Note: Descriptions are shown in the official language in which they were submitted.
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VEHICLE MINI LAMP MOUNTING ASSEMBLY
TECHNICAL FIELD
This disclosure relates to mini lamp mounting assemblies. More particularly,
this
disclosure relates to vehicle mini lamp mounting assemblies.
BACKGROUND
Several forms of vehicle mini lamp mounting means are known in the art.
Vehicle mini lamp mounting means known in the art suffer from a number of
drawbacks.
The present disclosure addresses certain drawbacks of vehicle mini lamp
mounting assemblies known in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[01] FIG. 1 is back view of a typical vehicle in which the positioning of a
plurality of one embodiment of the vehicle mini lamps can be seen.
[02] FIG. 2 is an exploded view of the vehicle mini lamp according to one
embodiment of the present invention.
[03] FIGS. 3A and 3B show cross-sectional views of one embodiment of the
electrical components of the vehicle mini lamp according to the present
invention.
[04] FIG. 4 shows a top perspective view of one embodiment of an attachment
member as used in the present invention.
[05] FIG. 5 shows a top perspective view of the vehicle mini lamp with some of
the electrical components assembled within the housing according to one
embodiment of the invention.
[06] FIG. 6 shows a top perspective view of the vehicle mini lamp with some of
the electrical components assembled within the housing and an alternate
embodiment of the flange according to an alternate embodiment of the vehicle
mini lamp.
[07] FIG. 7 shows some of the various possible positions on a vehicle where
the vehicle mini lamp can be positioned.
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[08] FIG. 8A shows a top perspective view of one embodiment of a mounting
structure on which the vehicle mini lamp is mounted in a vehicle mini lamp
system.
[09] FIG. 8B shows a side cross-sectional view of one embodiment of a
mounting structure with one vehicle mini lamp affixed thereto.
[10] FIG. 9A shows a top perspective view of an embodiment of an mounting
device for a vehicle mini lamp.
[11] FIG.9B shows a side view of the mounting device of FIG. 9A.
[12] FIG. 9C shows a bottom side view of the mounting device of FIG. 9A.
[13] FIG. 10A shows a top view of an embodiment of an mounting device for a
vehicle mini lamp.
[14] FIG.10B shows a side view of the mounting device of FIG. 10A.
[15] FIG. 11 shows a side view of an alternative embodiment of an mounting
device for a vehicle mini lamp.
[16] FIG. 12 shows a top perspective view of another alternative embodiment
of an mounting device for a vehicle mini lamp.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[17] For the purpose of promoting an understanding of the embodiments
disclosed herein, references are made in the text hereof to embodiments of a
vehicle mini lamp and assembly, only some of which are illustrated in the
drawings. It is nevertheless understood that no limitations to the scope of
the
invention are thereby intended. One of ordinary skill in the art will readily
appreciate that modifications may be made such as the shape and materials of
the components, the positioning of the components, the color of the LED or
lens,
and the number of vehicle mini lamps. Some of these possible modifications are
mentioned in the following description. Furthermore, in the embodiments
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depicted, like reference numerals refer to identical structural elements in
the
various drawings.
[18] The embodiments of the subject invention that are disclosed herein are
designed to satisfy the Society of Automotive Engineers (SAE) Standards. SAE
Standards J592e (7/72) and J592 (8/00) specify certain photometric
requirements, including luminous intensity requirements, for side marker
lamps;
SAE Standards J2042 (6/96), J2042 (3/00), and J2042 (3/03) specify certain
photometric requirements for clearance, side marker, and identification lamps;
SAE Standard J578c (2/77) specifies certain chromaticity requirements for
color.
All of these SAE Standards are all met by the vehicle mini lamp as disclosed
herein.
[19] The Department of Transportation (DOT), in its Federal Motor Vehicle
Safety Standards, 49 C.F.R. §571.108 (2000), or "FMVSS 108," regulates
all
lamps, reflective devices, and associated equipment. FMVSS 108 can be found
at www.nhtsa.dot.gov. DOT Standard 1383 (part of FMVSS108) adopts the
Society of Automotive Engineers (SAE) Standard J592 (July 1972 and August
2000), J2042 (September 1996, March 2000, and March 2003, and J578
(February 1977) for motor vehicle clearance, side marker, and identification
lamps.
[20] SAE Standard J592, paragraph 3.1 defines a "clearance lamp" as a lamp
"mounted on the permanent structure of the vehicle as near as practicable to
the
upper left and right extreme edges that provide light to the front or rear to
indicate
the overall width and height of the vehicle." SAE Standard J592, paragraph 3.2
further defines a "side marker lamp" as a lamp that is "mounted on the
permanent structure of the vehicle as near as practicable to the front and
rear
edges, that provide light to the side to indicate the overall length of the
vehicle."
