U.S. patent application number 16/806672 was filed with the patent office on 2020-06-25 for proximity sensor switched automotive lamp.
The applicant listed for this patent is Grakon, LLC. Invention is credited to Steven P. Freeder, Paul Jensen.
Application Number | 20200200376 16/806672 |
Document ID | / |
Family ID | 67540460 |
Filed Date | 2020-06-25 |
![](/patent/app/20200200376/US20200200376A1-20200625-D00000.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00001.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00002.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00003.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00004.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00005.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00006.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00007.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00008.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00009.png)
![](/patent/app/20200200376/US20200200376A1-20200625-D00010.png)
View All Diagrams
United States Patent
Application |
20200200376 |
Kind Code |
A1 |
Jensen; Paul ; et
al. |
June 25, 2020 |
PROXIMITY SENSOR SWITCHED AUTOMOTIVE LAMP
Abstract
A lamp that includes a lens, an electrode, and a sensing circuit
connected to a light source. The lens is spaced apart from the
sensing circuit. The forward-facing surface of the lens has a
sensing location. The electrode has a first portion opposite a
second portion. The first portion is connected to the sensing
circuit. The second portion is positioned alongside a backward
facing surface of the lens. The electrode senses an electric field
through the lens at the sensing location. The sensing circuit is
configured to turn on the light source when the light source is
turned off and the electrode senses the electric field. The sensing
circuit is configured to turn off the light source when the light
source is turned on and the electrode senses the electric
field.
Inventors: |
Jensen; Paul; (Seatac,
WA) ; Freeder; Steven P.; (Renton, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Grakon, LLC |
Seattle |
WA |
US |
|
|
Family ID: |
67540460 |
Appl. No.: |
16/806672 |
Filed: |
March 2, 2020 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15894349 |
Feb 12, 2018 |
10598365 |
|
|
16806672 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21V 7/0066 20130101;
B60Q 3/82 20170201; F21V 3/00 20130101; F21V 31/005 20130101; F21Y
2115/10 20160801; F21V 23/0485 20130101; F21V 15/01 20130101 |
International
Class: |
F21V 23/04 20060101
F21V023/04; F21V 7/00 20060101 F21V007/00; F21V 15/01 20060101
F21V015/01; F21V 31/00 20060101 F21V031/00; B60Q 3/82 20060101
B60Q003/82 |
Claims
1. A method of constructing a lamp comprising: connecting an
attaching end of an electrode to a sensing circuit of a printed
circuit board; positioning a remote sensing end of the electrode
proximate to a backward facing surface of a lens near a sensing
location for sensing an electric field; placing the printed circuit
board and the electrode inside an interior of a housing; and
attaching the lens to a front opening of the housing, wherein the
sensing circuit is configured to turn on one or more light emitting
diodes when the one or more light emitting diodes are turned off
and the remote sensing end of the electrode senses the electric
field.
2. The method of claim 1, further comprising: soldering the
attaching end of the electrode to a solder pad mounted on the
printed circuit board, wherein the sensing circuit is connected to
the solder pad and the one or more light emitting diodes, and
wherein the solder pad is in electrical communication with the
sensing circuit.
3. The method of claim 2, further comprising: inserting an anchor
portion of the attaching end of the electrode into a through-hole
formed in the printed circuit board before the attaching end of the
electrode is soldered to the solder pad.
4. The method of claim 1, further comprising providing the lens,
wherein the lens includes a front facing surface including the
sensing portion.
5. The method of claim 4, wherein attaching the lens to the front
opening of the housing results in the remote sensing end of the
electrode to be aligned with the backward facing surface of the
lens and across from the sensing portion.
6. The method of claim 1, further comprising: inserting a reflector
into the front opening such that the remote sensing end of the
electrode extends through an opening in the reflector.
7. The method of claim 1, further comprising: inserting a terminal
set into plated through-holes formed in the printed circuit board,
wherein the plated through-holes are in electrical communication
with the sensing circuit, and wherein the terminal set is
configured to supply power to the sensing circuit via the plated
through-holes.
8. The method of claim 7, further comprising: inserting the
terminal set through channels formed in the housing, wherein the
channels opening up into a first connector configured to mate with
a second connector.
