Abstract:
A lighted assembly includes a LED that emits light at a first frequency. The lighted assembly further includes an elongated light transmitting assembly having at least one illuminated area, and a non-illuminated area surrounding the illuminated area. The elongated light transmitting assembly includes a cover member on the outer side, a backing member on the inner side, and an intermediate member disposed between the cover member and the backing member. Light from the LED is transmitted along an optical path to the illuminated area. A layer of photo reactive material is disposed along the optical path. The photo reactive material produces light at a second frequency that is lower than the first frequency and provides a mixed light having a required color.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/659,254 filed on Jun. 13, 2012, entitled, ILLUMINATED ACCESSORY UNIT, the entire contents of which are incorporated herein by reference. 
     
    
     SUMMARY OF THE INVENTION 
       [0002]    One aspect of the present invention is a lighted assembly including an LED that emits light having a first frequency. The lighted assembly further includes an elongated light transmitting assembly defining inner and outer sides. The outer side defines at least one illuminated area having a predefined shape, and a non-illuminated area surrounding the illuminated area. The elongated light transmitting assembly includes a cover member on the outer side, a backing member on the inner side, and an intermediate member disposed between the cover member and the backing member. The LED is optically connected to the elongated light transmitting assembly whereby light from the LED is transmitted along an optical path defined by the elongated light transmitting assembly to the illuminated area. Photo reactive/photoluminescent material is disposed along the optical path. The photo reactive/photoluminescent material produces light having a second frequency that is lower than the first frequency. Light at the first and second frequencies is mixed to provide light having a color that is different than the light emitted by the LED the mixed light is emitted from the illuminated area. Different types of photo reactive/photoluminescent materials may be utilized to form illuminated areas having different colors. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0003]      FIG. 1  is an exploded isometric view of a lighted assembly according to one aspect of the present invention; 
           [0004]      FIG. 2  is a cross sectional view of the lighted assembly of  FIG. 1 ; 
           [0005]      FIG. 3  is an exploded isometric view of a lighted assembly according to another aspect of the present invention; 
           [0006]      FIG. 4  is an exploded cross sectional view of the lighted assembly of  FIG. 3 ; 
           [0007]      FIG. 5  is a cross sectional view of the lighted assembly of  FIG. 3 ; 
           [0008]      FIG. 5A  is a cross sectional view of the lighted assembly of  FIG. 5  taken along the line VA-VA; 
           [0009]      FIG. 6  is a cross sectional view of a lighted assembly according to another aspect of the present invention; 
           [0010]      FIG. 7  is a cross sectional view of a lighted assembly according to another aspect of the present invention; 
           [0011]      FIG. 8  is a cross sectional view of a lighted assembly according to another aspect of the present invention; 
           [0012]      FIG. 9  is a cross sectional view of a lighted assembly according to another aspect of the present invention; 
           [0013]      FIG. 10  is an exploded isometric view showing assembly of a lighted assembly according to one aspect of the present invention; and 
           [0014]      FIG. 11  is an exploded isometric view showing assembly of a lighted assembly according to another aspect of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0015]    One aspect of the present invention is a lighted assembly or accessory unit for a motor vehicle. The assembly  1  ( FIG. 1 ) may comprise a lighted door sill that includes an outer member  2  with cut outs or openings  10  forming letters, numbers, designs, or the like. Outer member  2  may be formed (e.g. stamped) from sheet metal utilizing known processes. Outer member  2  may also be fabricated from polymer materials utilizing molding or thermoforming processes. A lighted member  3  includes raised portions  12  forming letters, numbers, etc. that fit into openings  10  of outer member  2  when assembled. Member  3  may comprise a molded transparent or translucent thermoplastic polymer. A light source  15  may comprise one or more LEDs that are encapsulated in a thermoplastic polymer material as disclosed in U.S. Pat. No. 7,909,482 to Veenstra et al, issued Mar. 22, 2011 and/or U.S. Pat. No. 8,230,575, to Veenstra et al., issued