SAE Standard J592, paragraph 3.3 defines "combination clearance and side
marker lamps" as "single lamps which simultaneously fulfill performance
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requirements of clearance and side marker lamps." SAE Standard J592,
paragraph 3.4 defines an "identification lamp" as "lamps used in groups of
three,
in a horizontal row, that provide light to the front or rear or both, having
lamp
centers that are spaced not less than 150 mm nor more than 310 mm apart,
mounted on the permanent structure as near as practicable to the vertical
centerline and the top of the vehicle to identify vehicles 2032 mm or more in
overall width." Unless otherwise noted, the SAE definitions of these terms are
adopted and used herein. The lamp of the instant application is intended to be
used in any or all of these applications. The various embodiments discussed
infra
will satisfy all SAE standards for photometric requirements as well as
chromaticity.
121] SAE Standard J592 also specifies certain minimum and/or maximum
luminous intensity requirements for vehicular lamps functioning as clearance,
side marker, and identification lamps. According to the aforementioned
standards, a minimum luminous intensity must exist at various points in the
illumination zone to be in compliance. These specific photometric requirements
for clearance, side marker, and identification lamps, as set forth in SAE
Standard
J592, are included herein below.
1TABLE 1 PHOTOMETRIC REQUIREMENTS Test Points<sup>1</sup>,2 Minimum
Luminous Minimum Luminous Zone (in degrees) Intensity (cd), Red<sup>3</sup>,4
Intensity (cd), Yellow<sup>3</sup>,4 1 45L-10U 0.75 1.86 45L-H 45L-10D 2 V-10U 0.75
1.86 V-H V-10D 3 45R-10U 0.75 1.86 45R-H 45R-10D <sup>1Maximum</sup> luminous
intensities of red clearance and identification lamps shall not exceed 18 cd
within
the solid cone angle 45L to 45R # and 10U to 10D. When red clearance lamps
are optically combined with stop or turn signal lamps, the maximum applies
only
on or above horizontal. # The maximum luminous intensity shall not be exceeded
over any area larger than that generated by a 0.5 degree radius within the
solid
cone angle prescribed by the test points. <sup>2The</sup> requirements for side
markers used on vehicles less than 2032 mm wide need only be met for inboard
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test points at a distance of 4.6 m # from the vehicle on a vertical plane that
is
perpendicular to the longitudinal axis of the vehide and located midway
between
the front and rear side marker lamps. <sup>3When</sup> calculating zone totals, the
measured value at each test point shall not be less than 60% of the minimum
values in Table 2. <sup>4Combination</sup> clearance and side marker lamps shall
conform with both clearance and side marker photometric performance
requirements,
[22] 2TABLE 2 PHOTOMETRIC DESIGN GUIDELINES Test Points Minimum
Luminous Minimum Luminous (in degrees) Intensity (cd), Red<sup>1</sup>,2 Intensity
(cd), Yellow<sup>210U</sup> 45L 0.25 0.62 V 0.25 0.62 45R 0.250.62 H 45L 0.25 0.62
V 0.25 0.62 45R 0.25 0.62 10D 45L 0.25 0.62 V 0.25 0.62 45R 0.25 0.62
<sup>1The</sup> maximum design value of a lamp intended for the rear of the vehicle
should not exceed the listed design maximum over any area larger than that
generated # by 0.25 degree radius within the solid angle defined by the test
points in Table 2. <sup>2For</sup> combined clearance and side marker lamps, both
the
clearance and side marker photometric design values should apply.
[23] SAE Standard J592, paragraph 6.1.7 also requires that the color of the
emanating light produced by a front clearance lamp, front and intermediate
side
marker lamps, and front identification lamp be yellow, and that rear clearance
lamps, side marker lamps, and identification lamps shall be red, both as
specified
in SAE Standard J578. SAE J578, entitled "Color Specification," sets forth the
fundamental requirements for color, expressed as chromaticity coordinates
according to the CIE (1931) standard colorimetric system. Pursuant to SAE
J578,
paragraphs 3.1.1 and 3.1.2, respectively, the following requirements for red
and
yellow amber light shall apply when measured by the tristimulus or
spectrophotometric methods, as are well-known in the art.