9. The method of claim 8, further comprising: connecting the first
connector with the second connector thereby forming an electrical
connection between the lamp and a component of a vehicle.
10. A lamp for attaching to a component of a vehicle comprising: a
lens covering a front opening of a housing, the lens having a
backward facing surface, a forward facing surface, and a sensing
location; one or more light emitting diodes electrically connected
to a sensing circuit of a printed circuit board positioned inside
the housing; and at least one electrode having an attaching end for
connecting to the sensing circuit and a remote sensing end
positioned proximate the backward facing surface for sensing an
electric field at the sensing location, wherein the sensing circuit
is configured to turn on one or more light emitting diodes when the
one or more light emitting diodes are turned off and the remote
sensing end of the electrode senses the electric field.
11. The lamp of claim 10, further comprising: a solder pad mounted
on the printed circuit board and electrically connected to the
sensing circuit for soldering the attaching end of the electrode to
the printed circuit board.
12. The lamp of claim 10, wherein the attaching end of the
electrode includes an anchor portion for inserting in a
through-hole formed in the printed circuit board.
13. The lamp of claim 10, wherein the remote sensing end of the
electrode is aligned with the backward facing surface of the lens
and across from the sensing portion.
14. The lamp of claim 10, further comprising: one or more
reflectors positioned between the one or more light emitting diodes
and the printed circuit board, wherein the one or more reflectors
includes an opening through which a portion of the electrode
between the attaching end and the remote sensing end extends.
15. The lamp of claim 10, further comprising: a terminal set into
plated through-holes formed in the printed circuit board and in
electrical communication with the sensing circuit for supplying
power to the sensing circuit.
16. The lamp of claim 10, further comprising: one or more channels
formed in the housing, wherein the channels open into a first
connector configured to mate with an electrical component of the
vehicle.
17. The lamp of claim 10, further comprising an indicia for
communicating to a user where the sensing location of the lens is
located.
18. The lamp of claim 10, wherein the electrode is configured to
transmit a signal to the sensing circuit in response to the remote
sensing end of the electrode sensing a change in capacitance due to
a presence of the electrical field associated with a user touching
the sensing location of the lens.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/894,349, entitled "Proximity Sensor
Switched Automotive Lamp Comprising an Electrode to Sense an
Electric Field Through the Sensing Location From the Facing Surface
of a Lens," filed on Feb. 12, 2018, the content of which is
incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention is directed generally toward vehicle
lighting and more particularly toward interior automotive lamps
operable by a human user (e.g., a driver, a passenger, and the
like).
Description of the Related Art
[0003] Interior automotive lamps allow an occupant of a vehicle to
see the inside of the passenger compartment when it is dark outside
the vehicle. Unfortunately, such lamps are generally operated by
mechanical switches that have many drawbacks. For example,
mechanical switches require features (e.g., buttons) configured to
be pressed or otherwise manually operated by the occupant of the
vehicle. Implementing these features often requires that one or
more openings be formed in the lamp. Unfortunately, such openings
may allow materials (e.g., liquids and/or debris) to enter the lamp
where such materials can interfere with the functioning of the
lamp. Therefore, a need exists for a lamp configured to be operated
without a mechanical switch. A lamp that does not include any
openings through which liquids and/or debris may enter the lamp is
particularly desirable. The present application provides these and
other advantages as will be apparent from the following detailed
description and accompanying figures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0004] FIG. 1 is a perspective view of a lamp (with a capacitive
proximity switch) installed in an interior space of a vehicle.
[0005] FIG. 2 is a front perspective view of the lamp of FIG.
1.
[0006] FIG. 3 is a cross-sectional view of the lamp taken through a
line 3-3 depicted in FIG. 2.
[0007] FIG. 4 is an exploded front perspective view of the lamp of
FIG. 1.
[0008] FIG. 5 is a rear perspective view of a lens of the lamp of
FIG. 1.
[0009] FIG. 6 is a front perspective view of a housing of the lamp
of FIG. 1.
[0010] FIG. 7 is a rear perspective view of the housing of FIG.
6.
