WO2019231723A1

WO2019231723A1 - Articles of manufacture incorporating inset lighting

Info

Publication number: WO2019231723A1
Application number: PCT/US2019/032972
Authority: WO
Inventors: Debra CAPPUCCI
Original assignee: Abc Technologies Inc.
Priority date: 2018-05-31
Filing date: 2019-05-17
Publication date: 2019-12-05

Abstract

An inset lighting assembly is disclosed for mounting in a panel in a vehicle, such as an automobile or truck, is disclosed. The inset lighting assembly includes a light housing having at least one passage for receiving a light source to be contained therein. The light housing has an interface portion for engagement with the panel, and an illumination portion from which light emanates. The interface portion of the light housing is configured to seat within a channel provided in the panel

Description

ARTICLES OF MANUFACTURE INCORPORATING INSET LIGHTING

FIELD

[0001] The present disclosure pertains to the incorporation of lighting in articles of manufacture, and, in particular applications, articles of manufacture for vehicles that are formed to receive an extruded light housing that receives a light source.

BACKGROUND

[0002] Consumer goods continue to shape the way in which technology integrates with modern society. While goods were traditionally designed around providing a particular functionality, the aesthetic characteristics of a product are now regarded as a primary element in the area of consumer psychology.

[0003] The aesthetic experience between a product and the consumer can have a major influence over whether or not the product is commercially successful. While form follows function may continue to be a central tenet to product design, the extent to which form is secondary is lessening, in particular as markets become highly competitive.

[0004] As the offerings in market segments become more plentiful, manufacturers are looking for ways to distinguish themselves over their competitors, in particular by enhancing the consumer experience. Elements of shape, color and accent serve to attract and influence consumer behavior, so recognizing and incorporating these features has become critical in ensuring market success.

[0005] Functional and aesthetic illumination of consumer goods is increasingly being used as a means to enhance the consumer experience. Lighting is unique in that it can provide both functional attributes (i.e. to provide safety lighting), and design enhancement. With recent advancements in various lighting technologies, it is recognized that a need exists to facilitate the incorporation of these lighting technologies into modern consumer goods.

SUMMARY

[0006] According to an embodiment, a panel for use in a vehicle, such as an automobile or truck, includes an inset lighting assembly. The panel includes a base that forms a self-supporting structural layer for the panel. The inset lighting assembly includes a light housing having at least one passage for housing a light source. The base of the panel is formed to include a channel for receiving the light housing of the inset lighting assembly.

[0007] According to another embodiment, an inset lighting assembly for mounting in a panel in a vehicle, such as an automobile or truck, is disclosed. The inset lighting assembly includes a light housing having at least one passage for receiving a light source to be contained therein. The light housing has an interface portion for engagement with the panel, and an illumination portion from which light emanates. The interface portion of the light housing is configured to seat within a channel provided in the panel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The foregoing and other features and advantages of the disclosure will be apparent from the following description of the disclosure as illustrated in the accompanying drawings. The accompanying drawings, which are incorporated herein and form a part of the specification, further serve to explain the principles of the disclosure and to enable a person skilled in the pertinent art to make and use the disclosure. The drawings are not to scale.

[0009] Fig. 1 is a perspective view of an interior panel incorporating inset lighting according to an embodiment of the invention.

[0010] Fig. 2 is an exemplary section of the interior panel.

[0011] Fig. 3a is a sectional view through an interior panel showing a first embodiment of a light housing.

[0012] Fig. 3b is a view showing the light housing according to Fig. 3a, shown in isolation.

[0013] Fig. 3c depicts the interior panel and the light housing according to Fig. 3a, wherein a retainer feature is provided in the form of a pin.

[0014] Fig. 3d depicts the interior panel and the light housing according to Fig. 3a, wherein the retainer feature is provided in the form of a clip.

[0015] Fig. 3e depicts the interior panel and the light housing according to Fig. 3a with a plurality of fasteners.

[0016] Fig. 4a illustrates another embodiment of a light housing, having two light passages and a retainer feature.

[0017] Fig. 4b depicts the light housing of Fig. 4a, including some exemplary dimensional characteristics.

[0018] Fig. 5 illustrates another embodiment of a light housing, having three light passages and a retainer feature.

[0019] Fig. 6 illustrates another embodiment of a light housing, having three light passages and a retainer feature, where a center light passage is larger than the two adjacent light passages.

[0020] Fig. 7 illustrates another embodiment of a light housing, having three light passages and an alternative arrangement for the retainer feature.

[0021] Fig. 8 illustrates another embodiment of a light housing, having a single light passage, and wherein the light passage includes a secondary material to enhance reflection of light.

[0022] Fig. 9 illustrates another embodiment of a light housing, having three light passages, and a retainer feature, where the light housing is co-extruded from two different materials.

[0023] Fig. 10 illustrates another embodiment of a light housing, having a single light passage, wherein a slot is provided to permit for insertion/removal of a light source from the light passage.

[0024] Fig. 11 illustrates another embodiment of a light housing, having three light passages, and a retainer feature, where the light housing is provided with a separately formed cap.

