LED lighting unit with multi-layer bodies having a carrier layer, a stone layer, and an edgelit transparent layer

Patent metadata

Field	Value
Publication number	US-12122140-B2
Application number	US-202017642999-A
Country	US
Kind code	B2
Filing date	Sep 21, 2020
Priority date	Sep 30, 2019
Publication date	Oct 22, 2024
Grant date	Oct 22, 2024

Abstract

A lighting unit which includes a multilayer body and at least a first light emitting diode (LED) light source. The multilayer body includes, in sequence, a carrier layer of a black or gray translucent thermoplastic composition, a stone layer with an average thickness of 2 mm of less, and a transparent thermoplastic layer with an average thickness of 1 mm to 6 mm. The LED light source is disposed facing at least one lateral edge of the transparent thermoplastic layer, such that light from the LED light source is guided within the transparent thermoplastic layer.

First claim

The invention claimed is:

1. A lighting unit comprising:
a multilayer body including:
a carrier layer of a black or gray colored translucent thermoplastic material,
a stone layer having an average thickness of ≤2 mm over its total area,
a transparent layer of a thermoplastic material and having an average thickness 1 mm to 6 mm over its total area; and
a first LED light source, arranged at least one lateral edge of the transparent layer, and configured to project light into the transparent layer, such that light is projected out of a surface of the transparent layer facing away from the stone layer.

2. The lighting unit as claimed in claim 1 , wherein the material of at least one of the carrier layer or the transparent layer includes an aromatic polycarbonate.

3. The lighting unit as claimed in claim 1 , wherein the carrier layer has an average thickness over its total area of 0.5 to 6 mm.

4. The LED lighting unit as claimed in claim 1 , wherein the multilayer body has a planar rectangular shape.

5. The lighting unit as claimed in claim 1 , further comprising at least one protective layers.

6. The lighting unit as claimed in claim 1 , wherein the average thickness of the stone layer over its total area is ≤0.3 mm.

7. The LED lighting unit as claimed in claim 1 , wherein the stone layer, includes a flat side facing the transparent layer, the flat side having a topography with a maximum roughness R z of at least 0.1 μm.

8. The lighting unit as claimed in claim 1 , wherein the transparent layer covers at least 90% of the stone layer.

9. The lighting unit as claimed in claim 1 , wherein the carrier layer extends at least over the full area of the stone layer.

10. The lighting unit as claimed in claim 1 , further comprising a second LED light source arranged to backlight the multilayer body.

11. The lighting unit as claimed in claim 1 , wherein the second LED light source comprises one or more RGB LEDs.

12. The lighting unit as claimed in claim 1 , wherein the translucent thermoplastic material of the carrier layer comprises
a) 95% by weight to 99.95% by weight of aromatic polycarbonate,
b) 0.00001% by weight to 0.02% by weight of carbon black,
c) 0.00001% to 2% by weight of at least one scattering additive selected from the group consisting of acrylate-based scattering additives and silicone-based scattering additives,
d) up to 1.0% by weight of at least one white pigment,
e) at least one further additive, selected from the group consisting of demolding agents, antioxidants, flame retardants, UV absorbers, IR absorbers, flow improvers, opacifiers other than component c, antistats, anti-dripping agents, optical brighteners, and thermal stabilizers
f) a colorant mixture comprising a total amount of 0.0005% by weight to 0.02% by weight, of at least two colorants, other than component b and component d, selected from the group consisting of colorants based on anthraquinone, anthrapyridone, perinone, methine and quinoline.

13. The lighting unit as claimed in claim 1 , wherein the translucent thermoplastic material of the carrier layer is free of white pigment and contains
a) at least 90% by weight of aromatic polycarbonate,
b) 0.002% to 0.020% by weight of carbon black,
c) 0.05% to 1.0% by weight of at least one scattering additive selected from the group consisting of acrylate-based scattering additives and silicone-based scattering additives,
d) at least one further additive, selected from the group consisting of demolding agents, antioxidants, flame retardants, anti-dripping agents, thermal stabilizers, flow improvers, opacifiers other than component d, antistats, UV absorbers, and IR absorbers,
e) a colorant mixture of colorants comprising a total amount of up to 0.1% by weight, of at least two colorants, other than component b, comprising at least one anthraquinone-based colorant and an anthrapyridone-based colorant.

14. The lighting unit as claimed in claim 1 , wherein the translucent thermoplastic material of the carrier layer contains
a) at least 90% by weight of aromatic polycarbonate,
b) 0.0003% by weight to 0.020% by weight of carbon black,
c) 0.05% to 1.0% by weight of at least one scattering additive selected from the group consisting of acrylate-based scattering additives and silicone-based scattering additives,
d) 0.03% to 1.0% by weight of at least one white pigment,
e) at least one further additive selected from the group consisting of demolding agents, antioxidants, flame retardants, anti-dripping agents, thermal stabilizers, optical brighteners, flow improvers, opacifiers other than component d, antistats, UV absorbers, and IR absorbers,
f) a colorant mixture comprising a total amount of up to 0.1% by weight, of at least two colorants other than component b and component d, the colorants being selected from the group consisting of colorants based on anthraquinone, anthrapyridone, perinone, methine, and quinoline.

15. The LED lighting unit as claimed in claim 1 , in combination with of one selected from the group consisting of a floor covering, for furniture making, a wall panel, a door panel, part of a lamp, a lighting element, a housing of domestic appliances, electrical equipment, and a vehicle element.

16. The lighting unit as claimed in claim 1 , in combination with a vehicle element selected from the group consisting of a lighting element, a part of interior trim, a part of a dashboard, a part of an instrument panel, a decorative strip, a doorsill strip, a part of an armrest and a part of a center console.

17. The lighting unit as claimed in claim 1 , wherein the translucent thermoplastic material of the carrier layer contains:
a) at least 90% by weight of aromatic polycarbonate,
b) 0.00001% by weight to 0.05% by weight of carbon black,
c) 0.00001% to 2% by weight of at least one scattering additive selected from the group consisting of acrylate-based scattering additives and silicone-based scattering additives,
d) up to 1.0% by weight of at least one white pigment,
e) at least one further additives, selected from the group consisting of demolding agents, antioxidants, flame retardants, anti-dripping agents, thermal stabilizers, optical brighteners, flow improvers, opacifiers other than component c, antistats, UV absorbers, and IR absorbers,
f) a colorant mixture comprising a total amount of up to 0.1% by weight of at least two colorants, other than component b and component d.

18. The LED lighting unit as claimed in claim 17 , wherein the carbon black is nanoscale carbon black, and the scattering additive present comprises at least one silsesquioxane.

Assignees

• Covestro Intellectual Property Gmbh & Co Kg

Inventors

• Thust Torsten
• Schulz Thorsten
• Hagen Rainer
• Piermatteo Ciro
• Rogowski Marius
• Berger Armin
• Helmig Jan

Classifications

• G02B6/0065

  Manufacturing aspects; Material aspects · CPC title

• G02B6/0051

  Diffusing sheet or layer · CPC title

• F21V33/00

  Structural combinations of lighting devices with other articles, not otherwise provided for · CPC title

• B32B2607/02

  Wall papers, wall coverings · CPC title

• B32B2605/003

  Interior finishings · CPC title