracket (208b) is positioned between the first bracket (208a) and the bezel (210),wherein a gap (X) is provided between the first bracket (208a) and the second bracket (208b), wherein the gap (X) between the first bracket (208a) and the second bracket (208b) is between 1 mm and 1.5 mm.
12. The lighting device (200) as claimed in claim 8, wherein the plurality of splines (220) connects to the second bracket (208b) from the one or more brackets (208) to cover a remaining periphery of each opening of the plurality of openings (228).
13. The lighting device (200) as claimed in claim 1, comprises a lens (222) coupled to the housing (202).
14. The lighting device (200) as claimed in claim 13, wherein the lens (222) is coupled to the housing (202) using at least one of a screw, hot welding, snap-fit, or any combination thereof.
15. The lighting device (200) as claimed in claim 12, comprises a first polarizer array (230) and a second polarizer array (232), wherein the first polarizer array (230) is positioned between the PCB (204) and the one or more brackets (208), and the second polarizer array (232) positioned between the bezel (210) and the lens (222), wherein the first polarizer array (230) and the second polarizer array (232) are configured to reduce the light leakage to form alternating regions of orthogonal polarization states.
16. The lighting device (200) as claimed in claim 1, wherein the dispersive element (212) filled in each of the plurality of openings (228) of the opaque region (214) is configured to have a scattering structure in the middle of each of the plurality of openings (228).
17. The lighting device (200) as claimed in claim 11, wherein the first bracket (208a) is a white bracket and the second bracket (208b) is a black bracket, wherein the white bracket is configured to increase a pixel brightness, and the black bracket is configured to arrest the light leakage.
18. The lighting device (200) as claimed in claim 11, wherein at least one of the first bracket (208a) and the second bracket (208b) has a low refractive index, wherein the at least one of the first bracket (208a) and the second bracket (208b) is filled with a high refractive index material.
19. The lighting device (200) as claimed in claim 1, further comprising at least one dampening element (234) disposed along the periphery of the housing (202) to reduce vibration transfer to components of the lighting device (200).
20. The lighting device (200) as claimed in claim 1, wherein the bezel (210) is coupled to the housing (202) using at least one of a screw, a snap-fit, a press-fit, or any combination thereof.
21. The lighting device (200) as claimed in claim 1, wherein the lighting device (200) is configured to be used in a vehicle, wherein the lighting device (200) corresponds to a headlight, a taillight, or any lighting device mounted on the vehicle exterior or interior region.
22. A vehicle, comprising:
one or more lighting devices, wherein each of the one or more lighting device (200) comprises:
a housing (202) comprises:
a printed circuit board (PCB) (204) mounted in a rear portion inside the housing (202), wherein the PCB (204) comprises a plurality of light emitting diodes (LEDs) (206), wherein the plurality of LEDs (206) is configured to emit light;
one or more brackets (208) positioned in front of the PCB (204), wherein the one or more brackets (208) is configured to channel the light emitted from the plurality of LEDs (206); and
a bezel (210) positioned in front of the one or more brackets (208), wherein the bezel (210) comprises:
an opaque region (214) comprising a plurality of openings (228), wherein the opaque region (214) comprises a plurality of splines (220) protruding around each of the plurality of openings (228), and
a dispersive element (212) filled in each of the plurality of openings (228) of the opaque region (214), and wherein the one or more brackets (208) and the plurality of splines (220) of the bezel (210) are configured to prevent light leakage between adjacent openings of the plurality of openings (228).

Dated this 20th day of August 2025

ABHIJEET GIDDE
AGENT FOR THE APPLICANT
IN/PA- 4407