[0025] Figs. 12, 13 and 14 illustrate additional embodiments of the single, double and triple- passage light housings, including the retainer features having lateral tabs.

[0026] Figs. l5a, 15b and l5c illustrate arrangements of a light housing having two light passages in an interior panel with an opaque covering applied.

[0027] Figs. l6a and l6b illustrate embodiments of inset lighting, where a light passage is formed directly into an interior panel.

[0028] Fig. 17 illustrate an embodiment of inset lighting, wherein an interior panel additionally includes a bridge for additional panel strength.

[0029] Figs. 18 and 19 illustrate an alternative implementation of a light housing, wherein the light housing is configured as a stitchable light housing.

[0030] Fig. 20 illustrates an alternative embodiment where the light housing and the light source are co-extruded.

[0031] Fig. 21 is a cross-sectional profile through a running board, which includes a light housing received in a channel in accordance with an embodiment hereof.

DETAILED DESCRIPTION

[0032] Specific embodiments of the present invention will now be described with reference to the Figures, wherein like reference numbers indicate identical or functionally similar elements. The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. A person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the scope of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, brief summary or the following detailed description.

GENERAL INTERIOR PANEL STRUCTURE

[0033] Turning now to Fig. 1, shown is an automotive door panel configured to be mounted to the interior side of a vehicle door. It will be appreciated that within the automotive arts, a wide range of interior panels are required to finish the interior of a vehicle Accordingly, although a door panel is being shown for the purpose of discussion, the technology disclosed herein may be applied to a wide range of interior panels in a vehicle. In view of this, for the following discussion, the collective variety of automotive interior panels, including the door panel shown, will be referred to as an interior panel 10.

[0034] The sectional view of Fig. 2 is a schematic representation of an exemplary section of the interior panel 10, and shows a first side 24, herein referred to as an A-side 20, which is generally covered with a wear-resistant and/or aesthetically pleasing covering 22. The covering 22 may be made of a natural or synthetic material. For example, the covering 22 may be a textile fabric such as a woven or non-woven carpet. Other coverings 22, including, but not limited to vinyl, leather and other decorative applique may also be implemented. In some applications, the covering 22 is an applied clear coat, which may include additives to confer desired performance characteristics, such as UV stabilizers. The interior panel 10 also includes a second side 26, situated opposite to the first side 24, herein referred to as a B-side 28. The B-side 28 is generally not exposed to an occupant of the vehicle and therefore does not include a covering 22 as would typically be utilized on the A-side 20. The B-side 28 may be provided with various secondary features 30 including, but not limited to spacers and attachment hardware enabling the interior panel 10 to be securely attached to a supporting structure (i.e. body -in-white, vehicle door frame, etc.).

[0035] The interior panel 10 includes a base 34 that generally forms a self-supporting structural layer. The base 34 may be formed in a number of ways. For example, the base 34 may be molded using a fibrous mat that is impregnated and consolidated with a suitable plastic matrix. The fibrous mat may be selected from a range of materials. In a first embodiment, the fibrous mat is formed from virgin or recycled carbon fiber, or a combination thereof. In another embodiment, the fibrous mat may be formed from natural fiber. In a further embodiment, the fibrous mat may be formed from glass fiber. In yet another embodiment, the fibrous mat is a blended mat having two or more of natural fiber, virgin or recycled carbon fiber, and glass fiber. Natural fibers may be selected from a range of natural fibers including but not limited to kenaf, hemp, flax, coconut (coir), sisal, jute, and mixtures thereof. Both virgin and recycled carbon fiber are available commercially. For example, chopped reclaimed carbon fiber is available through Carbon Conversions (Lake City, South Carolina). Where the fibrous mat is formed from a blended recycled carbon fiber/natural fiber, the amount of recycled carbon fiber in the blended mat may range from 5% to 95% (w/w RCF to NF), with specific quantities contemplated including 5%, 7%, 15%, 17% 25%, 35%, 50%, 60%, 70%, 80%, 90%, and 95% (w/w). It will be appreciated that quantities of recycled carbon fiber both above and below this range, as well as between the specific values noted above may also be suitably implemented. Where the fibrous mat is formed from a blended glass fiber/natural fiber, the amount of glass fiber in the blended mat may range from 5% to 95% (w/w GF to NF), with specific quantities contemplated including 5%, 7%, 15%, 17% 25%, 35%, 50%, 60%, 70%, 80%, 90%, and 95% (w/w). It will be appreciated that quantities of glass fiber both above and below this range, as well as between the specific values noted above may also be suitably implemented.

[0036] In some embodiments, a synthetic fiber may be substituted for the natural fiber component in the blended mat. In other embodiments, the synthetic fiber may constitute a third component in the natural fiber/recycled carbon fiber or natural fiber/glass fiber blended mat. Suitable synthetic fibers may include, but are not limited to polymeric fibers (i.e. Kevlar or aramid fibers), mineral fibers, glass fibers or mixtures thereof.