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,
3TABLE 3 RED LIGHT The color of light emitted from the device shall fall
within
the following boundaries: y = 0.33 (yellow boundary) y = 0.98 - x (purple
boundary)
[24] 4TABLE 4 YELLOW AMBER LIGHT The color of light emitted from the
device shall fall within the following boundaries: y = 0.39 (red boundary) y =
0.79
- 0.67x (white boundary) y = x - 0.12 (green boundary)
[25] SAE J592 standard and SAE J578 standard can also be found at
www.sae.com.
[26] In addition, it is intended that the lamps of the present invention could
also
be used on mirrors, cabs, cars, and other non-trailer applications. Moreover,
the
lamps can be used on other types of vehicles, including but limited to
watercraft,
motorcycles, and the like, whether or not specific SAE or FMVSS photometric
standards apply.
[27] FIG. 1 is back view of a typical vehicle 50 in which the positioning of a
plurality of one embodiment of vehicle mini lamp 100, being used as
identification
lamp assembly 60, can be seen. In the embodiment shown, there are three
vehicle mini lamps 100 generally centered and along the top of back end 55 of
vehicle 50. However, this is not intended to be limiting, as provided and
described in detail infra.
[28] FIG. 2 shows an exploded view of one embodiment of one vehicle mini
lamp 100, which, in the embodiment shown, is comprised of housing 110, lens
120, and circuit board 130, all generally cylindrical about axis A, as well as
LED
140, resistor 150, cable 160, cable wires 162, 164, and cable seal 170. One of
ordinary skill in the art will recognize, however, that multiple LEDs can be
used
instead of the single LED 140 shown.
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[29] In the embodiment shown in FIG. 2, housing 110 is generally cylindrical
about axis A, with two ends, a top end 111 and a lower end 112. Lower end 112
allows cable 160 and cable wires 162, 164 to enter housing 110, and top end
111
allows the components to be assembled outside of housing 110 before being
sealed within housing 110, as discussed in greater detail infra. In the
embodiment shown, an interior portion 115 is also visible. Housing 110 is
comprised of interior portion 115 such as a ledge so that circuit board 130
rests
atop it when assembled, properly positioning the various elements within
housing
110,
[30] In an alternate embodiment, a body portion 113 of housing 110 is tapered
such that top end 111 is of a greater diameter than lower end 112. The
tapering
of body portion 113 of housing 110 allows for a snug fit between circuit board
130
and housing 110 as circuit board 130 is positioned within housing 110,
creating a
junction between the two components.
[31] Also visible on housing 110 is top surface 114. Top surface 114, in one
embodiment, is angled to receive corresponding bottom surface 124 of lens 120.
Lens 120 is then attached to housing 110 by use of a glue, adhesive, or epoxy
between bottom surface of lens 120 and top surface 114 of housing 110, forming
cavity 99 within housing 110. In an alternate embodiment, top surface 114 of
housing 110 and bottom surface 124 of lens 120 are horizontally flat and
secured
to one another. In yet another embodiment, the shape of top surface 114 of
housing is configured such that lens 120 snaps into housing 110, securing lens
120 to housing 110. Lens 120 and housing 110 can also be connected to one
other via high frequency welding, hot gas welding, ultrasonic welding, hot
plate
welding, or vibration welding. Lens 120 could also be attached to housing 110
via
a fastener such as a snap-ring, a screw, or a rivet, or both could be threaded
such that lens 120 threadedly engages housing 110. Glue or an 0-ring can
further be used at the junction between housing 110 and lens 120 to further
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produce a liquid and air-tight junction. In a further embodiment, lens 120 is
integrally formed with housing 110.
[32] In the embodiment shown in FIG. 2, lens 120 is made of polycarbonate
plastic, but could also be made of acrylic, glass, or any other material that
is
sufficiently durable and satisfies the requirements set forth in SAE J576
(7/91),
"Plastic Materials for Use in Optical Parts Such as Lenses and Reflectors of
Motor Vehicle Lighting Devices." Housing 110 is also made of polycarbonate
plastic in the embodiment shown in FIG. 2, but could also be made of acrylic
or
any other durable material that is compatible with the material chosen for
lens
120. The adhesive chosen to adhere lens 120 to housing 110 must be
compatible with the materials chosen for lens 120 and housing 110. For
example,
the embodiment shown in FIG. 2 uses a polycarbonate housing and a
polycarbonate lens 120.