[0011] FIG. 8 is a partial side perspective view of the lamp of
FIG. 1.
[0012] FIG. 9 is an exploded front perspective view of the
capacitive proximity switch of the lamp of FIG. 1.
[0013] FIG. 10 is a side perspective view of an electrode of the
lamp of FIG. 1.
[0014] FIG. 11 is a front perspective view of a support grommet of
the lamp of FIG. 1.
[0015] FIG. 12 is a rear perspective view of the support grommet of
FIG. 11.
[0016] FIG. 13 is a front perspective view of a reflector of the
lamp of FIG. 1.
[0017] FIG. 14 is a rear perspective view of the reflector of FIG.
13.
[0018] FIG. 15 is a partially exploded perspective view of a
pre-bent strip used to construct the electrode and a printed
circuit board of the lamp of FIG. 1.
[0019] FIG. 16 is a front perspective view of the printed circuit
board and the strip inserted into the housing of the lamp of FIG.
1.
[0020] FIG. 17 is a top perspective view of the reflector being
inserted into the housing of the lamp of FIG. 1.
[0021] FIG. 18 is a bottom perspective view of the strip being
inserted into the support grommet of the lamp of FIG. 1.
[0022] FIG. 19 is a bottom perspective view of the lens being
attached to the housing of the lamp of FIG. 1.
[0023] FIG. 20 is a front perspective view of the lamp of FIG. 1
omitting the lens.
[0024] FIG. 21 is a front perspective view of alternate embodiments
of the printed circuit board, the electrode, the support grommet,
and the reflector that may be used to construct the lamp of FIG.
1.
[0025] Like reference numerals have been used in the figures to
identify like components.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Capacitive proximity switches have been used for many years
to provide a control interface for lamps, elevators, smart phones,
and many other appliances. Capacitance switches offer advantages
over mechanical switches. For example, capacitance switches may be
more reliable (e.g., as measured by a number of on/off cycles until
failure), have a smaller size, and allow the sensor to be triggered
through solid membranes that are impermeable to liquids, dust, and
other physical objects.
[0027] FIG. 1 depicts a light or lamp 100 configured to be
installed in an interior space 102 (e.g., a passenger compartment,
a trunk, and the like) of a vehicle 104 (e.g., a car, a truck, and
the like). The lamp 100 includes a capacitive proximity switch 108
operable by a human user 110 (e.g., a driver, a passenger, and the
like). The capacitive proximity switch 108 is configured to sense
an electric field 112 (e.g., emitted by a finger 114 of the user
110). The capacitive proximity switch 108 operates the lamp 100
(e.g., toggles the lamp 100 on and off) when the capacitive
proximity switch 108 senses the electric field 112. In other words,
the lamp 100 is operated (turned on and off) without a mechanical
switch or direct physical contact between the user 110 and
components of a mechanical switch.
[0028] Referring to FIG. 4, the lamp 100 includes a cover or lens
120, a housing 124, a substrate or printed circuit board ("PCB")
128, one or more electrodes 132, one or more support grommets 136,
a reflector 140, a terminal set 144, and a vent patch 148. While
the lamp 100 may include more than one electrode and/or more than
one support grommet, for ease of illustration, the lamp 100 will be
described as including the single electrode 132 and the single
support grommet 136. However, through application of ordinary skill
in the art to the present teachings, embodiments may be constructed
that include two or more electrodes each like the electrode 132. In
such embodiments, a different support grommet like the support
grommet 136 may be provided for each of the electrodes.
Lens
[0029] Referring to FIGS. 2 and 3, the lens 120 is connected to the
housing 124 to form an enclosure 150. Referring to FIG. 4, the
enclosure 150 (see FIGS. 2 and 3) houses the PCB 128, the electrode
132, the support grommet 136, and the reflector 140. As will be
described below, the terminal set 144 is mounted on the PCB 128 and
extends outwardly therefrom through the housing 124.