[0037] The fibrous mat may be provided in a variety of forms, including but not limited to a woven and non-woven mat. In a preferred embodiment, the fibrous mat is a non-woven mat, for example as produced through a wetlaid process. It will be appreciated, however, that a variety of manufacturing methods for both non-woven and woven mats are known, and will not be detailed herein. In general, the fibrous mat includes fibrous content, for example the natural fiber and recycled carbon fiber in a uniformly dispersed arrangement within the mat, thereby exhibiting consistency with respect to both performance characteristics and matrix wetting during manufacture of the interior panel 10.

[0038] There are various ways in which the plastic impregnated fibrous mat may be molded into the desired form. For instance, the fibrous mat may be incorporated into molding processes including, but not limited to thermoform molding, thermoset molding, autoclave molding, casting, and stamping.

[0039] The plastic matrix may be selected from both thermoset and thermoplastic polymers. In a preferred embodiment, the matrix is a thermoplastic, such as polypropylene. Other embodiments may use a thermoset resin for the plastic matrix, in particular polyurethane. The polyurethane may be formulated in a variety of ways as generally known in the art to produce a rigid or semi rigid matrix once cured. The polyol component of the polyurethane may be derived from petroleum or bio-based sources, or may consist of a combination thereof.

[0040] In addition to the exemplary fiber-reinforced plastic structure described above, the interior panel 10 may be formed in a number of other ways. For instance, the interior panel may be formed of a plastic material (thermoplastic or thermoset), in accordance with any of the aforementioned molding processes, but without the addition of the fibrous mat. In some embodiments, the plastic material may receive additives (i.e. inorganic filler components) to achieve a preferred performance and/or aesthetic characteristic. Exemplary inorganic filler components include, but are not limited to glass, mica, calcium carbonate and talc.

[0041] Additional molding process methodologies may be implemented, depending on the desired panel product. For example, the interior panel may be formed using an injection molding process, a blow molding process, or any other suitable molding process methodology suitable for achieving the desired shape and form of the interior panel being manufactured.

EXTRUDED INSET LIGHT HOUSING

With reference again to Fig. 1, the interior panel 10 is shown as having inset lighting 36. Inset lighting may be added to the interior panel for a variety of reasons. In some applications, the addition of inset lighting is for aesthetic enhancement. In other applications, the addition of inset lighting serves to provide a particular functionality. For example, where the interior panel is provided in the cabin of a public transportation vehicle (i.e. a bus), the inset lighting may be used for emergency directional lighting. Regardless of the intended purpose, it will be appreciated that the inset lighting can be arranged in a variety of ways on the interior panel. In some embodiments, the inset lighting may be arranged proximal to the perimeter of the panel. In other embodiments, the inset lighting may be arranged to follow the contours around a particular feature, such as an armrest, bin, phone charger, etc. Regardless of the arrangement, the presence of inset lighting is intended to provide an enhanced visual experience.

[0042] Turning now to Fig. 3a shown is a partial sectional view through the interior panel 10 including an inset lighting assembly 40. The inset lighting assembly 40 includes a light housing 50 configured to house a light source 54. With reference to Fig. 3b, the light housing 50 is formed as an elongate body 56 that includes at least one passage 58 for receiving the light source 54. In an embodiment, the elongate body 56 is configures to be arranged to follow the contours around a particular feature, such as an armrest, bin, phone charger, etc. The light housing 50 is intended to be set into the interior panel 10 in a way that has the appearance of being at least partially recessed. The light housing 50 includes an illumination portion 60, defined as the area from which light emanates from the light source. The illumination portion 60 is generally the portion of the light housing 50 that is visible from the A-side of the interior panel 10. In some embodiments, in particular where the light housing is configured to protrude outward, or non flush, of the surrounding panel surface, a portion of the side walls of the light housing may additionally be illumination portions, denoted 60a, 60b in Fig. 3b. The light housing 50 also includes an interface portion 62, defined as the area of the light housing 50 that positions and anchors against the interior panel 10.

[0043] In the embodiment shown in Figs. 3a and 3b, the light housing 50 is shown as having a single passage 58. The inside surface 64 of the passage 58 is shaped to accommodate the light source intended to be housed therein. In the embodiment shown, the inside surface 64 of the passage 58 includes a hemispherical base 66 for supporting the light source 54, and opposing planar side walls 68 that extend from the base 66 towards the illumination portion 60. Each passage 58 is intended to receive a single light source 54, although other arrangements may be possible. For example, in a light housing 50 having a single passage 58, the light source situated therein may be configured to include two or more light sources (i.e. electroluminescent wires) in a single structure. It will be appreciated that the passage 58 provided in the light housing 50 may be used to house any arrangement of one or more light sources 54 compatible with the space provided. Where multiple light sources are provided, the multiple light sources may be arranged in a number of ways, including but not limited to side-by-side arrangement, braided, and twisted. Furthermore, the inside surface 64 of the passage 58 may be smooth, grooved or textured in some way to achieve a desired aesthetic character. Returning to the embodiment shown in Figs. 3a and 3b, the spacing between the opposing planar side walls 68 of the passage 58 is sized with a dimension that is slightly larger than the outside diameter of the light source intended to be located therein. In this way, the light source located within the passage is able to be cleanly seated and therein follows the path established by the light housing inset into the interior panel.