[33] As stated supra, lens 120 is adapted to meet with housing 110, forming
cavity 99, within which the other components of vehicle mini lamp 100 are
situated. As can be seen in FIG. 2, in one embodiment, lens 120 has a
generally
arcuate top surface 123. Top surface 123 need not be arcuate, but the shape
shown in FIG. 2 aids in maintaining a low profile of vehicle mini lamp 100
when
mounted to a mounting structure (not shown). In the embodiment shown, lens
120 is further comprised of lip 122 so that when lens 120 is secured to
housing
110, lip 122 is generally flush with an attachment member (not shown, but
discussed infra) or the mounting structure. In an alternate embodiment, lens
120
does not include lip 122, but is still generally flush with the attachment
member or
surface of the mounting structure. In the embodiment in which top surface 123
of
lens 120 is not arcuate, but flat, top surface 123 of housing 120 is still
generally
flush with the attachment member.
[34] Also visible in FIG. 2 is circuit board 130, which, when the embodiment
shown of vehicle mini lamp 100 is assembled, is positioned atop ledge 115. One
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embodiment of circuit board 130 is made of an epoxy fiberglass material, with
copper clad on both top surface 132 and bottom surface 134. The copper clad is
etched away, leaving copper traces behind which act as the electrical
circuitry
between the various electrical components mounted to circuit board 130, i.e.,
LED 140, resistor 150, and cable wires 162 and 164, as well as any other
electrical components that may be added, such as circuit protection. In an
alternate embodiment, circuit board 130 is a metalcord board comprised of a
base metal layer, a dielectric layer, and a copper layer. Also visible in FIG.
2 are
a plurality of throughholes 135, which penetrate the thickness of circuit
board
130. Throughholes 135 are plated with an electrically conductive material,
allowing electrical continuity between the traces on top surface 132 and
bottom
surface 134 of circuit board 130.
[35] The electrical components mounted to circuit board 130 can be mounted
in conventional ways, known to those of ordinary skill in the art, including,
but not
limited to, soldering, clinching, or using an adhesive. In the embodiment
shown in
FIG. 2, there are three components mounted to circuit board 130: LED 140,
resistor 150, and cable wires 162, 164. LED leads 144 of LED 140 penetrate the
length of throughholes 135 and are soldered to bottom surface 134 of circuit
board 130. Similarly, cable wires 162, 164 penetrate throughholes 135 of
circuit
board 130 and are soldered to top surface 132 of circuit board 130. Also
mounted to circuit board 130 is resistor 150, which is mounted to bottom
surface
134 of circuit board 130. In the embodiment shown, resistor 150 is a surface-
mounted resistor. Cable wires 162, 164, can alternately be mounted directly
onto
bottom surface 134 of circuit board 130, LED 140 can be mounted directly onto
top surface 132 of circuit board 130, and/or resistor 150 can be mounted to
top
surface 132 of circuit board 130 and situated between LED 140 and circuit
board
130. However, throughholes 135 or another way of providing electrical
continuity
between top surface 132 and bottom surface 134 of circuit board 130 known to
those of ordinary skill in the art would still be necessary in any embodiment
in
which all of the components are not mounted to the same side of circuit board
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130. For example, in an embodiment in which LED 140 is mounted to top surface
132 of circuit board 130 and resistor 150 and cable wires 162, 164 are mounted
to bottom surface 134 of circuit board 130, throughholes 135 are plugged with
solder which still allows for electrical continuity between all of the
electrical
components. In another alternate embodiment, cable wires 162, 164 penetrate
throughholes 135 and are mounted to top surface 132 of circuit board 130, and
LED 140 and resistor 150 are also mounted to top surface 132 of circuit board
130, making electrical continuity between top and bottom surfaces 132, 134 or
circuit board 130 unnecessary.
[36] LED 140, comprised of LED leads 144 and dome 149, can also be seen in
FIG. 2. LED 140 in the embodiment shown is a "Superflux" LED, well known to
those of ordinary skill in the art, but could be another commercially
available
LED. Although not visible from this perspective, there are four (4) LED leads
144,
which, because LED 140 is generally square, provides for a stable mount. Leads
144 are soldered to circuit board 130, but could be clinched or attached using
an
adhesive. In an alternate embodiment of vehicle mini lamp 100, a surface
mounted LED is employed, which does not have the leads, but produces vehicle
mini lamp 100 with a slightly shorter profile. However, use of the Superflux
LED,
with leads 144 creates a gap between LED 140 and circuit board 130, which
helps facilitate heat dissipation and permits the potting compound (discussed
infra) to fit between LED 140 and circuit board 130 for a more secure
attachment.
[37] Also visible in the embodiment of vehicle mini lamp 100 shown in FIG. 2
is
resistor 150 to control current to LED 140 and is mounted to bottom surface
134
of circuit board 130. In operation, resistor 150 generates heat. Resistor 150
is
therefore mounted to bottom surface 134 of circuit board 130 to facilitate
heat
dissipation. However, as included supra, resistor 150 could also be mounted to
top surface 132 of circuit board 130, between circuit board 130 and LED 140.