[0030] The lens 120 is transparent and/or translucent and allows
light to shine therethrough. Referring to FIG. 3, the lens 120 may
have a generally planar front facing surface 160 opposite a back
facing surface 162. Referring to FIG. 5, a rearward extending
sidewall 166 may be formed along a periphery 168 of the back facing
surface 162. A recess 170 may be formed in the back facing surface
162. Opposite the recess 170, referring to FIG. 4, the front facing
surface 160 has a remote sensing location 172. In this context, the
term "remote" refers to the position of the remote sensing location
172 with respect to the PCB 128.
[0031] Optionally, a label (e.g., a nameplate) may be positioned at
or near the remote sensing location 172. The label (not shown) may
indicate to the user 110 (see FIG. 1) where to touch the lens 120
to toggle the lamp 100 on or off.
[0032] The lens 120 may be constructed as a single continuous piece
without any through-holes formed therein (not even at the remote
sensing location 172). Thus, the lens 120 is impermeable to
liquids, dust, and dirt. In contrast, a mechanical switch cannot
include such a continuous covering. Additionally, the lack of
through-holes in the lens 120 may provide an aesthetically pleasing
appearance when compared to lamps that include buttons or other
features of conventional mechanical switches.
Housing
[0033] Referring to FIG. 6, the housing 124 has an open front
portion 180 connected to a closed rear portion 182 by a sidewall
184. The rear portion 182 and the sidewall 184 define a hollow
interior 190 that is accessible through the open front portion 180.
Referring to FIG. 4, the interior 190 is configured to house the
PCB 128, the electrode 132, the support grommet 136, and the
reflector 140. The terminal set 144 is mounted on the PCB 128 and
extends outwardly therefrom through the rear portion 182 of the
housing 124. The vent patch 148 is mounted on the housing 124.
[0034] Referring to FIG. 6, the front portion 180 has a forwardly
extending sidewall 192 configured to be positioned inside the
rearward extending sidewall 166 (see FIG. 5) of the lens 120 (see
FIGS. 2-5 and 19). The sidewall 192 has an inwardly facing surface
193 opposite an outwardly facing surface 194. Friction between the
sidewall 166 and the outwardly facing surface 194 of the sidewall
192 may form a friction fit between the lens 120 (see FIGS. 2-5 and
19) and the housing 124. Optionally, referring to FIG. 4, an
adhesive may be used to attach the lens 120 to the housing 124. By
way of another non-limiting example, the lens 120 may be attached
to the housing 124 by sonic plastic welding or vibration welding.
As described below, the lens 120 may be attached to the housing 124
as the last step, which allows the lamp 100 to be sealed making it
watertight and/or dust-tight.
[0035] Referring to FIG. 6, inside the interior 190, the rear
portion 182 includes one or more forwardly extending mounting pegs
196A-196H. The mounting pegs 196G and 196H may extend further
forward than the mounting pegs 196A-196F. Optionally, the rear
portion 182 may include one or more spacers 198 configured to space
the PCB 128 (see FIGS. 3, 4, 9, 15, and 16) apart from an inside
surface 200 of the rear portion 182. The rear portion 182 may
include one or more vent holes 202. The vent patch 148 (see FIGS. 3
and 4) is configured to cover the vent hole(s) 202.
[0036] The rear portion 182 includes one or more through-channels
210A-210C and one or more stop walls 214A-214C. The stop wall(s)
214A-214C are aligned with the through-channel(s) 210A-210C,
respectively. In the embodiment illustrated in FIG. 8, the
through-channel(s) 210A-210C each extend through the inside surface
200 (see FIG. 6) and into a connector 212 formed in the rear
portion 182. The connector 212 has an opening 216 configured to
receive an electrical connector (not shown). Power may be supplied
to the lamp 100 by the electrical connector (not shown). The
electrical connector (not shown) may be configured to form a seal
with the connector 212 that prevents materials (e.g., liquids
and/or debris) from entering the interior 190 (see FIGS. 3, 4, 6,
16, and 17) through the through-channel(s) 210A-210C. The
electrical connector (not shown) may be connected to cable (not
shown) that is connected to a system (not shown) within the vehicle
104 (see FIG. 1).
[0037] Referring to FIG. 6, reflector mounting tabs 220A and 220B
extend inwardly from the sidewall 184. The reflector mounting tabs
220A and 220B are opposite one another across the interior 190.