[0044] With reference now to Figs. 4a, 4b, 5 and 6, shown are additional configurations for a light housing. Figs. 4a and 4b depict a light housing 50b having two equally sized passages 58. Fig. 5 depicts a light housing 50c having three equally sized passages 58. Fig. 6 depicts a variation on a three-passage light housing 50d, where a center passage 58b is provided with an inside diameter that is greater than the inside diameter of each adjacent passage 58. It will be appreciated that the light housings shown in Figs. 4a, 4b, 5 and 6 are merely exemplary, and light housings having more than three passages and/or light housings having differently sized passages are possible design options, depending on the intended application. It will be further appreciated that the shape shown for the passages are exemplary, and that the passages may also be shaped differently depending on the light source intended to be housed therein.

[0045] An exemplary set of dimensions for forming the light guide is illustrated in Fig. 4b, although it will be appreciated that other dimensional characteristics may be selected depending on the intended application. Although shown as lmm, the spacing between adjacent light guide conduits can be as small as 0.5 mm, and as large as 4 mm or more, depending on the intended application.

RETAINER FEATURE

[0046] With reference now to Fig. 3a, to achieve the at least partially recessed appearance, the light housing 50 is received in a complementary channel 80 formed on the base 34 of the interior panel 10. More specifically, in the process of forming the interior panel 10, the molding tool used in the molding process is configured to form a channel that is complementary to the interface portion 62 of the light housing 50 to be situated therein. The depth of the channel 80 will define the extent to which the light housing is recessed, and this is generally established based on the desired aesthetic character of the lighted panel. While a suitable adhesive may be used to retain the light housing 50 in the channel 80, the light housings 50 described herein include retainer features to provide a mechanical lock to the receiving interior panel 10. As shown, the interface portion 62 includes one or more fastener elements 82 that engage the interior panel 10 to retain it in place. The fastener elements 82 are generally continuous elongate structures (see Fig. 3b) integrally formed on the interface portion 62, and are dimensioned to extend through complementary apertures 84 provided within the channel 80 formed on the interior panel 10. The fastener elements 82 may, for example, be arrowhead shaped to include one or more barbs 86 that engage the B-side 28 of the interior panel 10, therein mechanically locking the interface portion 62 of the light housing 50 within the channel 80. In an alternative embodiment, the fastener elements 82 may be discontinuous, therein defining a plurality of fastener elements 82 integrally formed on the interface portion 62, as shown for example in Fig. 3e.

[0047] Turning to Fig. 7, shown is a light housing 50e having an alternative fastener element 88 that includes a secondary barb 90. This arrangement of the fastener element 88, in particular where multiple barbs are provided serves to accommodate panels of varying thickness. This arrangement also serves to make a single light housing structure compatible for placement in multiple panels of various thicknesses.

[0048] Although the various light housings provide a centrally located fastener element, some embodiments of the light housings may position the fastener element off of a centerline of the elongated body. Additionally, some embodiments may include two or more fastener elements, which may be located towards each side of the interface portion of the light housing.

[0049] It will also be appreciated that the shape for the fastener element discussed above may be modified depending on the application. The‘arrowhead’ shape as shown may be modified to suit a particular installation. The fastener element may also be configured in the form of separately formed clips, that would be attach to the interface portion of the light housing, and subsequently to the channel formed in the interior panel.

[0050] In an alternative embodiments, as shown in Figs. 3c and 3d, a retainer feature is provided in the form of a fastener blade 91 that extends through the base 34 of the interior panel 10, and is retained in place on the B-side 28 through the use of one or more pins 92, as shown in Fig. 3c, or one or more clips 98, as shown in Fig. 3d. In the embodiment utilizing the clips 98, the clips may be configured as an elongated strip clip that engages extended portions of the fastener blade 91. The clips 98 may be provided with teeth or other engagement features to retain the clip 98 upon the blade 91, therein keeping the light housing firmly seated in the channel 80. CLEAR COAT COVER LAYER

[0051] As stated earlier, interior panels generally receive on the A-side a covering that provides a finished and aesthetically pleasing appearance. For interior panels 10 receiving a light housing 50, in particular the light housing configuration based on that shown in Fig. 3a (and the variants shown in Figs. 4a, 4b, 5, 6 and 7), a covering layer 22 is preferably a clear or translucent covering, for example a clear coat. Exemplary clear coat finishes include, but are not limited to polyurethanes. The use of a clear coat over the light housing is particularly preferred where the desired effect is to have the light housing encapsulated in the finished interior panel. It will be appreciated, however, that other arrangements are possible where the covering layer 22 is applied to the interior panel prior to the installation of the light housing. In such an arrangement, the light housing, and in particular the illumination portion of the light housing would not be covered by the covering layer.