In
the embodiment shown in FIG. 2, resistor 150 is a 0.5 Watt surface mount,
readily available. However, one of ordinary skill in the art will recognize
that other
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resistors could be used, as long as they have a similarly small profile. The
exact
resistor will depend on the power supply and the LED bin that is used.
[38] FIGS. 3A and 3B show cross-sectional, side perspective views of the
embodiment of the electrical components of vehicle mini lamp 100 as shown in
FIG. 2, in which the electrical components have been assembled. FIG. 3A is
from
one side and FIG. 3B is from a perspective in which vehicle mini lamp 100 has
been turned ninety degrees (90°) about axis A. As can be appreciated,
LED leads 144 penetrate through circuit board 130 via throughholes 135 and are
soldered to bottom surface 134 of circuit board 130, and resistor 150 is
mounted
to bottom surface 134 of circuit board 130.
[39] Referring again to FIG. 2, cable 160, cable wires 162, 164, and cable
seal
170 can all be appreciated. In the embodiment shown, cable 160 is a two-
conductor cable, comprised of cable wires 162, 164, which is inserted through
lower end 112 of housing 110 and cable seal 170. Cable wires 162, 164 are then
electrically connected to circuit board 130, as discussed supra. When
assembled, cable seal 170 is situated within the narrow portion of the bore
within
housing 110. The embodiment of cable seal 170 shown In FIG. 2 is comprised of
three (3) flanges 173, which aid in creating an air and water-tight seal with
housing 110, and define the bottom surface of cavity 99 within housing 110. In
the embodiment shown, cable seal 170 is made of silicone, but can alternately
be
made of PVC, Teflon, or any comparable material. End portion 119 of housing
110, in the embodiment shown in FIG. 2, is thicker than the remainder of
housing, making lower end 112 of housing 110 of a lesser diameter than the
rest
of the housing bore to prevent cable seal 170 from disengaging housing 110.
[40] FIG. 4 shows a top perspective view of one embodiment of an attachment
member 180 of vehicle mini lamp 100. As used herein, the term "attachment
member" refers to any element used to secure, permanently or non-permanently,
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vehicle mini lamp 100 to mounting structure 190, including but not limited to
a
flange, a grommet, or any other rigid or flexible material.
[41] As can be seen, in the embodiment shown attachment member 180 may
be, but is not limited to, a flange. Attachment member 180 has three legs 181,
182, and 183, and is flush with and fixedly secures the vehicle mini lamp 100
(not
shown) within the mounting structure 190 (not shown). The use of three legs
181,
182, and 183 is exemplary only and not intended to be limiting. This implies
that,
any number of legs can be used that secure attachment member 180 and the
vehicle mini lamp to mounting structure 190. In the embodiment shown,
attachment member 180 has a sleeve portion 185 with an open top end. Sleeve
portion 185 is further comprised of a catch member 187 adapted to receive, in
part, the lens (not shown) and sleeve portion 185 is generally arcuate as will
be
discussed infra. Attachment member 180 is made of nylon or another material
with similar flexibility. Attachment member 180 secures vehicle mini lamp 100
to
mounting structure 190 to prevent vehicle mini lamp 100 from being removed
once installed, i.e., theft-resistant. Attachment member 180, in the
embodiment
shown, is made of nylon, but could also be made of polycarbonate, another
thermoplastic, or another material of similar properties and characteristics.
Although not depicted in FIG. 4, vehicle mini lamp could further include a
gasket
between attachment member 180 and mounting structure 190 to provide a water-
tight seal.
[42] In alternate embodiments of vehicle mini lamp 100, vehicle mini lamp 100
is secured to mounting structure 190 by glue, a fastener, or a snap. In an
embodiment in which attachment member 180 is a grommet, the grommet
functions the same as attachment member 180 in that it provides a structure
for
mounting vehicle mini lamp 100 to mounting structure 190, but does so in a
more
temporary way so that vehicle mini lamp 100 can be easily removed and
replaced. The grommet is typically made of PVC plastic, but can alternately be
made of any material with comparable properties.
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[43] FIG. 5 shows a top perspective view of vehicle mini lamp 100, in which
the
electrical components are assembled within housing 110 and further including
attachment member 180. As can be appreciated, catch member 187 in sleeve
portion 185 of attachment member 180 allows lens 120 to be flush with
attachment member 180 when vehicle mini lamp 100 is set within aperture 196 of
mounting structure 190. FIG. 5 also shows housing 110, lens 120, circuit board
130, LED 140, resistor 150, cable seal 170, and attachment member 180.