Jul. 31, 2012 the entire contents of each being incorporated herein by reference. Light source  15  may be connected to light guide or pipe  4  utilizing light-transmitting adhesive and/or mechanical connectors  14  and  16  as disclosed in U.S. Pat. No. 7,712,933, the entire contents of which are incorporated by reference. Light guide  4  may comprise a sheet of transparent polymer material that is cut to form perimeter edge  6 . End edge portion  8  may be cut to form a T-shaped female “puzzle piece” type connector  14  that interconnects with a T-shaped male connector  16  on LED light source  15  as described in U.S. Pat. No. 7,712,933. Upper and lower surfaces  18  and  18 A of light guide  4  may be substantially smooth to internally reflect light from light source  15 . Alternatively, the entire upper surface  18  may be treated utilizing a laser to form a rough surface that emits light that illuminates areas  12 . Alternatively, only regions  24  may be treated to provide rough surface areas having shapes that are substantially identical to the shapes of openings  10  and raised portions  12 . Regions  24  form illuminated areas that illuminate raised areas  12 . Raised areas  12  protrude through openings  10 , and are therefore visible, especially when illuminated. A backer member  5  has a “hat-shaped” profile ( FIG. 2 ) forming a shallow cavity that receives members  3  and  4 . Backer member  5  may be formed from sheet metal or polymer material. When assembled, adhesive/sealant on flanges  5 A contacts the inner surface  11  of outer member  2  and/or the edge portions of members  2  and/or  3  to seal the cavity. Outer member  2  may include an outer flange  13  that extends past edges  9  of flanges  5 A when assembled. 
         [0016]    The light source  15  may include one or more LEDs  17 . The LEDs may comprise white or other color LEDs. The LEDs  17  may comprise blue LEDs, and a layer of photo reactive/photoluminescent material  25  ( FIG. 2 ) may be disposed on at least a portion of upper side  4 B of light guide  4 . The photo reactive material  25  may comprise an ink or other suitable coating material available from Performance Indicator, LLC of Lowell, Mass. The photo reactive materials may comprise fluorescent or phosphor based materials. It will be understood that various coating materials are available, and photo reactive material  25  may be mixed/selected as required for a particular application to emit light having a specific wavelength/color. As the light from LEDs  17  passes through the layer of material  25 , some of the light is absorbed and light having a lower frequency is emitted by the material  25 . The layer of material  25  may be configured such that some of the light from LEDs  17  passes through material  25  and remains at the original frequency. This light mixes with the lower frequency light emitted by material  25  to provide light having a desired color. For example, the material  25  may comprise a fluorescent ink having similar properties to the fluorescent material presently used in commercially available white LEDs. Commercially available “white” LEDs may comprise blue LEDs having a “YAG” (Yttrium Aluminum Garnet) phosphor coating that mixes down-converted yellow light with blue light to produce light that is substantially white. The photo reactive material  25  may comprise a YAG phosphor coating that is printed or otherwise deposited on surface  4 B of light guide  4  to thereby mix with blue light from LEDs  17  to create white light that travels into lighted member  3  to thereby illuminate the raised portions  12 . The photo reactive material  25  may be printed or otherwise deposited on an area  22  of surface  18  of light guide  4 . Light from LEDs  17  travels inside light guide  4 , and escapes at area  22  as a result of photo reactive material  25  being deposited on surface  18 . Surface  18  does not necessarily need to be treated to form a rough surface to permit escape of light, and photo reactive material  25  may be printed or otherwise deposited directly on a smooth portion of surface  18 . Alternatively, photo reactive material  25  may be deposited on surface  18  only at areas  24 A- 24 D having shapes corresponding to raised areas  12  and openings  10 . 
         [0017]    Also, photo reactive materials  25 A- 25 D having different light-emitting properties may be deposited at areas  22 A- 22 D, respectively, or at areas  24 A- 24 D, respectively. The photo reactive materials may be selected to emit different colors of light. For example, material  25 A may emit red light, material  25 B may emit green light, material  25 C may emit yellow light, and material  25 D may emit blue light. The light emitted from materials  25 A- 25 D mixes with light (e.g. blue) from LED  17  to provide a desired color at raised portions  12 . 