SURFACE TREATMENTS TO ENHANCE AESTHETIC CHARACTER

[0052] An outside surface 94 (noted in Fig. 3b) of the illumination portion 60 of the light housing 50 may be formed without texture (i.e. smooth), or it can be enhanced for improved performance and/or aesthetics. Enhancements of the outside surface 94 may be provided in the form of texturing, or the application of advertising/logos. Texturing may be achieved using laser etching. In some embodiments, the outside surface 94 of the illumination portion 60 may be provided with a ribbed texture, to enhance the appearance when lit or unlit, or to provide a light refraction effect. The inclusion of ribs may also provide additional mechanical properties to improve retention. The outside surface 94 may also include the use of applied films cut to provide an illuminated logo, graphic or words. The outside surface 94 can have a combination of opaque and translucent areas, to achieve a desired decorative effect. A wide variety of film choices are available. For instance a film may be selected on the basis that it has color changing effects, or provides a certain functionality, such as haptic touch.

MATERIAL

[0053] The light housings described herein may be extruded from a suitable clear or translucent plastic material. Exemplary materials will include, but are not limited to ABS (Acrylonitrile- Butadiene- Styrene), acrylic, EVA (Ethylene Vinyl Acetate), flexible PVC (Poly Vinyl Chloride), HDPE (High Density Polyethylene), LDPE (Low Density Polyethylene), PC (Polycarbonate), PP (Polypropylene), PU (Polyurethane), rigid PVC (Poly Vinyl Chloride), TPE (Thermoplastic elastomers), styrene, TPO (Thermal Plastic Olefin). The selection of material will depend on various factors, including the required stiffness of the light housing. In some instances, a relatively ridged light housing may be preferred, in which case a rigid PVC may be selected. In other instances, a more flexible light housing may be preferred, in which case a flexible PVC may be selected. It will be appreciated that the requirements in terms of flexibility will be dependent upon the application. As the light housing is preferably extruded, for instances where the light housing will follow a non-linear path, a more flexible construction is preferred, and will offer a greater range of applications.

[0054] The plastic selected for the light housing may include additives, including but not limited to UV stabilizing agents, impact modifying agents, and processing aids to assist in the extrusion process. The plastic may be either clear or translucent, and may additionally contain a colorant. For some applications, the light housing may undergo a post-extrusion treatment, such as the addition of a UV protectant.

TREATMENTS TO ENHANCE LUMINESCENCE

[0055] In addition to receiving a colorant, the extruded light housing may be subject to post- extrusion treatment to enhance luminescence. For example, as shown in Fig. 8, the interior surface of the passage 58, in particular the hemispherical base 66 and in some embodiments at least a portion of the planar side walls 68 may be treated with a secondary material 96 that increases reflection of light in the direction of the illumination portion 60 of the light housing 50. The secondary material may be a reflective coating, including but not limited to paint, film and foil. In other embodiments, the use of a secondary material to enhance luminescence may be incorporated into the molding process. For example, in some constructions, a suitable reflective film may be co-extruded in a manner that places the film on the hemispherical base 66 and/or at least a portion of the planar side walls 68.

CO-EXTRUDED TO DELIVER SELECT MATERIALS

[0056] In some embodiments, as shown in Fig. 9, a light housing 50f may be extruded from two or more different materials, to impart a desired performance characteristic in certain portions of the light housing. For example, having regard to Fig. 9, the light housing 50f is formed from two co-extruded materials, where a first material 100 is used to form the illumination portion 60, while a second material 102 is used to form the interface portion 62. While both materials may exhibit similar flexibility, the first material 100 may be selected for its clarity/translucency, while the second material 102 may be selected for its reflective properties, to enhance luminescence of the light housing 50f. In another embodiment, the first material may be selected for its abrasion resistance, while the second material may be selected for its rigidity, particularly where the intended application for this embodiment of the light housing is largely linear and flexibility is not a required performance characteristic.

[0057] It will be appreciated that the selection of materials for each of the co-extruded portions will be dependent upon the performance/aesthetic characteristic provided by the material in question. In some cases, the materials for the first and second portions may be the same (i.e. PVC), but differ only in respect of the additive agents added (i.e. UV stabilizers, colorants, etc.). LIGHT HOUSING WITH SLIT

[0058] In general, light housings in accordance with embodiments hereof are configured to receive a light source by inserting the light source into a light housing passage through one end, and feeding it along until fully inserted and seated. The light source will include power leads that connect to a wire harness/control module (not shown), generally positioned on the B-side of the panel, or otherwise out-of-sight from the passenger. As shown in Fig. 10, as an alternative to inserting the light source from one end, a light housing 50g in accordance with another embodiment hereof may be modified to include a slit 106 through which the light source 54 can be inserted or removed when necessary (i.e. for servicing and/or changing the aesthetic character of the inset lighting system), from the B-side 28 of the interior panel 10. With this arrangement, the interior panel 10 includes a complementary slit 108 that aligns to the slit on the light housing 50g. The gap spacing of the slits are selected to be slightly smaller than the outside diameter of the light source 54, so as to retain the light source 54 within the passage 58. SEPARATELY FORMED CAP

[0059] With reference now to Fig. 11, shown is another embodiment where an illumination portion 60 is provided as a separately formed cap 114, that is affixed to the interface portion 62 subsequent to installation of the light housing 50h onto the interior panel (not shown). In this arrangement, the separate interface portion is first aligned to and installed upon the interior panel. The passages 58 for receiving the light source are configured as exposed channels. This arrangement facilitates the installation of the light source, as it can be directly laid within the channel. ETpon secure placement of the light source, the cap 114 is attached to the interface portion 62, using a suitable adhesive. In some embodiments, the cap 114 and/or interface portion 62 may be provided with a snap-fit feature or some other mechanical element that enables the cap 114 to be securely attached to the interface portion 62 and retained thereto. Where the light housing is not covered by a clear coat, as will be described later in an alternative embodiment, the separately formed cap may be configured to be removable, to facilitate servicing of the light source. The cap 114 may be clear or translucent, and may include a colorant.