Furthermore, in the embodiment shown in FIG. 5, sleeve portion 185 of
attachment member 180 is wider than aperture 196 of mounting structure 190
and slightly arcuate so that vehicle mini lamp 100 is generally flush with
surface
192 of mounting structure 190 (discussed in greater detail infra) into which
it is
set, creating a low profile. Also visible in the embodiment of attachment
member
180 shown in FIG. 5 is side recess 186. Side recess 186 is of a length that is
the
same as mounting structure 190 is thick. Also visible is an open bottom end
188.
Open bottom end 188 is of a thickness that is slightly wider than aperture 196
of
mounting structure 190, so that when vehicle mini lamp 100 is positioned
within
aperture 196 of mounting structure 190õ the combination of side recess 186,
open bottom end 188, and open top end 185 secures vehicle mini lamp 100
within aperture 196 of mounting structure 190.
[44] FIG. 6 shows a top perspective view of an alternate embodiment of
vehicle mini lamp 100 in which, like FIG. 5, housing 110, lens 120, circuit
board
130, LED 140, resistor 150, cable seal 170, and rail can all be seen. However,
FIG. 6 shows an alternate embodiment of vehicle mini lamp 100 in which flange
is grommet 184. Grommet 184 also uses recess 186' to secure vehicle mini lamp
100 within aperture 196 of mounting structure 190, and grommet base 188' is
shaped differently from that of open bottom end 188 as shown in FIG. 5, but
still
prevents moisture from entering vehicle mini lamp 100.
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[45] Also shown in FIG. 6 is the volume in which potting compound 230 is
disposed within cavity 99 of housing 110. In one embodiment, potting compound
230 completely encases resistor 150, circuit board 130, that part of the cable
wires (not shown), that are within cavity 99 and part of LED 140, fully
encapsulating all of the electrical components (except part of LED 140) and
all of
the electrically active areas. Potting compound 230 is also in the area
between
circuit board 130 and cable seal 170. However, potting compound 230 only
partially encapsulates LED 140, such that LED leads 144 are encapsulated, but
dome 149 is not covered by potting compound 230 as this could affect the
amount of light emitted from vehicle mini lamp 100. In an alternate
embodiment,
potting compound 230 does not encase the electrical components, but only the
electrical connections between the electrical components. Two examples of
potting compound 230 are Resin ER 1005 LV, manufactured by Star Technology,
Inc. .TM. and a two-part potting compound which combines Resin E-285-1A with
Hardener E-285-1B, which cures when exposed to UV light, also manufactured
by Star Technology, Inc. .TM..
[46] Potting compound 230 provides a heat sink to vehicle mini lamp 100 and
withdraws thermal energy directly away from LED 140. Potting compound 230
further provides protection for the electrical components, i.e., LED 140,
circuit
board 130, resistor 150, and the wires from vibration, fatigue, and moisture.
[47] For the purpose of describing the method of assembling vehicle mini lamp
100, FIG. 2 will again be referred to. One of ordinary skill in the art will
realize,
however, that unless otherwise noted, the steps need not be followed in any
specific order and that additional steps may be added. Additional steps are
possible and the steps in the formation of vehicle mini lamp 100 may be
performed in alternate orders.
[48] The first step in the formation of vehicle mini lamp 100 is to attach the
electrical components to the circuit board. Leads 144 of LED 140 are soldered
or
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otherwise electrically connected to circuit board 130, whether to top surface
132
or first passed through throughholes 135 and then soldered to bottom surface
134 of circuit board 130. Resistor 150 is also soldered to circuit board 130.
In an
embodiment in which resistor 150 is electrically connected to bottom surface
134
of circuit board 130, resistor 150 can be electrically connected to circuit
board
130 either before or after LED 140 is electrically affixed to circuit board
130.
However, in an embodiment in which resistor 150 is electrically affixed to top
surface 132 of circuit board 130, resistor 150 should be affixed before LED
140 is
affixed for ease of assembly. Cable wires 162, 164, further comprised of cable
seal 170 and cable 160 (as in the embodiment shown in FIG. 2) are also
soldered or otherwise electrically connected to circuit board 130, whether
directly
to bottom surface 134 or to top surface 132 after first passing through
throughholes 135.