         [0018]    The photo reactive material  25  (or  25 A- 25 D) may alternatively be initially deposited on lower side surface  3 B of lighted member  3 , or the photo reactive material  25  may be preprinted on a thin layer of material (e.g. tape) that is adhesively secured to lighted member  3  or light guide  4 . For example, photo reactive materials  25 A- 25 D may be preprinted on large rolls of transparent thin polymer sheet material. The rolls of material may have adhesive disposed on one side thereof, or adhesive may be applied at the time the sheet material is adhered to lighted member  3  or light guide  4 . If all of the raised areas  12 A- 12 D are to have the same color, a single piece of the sheet having the shape of area  22  can be cut out and applied to lighted member  3  or light guide  4 . Alternatively, individual pieces of material having shapes (e.g. letters)  24 A- 24 D can be cut out and applied to lighted member  3  or light guide  4 . If areas  12 A- 12 D are to have different colors, pieces of sheet material with photo reactive materials  25 A- 25 D can be cut to the shapes  22 A- 22 D or the shapes  24 A- 24 D, and the pieces can be applied to lighted member  3  or light guide  4 . 
         [0019]    An illuminated assembly  20  according to another aspect of the present invention ( FIG. 3 ) includes an appliqué  2 A comprising a thin sheet of transparent polymer material having opaque ink printed on upper surface  21 A and/or lower surface  21  thereof, except at regions  10 A. Light therefore passes through regions  10 A, but not the printed area  10 B. Appliqué  2 A may be adhesively secured to upper surface  18  of light guide  4 A, and/or to flanges  5 A of backer tub  5 B. Regions  10 A may alternatively comprise holes that are cut out to form letters, designs, etc. Light pipe  4 A, light module  15 A, and backer tub  5 B may be substantially similar to the corresponding components shown in  FIG. 1  and described above. Photo reactive material  25  (or  25 A- 25 D) may be deposited on lower surface  21  of appliqué  2 A or on upper surface  18  of light guide  4 A to thereby generate light having the desired color that is emitted through regions  10 A. One or more of the photo reactive materials  25 A- 25 D may be printed/deposited directly onto the upper or lower surfaces of appliqué  2 A or light guide  4 A, or the photo reactive material may be disposed on tape or other suitable material that is cut to shapes  22 A- 22 D and/or  24 A- 24 D and adhered to the upper or lower surfaces of appliqué  2 A and/or light guide  4 A. 
         [0020]    With further to  FIGS. 4 and 5 , a light assembly  30  according to another aspect of the present invention includes a molded polymer member  34  having a concave lower surface  26  and a substantially flat upper surface  28 . The member  34  may include connectors  14 A ( FIG. 5A ) that connect the light guide  34  to a light engine  15 B having one or more LEDs  17  in substantially the same manner as described in more detail above in connection with  FIGS. 1 and 3 . LEDs  17  of light engine  15 B may be blue LEDs that can be utilized to provide illuminated areas  24 A- 24 D having the desired colors. Light engine  15 B ( FIG. 5A ) includes a transparent polymer body  19  having one or more LEDs  17  and associated electrical circuit elements  17 A disposed therein. Electrical lines  17 B provide power to the circuit elements  17 A and LEDs  17 . Lower surface  26  of member  34  is spaced apart from surface  42  of backing member  36  to form a space or gap  40  that extends along the length of member  34  (member  34  may have an elongated shape similar to light guides  4 ,  4 A, etc.). One or more LEDs  17  are positioned adjacent side surface  23  of body  19  such that light from LEDs  17  is emitted into space  40 . Body  19  may include a connector  16 A that connects to a connector  14 A of member  34  in substantially the same manner as described above in connection with  FIG. 3 . Upper surface  28  of member  34  may optionally include light emitting areas  24  having a rough surface formed by laser treatment or other suitable process. Alternatively, the entire upper surface  28  may be a rough surface that emits light, or the entire upper surface  28  may be smooth. The assembly  30  includes an outer member  32  that may be substantially the same as the appliqué  2 A described in more detail above in connection with  FIG. 3 . The outer member  32  may be adhesively secured to flanges  38  of backer member  36 . 