LIGHT HOUSING WITH TABS

[0060] In addition to the configuration shown above where the light housing is covered or encapsulated by a clear coat (as shown for example in Fig. 3a), the light housing may be configured for applications where the covering is provided in the form of a textile fabric, leather, vinyl or any other type of covering that is generally opaque. Where the selected covering (i.e. the textile fabric) is one that does not permit light to pass through, the covering must provide a suitable gap spacing in the region of the illumination portion of the light housing. Figs. 12 to 14 provide alternative configurations for the light housing, suitable for use where a gap spacing is required in the covering of the interior panel. To facilitate this, the light housings are provided with lateral tabs that aid in arranging the covering in a manner that establishes the required gap spacing over the illumination portion. This alternative arrangement is shown in Figs. 12 to 14, where lateral tabs 120 are shown with respect to a single-passage light housing 50i (Fig. 12), a double- passage light housing 50j (Fig. 13), and a triple- passage light housing 50k (Fig. 14).

[0061] With reference now to Figs. l5a and 15b, shown is the double-passage light housing 50j incorporated into an interior panel 10. Fig. l5a depicts the light housing 50j in the interior panel 10 such that an outside surface 122 of the illumination portion 60 is somewhat recessed relative to the covering 22. Fig. 15b, is similar, but depicts the light housing 50j in the interior panel 10 such that the outside surface 122 of the illumination portion 60 is relatively flush to the adjacent covering 22. In another alternative embodiment (not shown), the light housing may be disposed in the interior panel such that the outside surface of the illumination portion protrudes from the adjacent covering. The positioning of the light housing 50j relative to the interior panel 10, that is the extent to which it is recessed relative to the covering 22, may depend on the placement of the lateral tabs 120. Regardless, in both instances, the base 34 of the interior panel 10 includes a channel 130 that includes a lateral channel extension 132 to accommodate the lateral tabs 120. The lateral tabs 120 engage the base 34 on a first side 136, and receive/engage the covering 22 on a second side 138. As the channel 130 and channel extensions 132 are arranged to recess the second side 138 of the lateral tab 120 relative to an A-side surface 140 of the base 34, the covering 22 can be arranged to fold as shown, therein forming an aesthetically pleasing edge 144 adjacent the illumination portion 60 of the light housing 50j. In some applications, the covering 22 may be folded over a secondary material, including but not limited to foam 148, as shown in Fig. l5c. It will be appreciated that in some applications where the light housing is provided with lateral tabs, it may not be necessary to provide a retainer feature (i.e. the arrowhead fastening element).

LIGHT CHANNEL INCORPORATED INTO PANEL WITH SEPARATELY FORMED CAP

[0062] In another alternative embodiment shown in Figs. l6a and l6b, the inset lighting assembly includes a separately formed cap 160 that is fitted to a molded channel 162 provided in the base 34 of the interior panel 10. The molded channel 162 includes a hemispherical base 166, similar to the light housings described above, with the exception that it is formed directly in the base 34 of the interior panel 10. The hemispherical base 166 may include any of the enhancements previously described, to improve luminescence. The separately formed cap 160 may be attached to the base 34 using a suitable adhesive, or may be welded thereto. Fig l6a depicts an embodiment where this arrangement is incorporated into an interior panel 10 receiving a covering 22 in the form of a clear coat. Fig. l6b depicts an embodiment where this arrangement is incorporated into an interior panel 10 having a covering 22 in the form of an opaque layer, such as a textile fabric.

LIGHT HOUSING WITH BRIDGE

[0063] In certain embodiments, an interior panel 10 may be formed with a bridge 164 to provide additional strength. A shown in the embodiment depicted in Fig. 17, the bridge 164 is configured to span the aperture 84 that receives the fastener element 82. Although the bridge is shown being implemented in a light housing 50j having lateral tabs 120, the bridge 164 may also be implemented in configurations not having lateral tabs.

SUITABLE LIGHT SOURCES

[0064] The light housings described herein are intended to receive a light source configured in rope or cable form, and which is designed to release light along the length thereof. Any such rope or cable lighting may be considered for use in the above-described applications. For instance, fiber optic cables are a particularly suitable lighting source, for example as provide by SCHOTT North America, Inc. Other lighting sources will include, but are not limited to LED rope light, and electroluminescent wire. Control of the light source is generally provided by a controller.

