Structural composites with embedded lighting

A lighted object body structure, comprising:

• an object body structure having an outer surface;
• a lighting apparatus, comprising:
• at least one optical fiber having a length and a longitudinal axis, and an outer surface;
• wherein the at least one optical fiber is attached to a textile layer;
• wherein textile layer and the at least one optical fiber are covered by a resin that has been cured, forming a lighting apparatus wherein the cured resin is in contact with at least a portion of the outer surface of the at least one optical fiber, forming a fiber-resin boundary, for at least a portion of the length of the optical fiber;
• wherein, when the at least one optical fiber is attached to a source of light energy so as to be in optical communication with the source of light energy, light energy from the source of light energy is communicated to and received by the at least one optical fiber and propagates along the at least one optical fiber when the source of light energy is activated;
• wherein an index of refraction of the cured resin is related to an index of refraction of the at least one optical fiber such that a desired portion of the light energy propagating along the at least one optical fiber escapes the at least one optical fiber when it encounters the fiber-resin boundary and is observable from outside the object body structure;
• while a remainder of the energy propagating along the at least one optical fiber is reflected back into the optical fiber and continues to propagate along the fiber until it again encounters the fiber-resin boundary;
• and
• wherein the lighting apparatus is disposed in the object body structure in proximity to an outer surface of the object body structure such that the light energy escaping the fiber-resin boundary is observable from outside the object body structure outer surface.

A method for producing a lighting apparatus, comprising the steps of:

• providing a smooth molding surface;
• applying a layer of clear gel coat to the smooth molding surface;
• applying a first layer of resin to the clear gel coat;
• applying a lighted fabric to the first layer of resin, the lighted fabric having a light emitting side, the light emitting side oriented against the first layer of resin;
• applying a second layer of resin to the non-light emitting side of lighted fabric;
• applying a layer of white gel coat to the second layer of resin to form a background layer;
• and
• curing the layers of resin;
• wherein the lighted fabric comprises:
• at least one optical fiber having a length and a longitudinal axis, and an outer surface;
• wherein the at least one optical fiber is attached to a textile layer;
• wherein the textile layer and the at least one optical fiber are saturated by the first and second layers of resin prior to curing, and wherein the first and second layer cured resin is in contact with at least a portion of the outer surface of the at least one optical fiber, forming a fiber-resin boundary, for at least a portion of the length of the optical fiber;
• wherein the at least one optical fiber is attachable to a source of light energy so as to be in optical communication with the source of light energy, such that light energy from the source of light energy is communicated to and received by the at least one optical fiber and propagates along the at least one optical fiber when the source of light energy is activated;
• and
• wherein an index of refraction of the cured resin is related to an index of refraction of the at least one optical fiber such that a desired portion of the light energy propagating along the at least one optical fiber escapes the at least one optical fiber when it encounters the fiber-resin boundary and is observable from outside the composite structure;
• while the remainder of the energy propagating along the at least one optical fiber is reflected back into the optical fiber and continues to propagate along the fiber until it again encounters the fiber-resin boundary.

A method for producing a lighted composite structure, comprising:

• providing a smooth molding surface for molding a desired surface of a composite structure;
• applying a layer of clear gel coat to the smooth molding surface;
• applying a first layer of resin to the clear gel coat;
• applying a lighted fabric to the layer of co-cure resin, the lighted fabric having a light emitting side, the light emitting side oriented against the first layer of resin;
• applying a second layer of resin to the non-light emitting side of the lighted fabric;
• applying one or more alternating structural fabric-resin layers to achieve a desired structural composite structure;
• and
• curing the layers of resin;
• wherein the lighted fabric comprises:
• at least one optical fiber having a length and a longitudinal axis, and an outer surface;
• wherein the at least one optical fiber is attached to a textile layer;
• wherein the textile layer and the at least one optical fiber are saturated by the first and second layer of resin prior to curing, and wherein the first and second layer cured resin is in contact with at least a portion of the outer surface of the at least one optical fiber, forming a fiber-resin boundary, for at least a portion of the length of the optical fiber;
• wherein the at least one optical fiber is attachable to a source of light energy so as to be in optical communication with the source of light energy, such that light energy from the source of light energy is communicated to and received by the at least one optical fiber and propagates along the at least one optical fiber when the source of light energy is activated;
• and
• wherein an index of refraction of the cured resin is related to an index of refraction of the at least one optical fiber such that a desired portion of the light energy propagating along the at least one optical fiber escapes the at least one optical fiber when it encounters the fiber-resin boundary and is observable from outside the composite structure;
• while the remainder of the energy propagating along the at least one optical fiber is reflected back into the optical fiber and continues to propagate along the fiber until it again encounters the fiber-resin boundary.