         [0021]    Interior surface  42  of backing member  36  may comprise a reflective surface (e.g. white) such that space  40  forms a light guide whereby light from LEDs  17  is reflected internally. The blue light from LEDs  17  is thereby distributed along the lower surface  26  of light guide  34 . Lower surface  26  of member  34  may be coated with one or more photo reactive materials  25 A- 25 D such that light in space  40  causes material  25  to emit lower frequency light that is emitted from upper surface  28  of member  34 . Some of the light from LEDs  17  passes through photo reactive material  25  and mixes with light from LEDs  17 , and is emitted from surface  28  and travels through transparent areas  10 A of cover  32 . The entire surface  26  of member  34  may be coated with photo reactive material  25 . Alternatively, a layer  27  of ink or other suitable opaque/reflective material may be disposed on portions of surface  26  to internally reflect light. Photo reactive materials  25 A- 25 D may be deposited (e.g. printed) directly on surface  26 , or the photo reactive materials  25 A- 25 D may be preprinted on tape or other suitable material that is adhesively secured to surface  26  through photo reactive material  25 , through member  34 , and through openings or transparent regions  10 A of cover  32 . Upper surface  33  or lower surface  33 A of cover  32  may be coated with an opaque ink or other material except in the regions of letters or areas  10 A, and the cover  32  may comprise a substantially transparent polymer material. Thus, the regions  10 A are illuminated by light from LEDs  17  and photo reactive material  25 . 
         [0022]    With further reference to  FIG. 6 , a lighted assembly  50  according to another aspect of the present invention includes a cover or appliqué  52 , a molded polymer member  54 , and a backer member  56  having an upper surface  62  that is preferably reflective. The molded polymer member  54  may be made from transparent polymer or the like. The backer member  56  may comprise a sheet of substantially flat polymer material that is adhesively bonded to molded polymer member  54  at joints  58 . Molded polymer member  54  includes a curved lower surface  60  that is spaced apart from upper surface  62  of backer member  56  to define a gap or space  64 . A light engine  15 B ( FIG. 5A ) may be utilized to direct light from one or more LEDs into space  64 . The cover  52  includes upper and lower surfaces  66  and  68 , respectively. Lower surface  68  of cover  52  may be adhesively bonded to upper surface  70  of molded polymer member  54 . A layer of photo reactive material  25  may be disposed between the lower surface  68  of cover  52  and upper surface  70  of polymer member  54 . Alternatively, photo reactive material  25  may be disposed on upper surface  66  of cover  52 . The photo reactive material  25  may be disposed only in the regions  10 A, and an opaque ink material or the like may be utilized to cover the other portions of upper surface  66  of cover  52 . Alternatively, photo reactive material(s)  25 A- 25 D and reflective material  27  may be disposed on lower surface  60  of member  54 . The photo reactive material may be deposited directly onto one of cover  52  and member  54 , or the photo reactive material may be preprinted onto sheets of material that are adhesively attached to cover  52  or member  54 . 
         [0023]    A light engine  15 B ( FIG. 5A ) may be connected to molded polymer member  54  and/or cover  52  and/or backer member  56  to thereby direct light (e.g. blue light) from LED  17  into the space  64 . Light from the LEDs  17  travels through the space  64 , through the photo reactive material  25 , through the molded polymer member  54 , and through areas  10 A to thereby illuminate the areas  10 A. 
         [0024]    With further reference to  FIG. 7 , an assembly  80  according to another aspect of the present invention includes a transparent polymer cover  82  and a backing member  84  that are adhesively secured to opposite side faces  86  and  88  of a polymer member  90 . Inner surfaces  92  of polymer member  90  (see also  FIG. 11 ) and inner surface  94  of backing member  84  may be reflective (e.g. coated with white ink) to thereby guide light from LEDs  17  through gap  85 . Upper and/lower surfaces  83  of cover member  82  may be at least partially coated with photo reactive material  25  (or materials  25 A- 25 D) such that light emitted through areas  10 A is substantially white or other desired color. Opaque ink  72  or other material may be disposed on upper and/or lower surfaces  81  and  83  of cover  82  to thereby block light except in the regions  10 A. Member  90  may have a ring-like shape ( FIG. 11 ), and a light engine  15  may be connected to member  90  utilizing connectors  14  and  16  ( FIG. 1 ). 