ALTERNATIVE PANEL SUBSTRATES

[0065] It will be appreciated that inset lighting as achieved in accordance with embodiments of the above described light housing may be applied to other panel substrates capable of being formed or shaped to include a channel for receiving the light housing. Examples of alternative panel substrates include, but are not limited to metal, wood, glass, as well as composite layered structures (which may include foam core, honeycomb cores, etc.). In addition, while the various arrangements described herein make reference to the panel as being an interior panel, the technology may also find application in a range of exterior panel systems. Examples of exterior panel systems that may incorporate inset lighting include, but are not limited to running boards, tonneau covers, cargo/storage boxes, roof racks, tow-package components, wheel wells, and door panels.

LIGHT HOUSING STITCHING

[0066] It is also contemplated that a light housing in accordance with embodiments hereof may be formed that is used to provide illuminated accent stitching. A stitchable light housing is shown in Fig. 18, and takes the form of a flexible light housing 50k configured to receive a light source 54. The stitchable light housing may be used to achieve a range of stitching patterns, including but not limited to baseball stitching, as shown in Fig. 19. A suitable material for forming the flexible light housing 50k is flexible PVC. The flexible light housing may be used for accent stitching on a wide array of interior automotive components, including but not limited to seats, center consoles, armrests, center armrests, dashboards, steering wheels, etc. NON- AUTOMOTIVE APPLICATIONS

[0067] Although the various embodiments of inset lighting assembly detailed herein have been described within the context of automotive applications, it will be appreciated that the various light housings can be applied in other areas where panel-like structures are suited for receiving accent/functional lighting. For instance, the inset lighting assembly could find application in any form of transportation vehicle including land, marine and aerospace. A wide range of consumer goods (i.e. upholstered furniture, apparel, costumes, drones, bars, pools, office furniture, medical equipment, theater seating, casino gaming furniture and equipment, etc.) would be visually enhanced using this technology. There is no intention to be limited to any particular application. It is contemplated that the inset lighting assembly could find application in any article of manufacture capable of being formed or configured to receive the aforementioned light housings of the inset lighting assembly.

NON-LIGHTING COMPONENTS ADDED TO LIGHT HOUSING

[0068] In some embodiments, a light housing may contain other items, either in addition to, or as a substitute for the light source. For example, the passage of the light housing may receive one or more unlit flexible rods. Flexible rods may be etched, colored, and/or include certain surface features (i.e. grooves) that enhance the reflective and/or aesthetic properties of the light housing. The unlit flexible rod may also be configured to provide a logo or text information. A passage may also be configured to receive, in addition to the light source, a grout or gel-like substance that further enhances the optical character of the light housing. The grout or gel-like substance may contain sparkles, glitter or other reflective elements.

CO-EXTRUDED CONSTRUCTION

[0069] In some embodiments, the light housing may be co-extruded with the light source. For example, with reference to Fig. 20, shown is a double-passage inset lighting arrangement where the light source 54 is positioned in a housing 50n, wherein the passage 58 containing the light source 54 is free of voids between the inside surface 64 thereof, and the outside surface 170 of the light source 54. The light housing/light source as shown in Fig. 20 may be formed using a suitable co-extrusion process, for example one that implements a cross-head die head. The cross-head die head permits the preformed light source to be fed into the die head, while a resin for forming the light housing is channeled and formed generally as an annular layer around the light source, therein avoiding the formation of a space or void around the light source. ALTERNATIVE MOUNTING ARRANGEMENT FOR INSET LIGHTING ASSEMBLY

[0070] In some embodiments, constructs such as boards (i.e. automotive running boards) may be configured to receive a light housing, to provide enhanced functionality and aesthetics to the finished product. With reference to Fig. 21, shown is a cross-sectional profile through a running board 174, which includes a light housing 50p received in a channel 176. In the embodiment shown, the outside surface 94 of the illumination portion 60 is arranged to be flush with the adjacent outside surface 178 of the running board 174. Instead of the arrowhead-shaped fastener elements shown in Fig. 3a, the light housing 50p includes tab retainers 180 that generally extend laterally from the interface portion 62. The tab retainers 180 are intended to perform as anchors within the board, by positioning within corresponding apertures 182 formed between an upper wall element 184 and a lower wall element 186. Additional supporting wall elements 188 may be provided to support the interface portion 62, as shown. It will be appreciated that the arrangement of the upper and lower wall elements 184, 186 may take on a variety of forms to achieve the required aperture 182 to receive the tab retainer 180. There is no intention to be limited to the exemplified arrangement shown in Fig. 21. It will also be appreciated that the running board 174 may take on a variety of forms, and may be constructed in a number of ways including extrusion, injection molding and blow molding. The running board 174 may be formed of any suitable material, including but not limited to thermoplastic and metals (i.e. aluminum). The light housing 50p may be formed and later fitted with the light source, or may be co-extruded with the light source. Both methods for forming and assembling the inset lighting assembly are contemplated for this application. Although exemplified as a running board, this alternative embodiment may find application is any construct suitable in form to include the required channel 176 and aperture 182 to seat and mechanically lock in position the light housing 5 Op.