[49] The electrical components, i.e. circuit board 130, LED 140, resistor 150,
and cable wires 162, 164, are then positioned within housing 110. In the
embodiment shown, circuit board 130 is positioned to rest on ledge 115 of
housing 110. In an embodiment in which housing has a tapered inner surface
113, circuit board 130 is positioned within housing 110 such that it is snugly
disposed therein. Cable seal 170 is also positioned within housing 110, but
within
a lower portion of housing 110 such that it is substantially disposed
substantially
adjacent to lower end 112 of housing. Cable seal 170, along with housing 110
form cavity 99.
[50] Potting compound 230 (not shown in FIG. 2) is then injected into cavity
99
and allowed to cure. As discussed supra, only enough potting compound 230 is
disposed within cavity 99 to encase the electrical components and form a seal
with cable seal 170, but not fully encapsulate LED 140 or the area between LED
140 and lens 120. When allowed to cure, potting compound 230 encapsulates
circuit board 130, resistor 150, that portion of cable wire 162, 164 between
cable
seal 170 and circuit board 130, all electrical connections, and part of LED
140,
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including leads 144, but not dome 149, so as not to affect the light emitted
from
LED 140.
[51] Lens 120 is affixed to housing 110 via means provided supra. In an
embodiment of vehicle mini lamp 100 in which top surface 185 of attachment
member 180 further has recess(catch member) 187 disposed thereon,
attachment member 180 is placed over and around housing 110 before affixing
lens 120 to housing 110 or to housing 110 and attachment member 180.
[52] Vehicle mini lamp 100 is intended to be used alone, in combination with
other vehicle mini lamps 100, or in combination with other lamps of other
sorts. In
addition, vehicle mini lamp 100 can emit red light, yellow-amber light, or any
other color light, depending on the position on vehicle 50. In order to
achieve a
desired color (i.e., red, yellow-amber, white, or other), lens 120 can be
colored,
LED 140 can be colored, or a combination of the two. FIG. 7 shows some of the
various possible positions on vehicle 50 where vehicle mini lamp 100 could be
positioned: as rear identification lamp 60 (as shown in FIG. 1), as rear
clearance
lamps 61, as rear side marker lamps 62, as front clearance lamps 63, as front
side marker lamps 64, and as intermediate side marker lamps 65. As is required
by the SAE standards and federal law as provided supra, identification lamps
60,
rear clearance lamps 61, and rear side marker lamps 62 must be red, and front
clearance lamps 63, front side marker lamps 64, and intermediate side marker
lamps 65 must be yellow amber.
[53] A single vehicle mini lamp 100 can be positioned at any particular
location
on vehicle 50 as shown in FIG. 7 or other locations, or a set of vehicle mini
lamps
100 can be used to satisfy the lighting requirements. For example,
identification
lamps 60 of FIG. 1 are three (3) vehicle mini lamps mounted on mounting
structure 190, equally spaced apart from one another and adapted to be affixed
to vehicle 50 at the position shown in FIGS. 1 and 7.
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17
[54] FIG. 8A shows a top perspective view of one embodiment of mounting
structure 190, on which vehicle mini lamp 100 is mounted in a vehicle mini
lamp
system. Mounting structure 190 is comprised of three (3) apertures 196, each
adapted to receive one vehicle mini lamp 100. One alternate embodiment of
mounting structure 190 has Ave (5) apertures 196 and corresponding vehicle
mini
lamps 100, equally spaced apart, as is required for identification lamp 60 in
Canada. Still another embodiment of mounting structure 190 also has five (5)
apertures 196 and corresponding vehicle mini lamps 100, but instead of having
five (5) apertures 196 and five (5) corresponding vehicle mini lamps 100
functioning as identification lamp 60, mounting structure 190 is the entire
width of
vehicle 50, with three (3) apertures 196 and corresponding vehicle mini lamps
100 functioning as identification lamp 60 and the two (2) outermost apertures
196
and corresponding vehicle mini lamps 100 functioning as rear clearance lamps
61. Mounting structure 190 can be made of any material which provides
adequate durability and corrosion-resistance and is structurally sound. For
example, mounting structure 190 can be made of metal (e.g., aluminum or A36
steel), plastic, wood, or fiberglass.
[55] FIG. 8B shows a side cross-sectional view of one embodiment of
mounting structure 190 with one (1) vehicle mini lamp 100 affixed thereto
according to one embodiment of the invention. Lens 120, attachment member
180, housing 110, cable 160, and cable wires 162, 164 of vehicle mini lamp 100
can all be appreciated, as well as aperture 196 of mounting structure 190. As
can
be seen, recess (catch member) 186 in attachment member 180 corresponds
with the thickness of mounting structure 190 so that there is a tight sealed
junction between vehicle mini lamp 100 and mounting structure 190. In another
embodiment, vehicle mini lamp 100 is secured to mounting structure 190 with a
clamp or similar securing device to prevent theft or unauthorized removal of
lamp
100.