         [0025]    With further reference to  FIG. 8 , a light assembly  100  according to another aspect of the present invention includes a molded polymer member  102  that may be made from transparent polymer or the like. The molded polymer member  102  includes raised areas  104  that may form letters or other shapes. A formed metal cover  106  covers upper surface  107  of molded polymer member  102 . The formed metal component  106  may include openings  108 , and the raised areas  104  of molded polymer member  102  may protrude through the openings  108 . A polymer backing member  110  may be adhesively secured to side portions  112  of molded polymer member  102  to form an elongated channel or space  114  that receives light from LEDs  17  as described above in connection with  FIG. 5A . Photo reactive material  25  and/or  25 A- 25 D may be disposed on the curved lower surface  116  of molded polymer member  102  such that blue light from LEDs  17  mixes with lower frequency light emitted by coating  25  prior to being emitted through raised areas  104 . Inner surface  118  of backing member  110  may comprise a reflective (e.g. white) surface, and inner surfaces  120  of polymer member  102  may also comprise reflective surfaces. Opaque/reflective material  27  may be disposed on lower surface  116  of member  102  below cover  106 . Photo reactive materials  25 ,  25 A- 25 D may be printed on surface  116  or preprinted on tape that is adhesively applied to lower surface  116 . 
         [0026]    With further reference to  FIG. 9 , a lighted assembly  130  according to another aspect of the present invention includes a molded polymer member  132  having a generally planar lower surface  133 . A backing member  134  may be adhesively secured to lower surface  133  of molded polymer member  132 . Molded polymer member  132  may comprise a transparent or other light-transmitting polymer material, and backing member  134  may comprise opaque polymer or other suitable material. A layer of photo reactive material  25  may be disposed between upper surface  136  of backing member  134  and lower surface  133  of molded polymer member  132 . A formed metal member  138  extends over upper surface  140  of molded polymer member  132 . Molded polymer member  132  may include raised areas  142  that extend through openings  144  in formed metal member  138 . Molded polymer member  132  may include an integrally molded connector  14  ( FIG. 1 ) that connects to a connector  16  of a light engine  15  to thereby provide blue light from LEDs  17 . As the light travels through the molded polymer member  132 , some of the light reflects internally from the photo reactive material  25 , and some of the light causes photo reactive material  25  to emit lower frequency light into member  132 . The two frequencies of light mix to produce light having the desired color. The missed light is emitted through raised portions  142 . Raised portions  142  may form letters or other designs. 
         [0027]    With further reference to  FIG. 10 , during fabrication of the light assemblies  1 ,  20 ,  30 ,  50 ,  100 , and  130 , the polymer member  3 ,  4 A,  34 ,  54 ,  102 , or  132  is first molded, and a light engine  15  (or  15 B) is connected to the polymer member. Fluorescent material  25  is then deposited on the polymer member, and the polymer member  3  is then assembled with an outer member  2  and backing member  5 . The polymer member designated “ 3 ” in  FIG. 10  may comprise any of the polymer members described above in connection with  FIGS. 1-9 , and the cover member designated “ 2 ” in  FIG. 10  may comprise any of the formed metal members described in more detail above in connection with  FIGS. 1-9 . Similarly, backing member  5  may comprise any one of the backing members described in more detail above in connection with  FIGS. 1-9 . 
         [0028]    With further reference to  FIG. 11 , fabrication of assembly  90  (see also  FIG. 7 ) includes molding a polymer member  90  having a central opening  96 . A light engine  15  is connected to the polymer member  90 , and cover  82  and backing member  84  are adhesively secured to the polymer member  90 . 
         [0029]    The processes for forming illuminated assemblies  1  and  20  are shown in  FIG. 3 . As shown in  FIG. 3 , a light source  15  may be operably connected to a ring-like light pipe  40  having a central opening  42 . 
         [0030]    Although an illuminated sill assembly is shown, it will be understood that the same constructions described above may be utilized to form lighted badges, signs, etc. 
         [0031]    These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following appended drawings.