ALTERNATIVES

[0071] Although extrusion is a preferred manufacturing process for forming a light housing in accordance with embodiments hereof, certain configurations of the light housing, for example the housing having a separately formed cap (as shown in Fig. 11) may have the cap and/or interface portions formed through an injection molding process. It will be appreciated that where the molding technology permits, the light housing may be molded using any available molding process. [0072] In some embodiments, the light housing may be modular to enable post-mold/extrusion assembly into various configurations of small, large or multiple passage options, both with and without lighting. In some embodiments, the light housing may be molded to provide additional functionality, such as the ability to retain items including pens, stylus, coins, etc.

[0073] In some embodiments, the light housing may be configured to function as a gasket/spacer between mating panels, where the mating panels are arranged perpendicular to one another, or at any other angle. For example the light housing may be used around windows in automobiles, aircraft, and as accent lighting on motorcycle windshields, boats, etc.

[0074] In some embodiments, a light housing may be configured to accommodate each passage in a separate housing, where the housings are modular and intended to assemble in a variety of configurations such as in triangular form, as well as L-shaped form (i.e. to have a corner housing).

[0075] Although a light source is shown as having a round cross-sectional profile, it will be appreciated that light sources having non-round cross-sectional profiles may be used with the light housing. In addition, a passage may be differently shaped to that shown to accept and/or correspond to any non-round light source configurations.

[0076] In some embodiments, a light housing may be configured to anchor via the lateral tabs only, that is with no retainer feature (i.e. arrowhead), and provide illumination portions on both the A and B-sides of the interior panel.

[0077] In some embodiments, the ends of the light housing may be provided with a cap or sealing element to prevent the ingress of water/debris into the passage, as well as to prevent the loss of contents (i.e. optical grout, glitter, etc.) from the passage.

[0078] In some embodiments, the materials used to mold the light housing may be chosen to confer certain shielding characteristics. For instance, the plastic used to mold the light housing may be modified with additives that confer radio frequency interference (RFI) shielding, or electromagnetic interference (EMI) shielding.

[0079] While various embodiments have been described above, it should be understood that they have been presented only as illustrations and examples of the present disclosure, and not by way of limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the disclosure. Thus, the breadth and scope of the present disclosure should not be limited by any of the above- described exemplary embodiments, but should be defined only in accordance with the appended claims and their equivalents. It will also be understood that each feature of each embodiment discussed herein, and of each reference cited herein, can be used in combination with the features of any other embodiment. All patents and publications discussed herein are incorporated by reference herein in their entirety.

Claims

CLAIMS What is claimed is:

1. An inset lighting assembly for mounting in a panel, the inset lighting assembly comprising:

a light housing having at least one passage for receiving a light source to be contained therein, an interface portion for engagement with the panel, and an illumination portion from which light emanates,

wherein the interface portion is configured to seat within a channel provided in the panel.

2. The inset lighting assembly according to claim 1, wherein the at least one passage is defined by a hemispherical base for supporting the light source, and opposing planar side walls that extend from the hemispherical base towards the illumination portion.

3. The inset lighting assembly according to claim 1, wherein the at least one passage has an inside surface that may be smooth, grooved or textured.

4. The inset lighting assembly according to claim 1, wherein the at least one passage is a plurality of passages, and wherein at least one of the plurality of passages is configured with a larger inside diameter than one or more other of the plurality of passages in the assembly.

5. The inset lighting assembly according to claim 1, wherein the interface portion includes one or more fastener elements that engage a complementary aperture on the panel, to retain the inset lighting assembly in place.

6. The inset lighting assembly according to claim 5, wherein the one or more fastener elements are elongate structures.

7. The inset lighting assembly according to claim 6, wherein the fastener elements include one or more barbs that engage a B-side of the panel, to mechanically lock the interface portion of the light housing to the panel.

8. The inset lighting assembly according to claim 1, wherein an outside surface of the illumination portion is smooth, textured or provided with an applied film to improve the performance and/or aesthetics of the light housing.

9. The inset lighting assembly according to claim 2, wherein the hemispherical base is provided with a secondary material to enhance luminescence of the light housing.

10. The inset lighting assembly according to claim 9, wherein the secondary material is a reflective material that increases reflection of light in the direction of the illumination portion of the light housing.

11. The inset lighting assembly according to claim 1, wherein the illumination portion and the interface portion are formed by extrusion, and formed of the same material.

12. The inset lighting assembly according to claim 1, wherein the illumination portion and the interface portion are co-extruded, and wherein the illumination portion is extruded from a first material, and the interface portion is extruded from a second material.

13. The inset lighting assembly according to claim 1, wherein the illumination portion is provided as a separately formed cap, that is affixed to the interface portion subsequent to the installation of the light source.

14. The inset lighting assembly according to claim 1, wherein the interface portion of the light housing includes a slit to permit for insertion/removal of the light source from a B-side of the panel.

15. The inset lighting assembly according to claim 1, wherein the light housing includes lateral tabs that extend laterally from the interface portion, and which facilitate in arranging an opaque covering in a manner that establishes a gap spacing over the illumination portion.

16. A panel having inset lighting, the panel comprising:

a base that forms a self-supporting structural layer of the panel; and

an inset lighting assembly comprising a lighting housing having at least one passage for housing a light source,

wherein the base of the panel is formed to include a channel for receiving the light housing of the inset lighting assembly.