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18
[56] FIGs. 9-12 illustrate a vehicle mini lamp assembly 200 that includes an
mounting device 205 and vehicle mini lamp 100 (figure 11). The vehicle mini
lamp assembly 200 is shown in an installed condition in figure 11. Mounting
device 205 is adapted to attach vehicle mini lamp 100 to a vehicle surface
206,
as shown in Figure 11, and allows vehicle mini lamp 100 to be positioned in an
existing vehicle opening or mounted to a vehicle surface 206 without an
opening
for various retrofit applications. Therefore, vehicle mini lamp 100 may be
retrofitted into vehicles without requiring new holes to be drilled in vehicle
surface
206. Vehicle surface 206 may be a mounting structure, a wall of a vehicle, or
other attachment surface. Lens 120 of mini lamp 100 forms a substantially
continuous curve with mounting device 205 such that mini lamp 100 is protected
from damage.
[57] In one embodiment, mounting device 205 includes first and second sides
208 and 209, a top surface 215 and a bottom side 217. Bottom side 217 of
mounting device 205 is adapted to abut a mounting structure. Mounting device
205 also includes an aperture 220 therein to receive body 113 of housing 110
such that vehicle mini lamp 100 is positioned within mounting device 205, as
shown in Figure 11. Further, mounting device 205 may include openings 230
and 231 for receiving fastening members, such as screws (not shown), to attach
assembly 200 to vehicle surface 206.
[581 When lamp 100 is positioned within aperture 220, only the lens 120 of
vehicle mini lamp 100 is exposed above top surface 215 of mounting device 205.
Further, mounting device 205 is formed with rails 240 extending perpendicular
top surface 215 at first and second sides 208 and 209. Rails 240 are adapted
to
shield lens 120 and from damage.
[59] In the embodiment shown in figures 9A-9C, mounting device 205 has a
low profile that results in the overall vehicle lamp assembly 200 having a low
profile when installed on vehicle surface 206. This arrangement protects mini
CA 02663620 2009-04-22
19
lamp 100 from damage due to vibration, impact, etc. In this embodiment, top
surface 215 is substantially planar and the depth of sides 208 and 209 is less
than the length of the body of lamp 100. Therefore, the embodiment of the
mounting device shown in figures 9A-9C may be mounted to a vehicle surface or
mounting structure having a hole drilled therein for receiving body 113 of
lamp
housing 110. Mounting device 205 may also be mounted over an existing hole in
a vehicle surface or mounting structure. Support structures 250, such as ribs,
may be molded within mounting device 205 for added support.
[60] In the embodiment shown in figures 10A-10B, mounting device 205 has a
higher profile so that vehicle lamp assembly 200 may be mounted to a vehicle
surface 206 without the need to drill a hole to accommodate the body 113 of
lamp housing 110. In this embodiment, top surface 215 is convex and the depth
of sides 208 and 209 is great enough to accommodate body 113 of lamp 100.
Therefore, the body 113 of lamp housing 110 is positioned behind front surface
215, but does not enter the vehicle surface 206. As discussed above with
reference to Figures 9A-9B, support structures 250, such as ribs, may be
molded
within mounting device 205 for added support.
[61] As shown in figures 11 and 12, top surface 215 and bottom end 217 of
mounting device 205 may also be curved such that mounting device 205 may be
mounted to a curved vehicle surface 206. In the embodiment show in figure 11,
lens 120 includes an optical feature 209 that produces a 180 light output
pattern
to meet PC (combination) photometrics. Inner portion of the optic is designed
with standard material wall thickness to "fill-in" the remainder of the 180
light
pattern spread. Optical surfaces are designed at the materials critical angle
such
that internal reflection occurs. The light is directed outward instead of
being
refracted through the optic surface.
[62] As shown in FIG. 11, an attachment member, such as a flange, a grommet,
or any other rigid or flexible fitting may be used to secure, permanently or
non-
CA 02663620 2013-12-02
permanently, vehicle mini lamp 100 to mounting device 205, including but not
limited to a flange, a grommet, or any other rigid or flexible material.
[62] Mounting device 200 may be constructed of a flexible material, rigid
material or a combination of flexible and rigid materials depending on the
specific
application. As discussed above, additional support structures 250 may be
incorporated in order to enhance the strength of the mounting device 205.