Optionally, the sidewall 184 may include a channel 222 that extends
along the interior 190 from the rear portion 182 to the front
portion 180.
PCB
[0038] Referring to FIG. 9, the PCB 128 has a forward-facing side
230 opposite a rear facing side 232. The PCB 128 includes one or
more mounting through-holes 236A-236H. The mounting through-hole(s)
236A-236H are configured to receive the forwardly extending
mounting peg(s) 196A-196H (see FIGS. 6 and 16), respectively, of
the housing 124 (see FIGS. 2-4, 6-8, and 16-20). The mounting
peg(s) 196A-196FI (see FIGS. 6 and 16) are configured to extend
from the rear facing side 232 through the mounting through-holes
236A-236H, respectively. The mounting peg(s) 196A-196F (see FIGS. 6
and 16) may be heat-staked to the PCB 128. Thus, the PCB 128 may be
non-removably attached to the housing 124 (see FIGS. 2-4, 6-8, and
16-20). The mounting peg(s) 196G and 196H (see FIGS. 6 and 16) may
be longer than the mounting peg(s) 196A-196F (see FIGS. 6 and 16)
and may extend forwardly beyond the forward-facing side 230 of the
PCB 128.
[0039] The PCB 128 includes plated through-holes 244A-244C
configured to receive the terminal set 144 and form an electrical
connection with the terminal set 144. One or more electrical
circuits 250 are mounted on the PCB 128 and connected to the plated
through-holes 244A-244C. The terminal set 144 provides power to the
circuit(s) 250 via the plated through-holes 244A-244C.
[0040] The PCB 128 includes a through-hole or slot 246 configured
to receive the electrode 132. Thus, the electrode 132 is configured
to be physically inserted into the through-slot 246. Optionally,
the through-slot 246 may be plated. In such embodiments, the plated
through-slot 246 may be connected to the circuit(s) 250 and forms
an electrical connection between the electrode 132 and the
circuit(s) 250. Alternatively, the PCB 128 may include an
electrically conductive contact or solder pad 256 configured to be
soldered to the electrode 132. In such embodiments, the solder pad
256 is connected to the circuit(s) 250 and forms an electrical
connection between the electrode 132 and the circuit(s) 250.
[0041] The circuit(s) 250 include(s) or is/are connected to one or
more light sources 252. In the embodiment illustrated, the light
source(s) 252 has/have been implemented as six separate light
emitting diodes ("LEDs") 252A-252F mounted on the forward-facing
side 230 of the PCB 128. The light source(s) 252 is/are positioned
to face forwardly so that the light generated by the light
source(s) 252 shines forwardly through the lens 120 (see FIGS. 2-5
and 19).
[0042] The circuit(s) 250 include(s) a microprocessor 254 connected
to the light source(s) 252 by conductors (not shown). By way of a
non-limiting example, the conductors (not shown) may be implemented
as conventional surface mounted traces. The microprocessor 254 may
be implemented as control chip. The electrode 132 is configured to
conduct a conductive signal to the circuit(s) 250 when the electric
field 112 (see FIGS. 1 and 3) is at or near the remote sensing
location 172 (see FIGS. 1-4 and 19). The circuit(s) 250 is/are
configured to conduct the capacitive signal between the electrode
132 and the microprocessor 254. The microprocessor 254 is
configured to detect when the capacitive signal indicates the user
110 (see FIG. 1) is touching the remote sensing location 172 (see
FIGS. 1-4 and 19). The microprocessor 254 is configured to turn on
the light source(s) 252 when the light source(s) 252 are off and
the microprocessor 254 determines the user 110 (see FIG. 1) is
touching the remote sensing location 172 (see FIGS. 1-4 and 19).
The microprocessor 254 is configured to turn off the light
source(s) 252 when the light source(s) 252 are on and the
microprocessor 254 determines the user 110 (see FIG. 1) is touching
the remote sensing location 172 (see FIGS. 1-4 and 19). In other
words, the microprocessor 254 is configured to toggle the light
source(s) 252 on and off.
[0043] Referring to FIG. 3, the electrode 132 transmits the
capacitive signal sensed by its sensing portion 280 at the remote
sensing location 172 to the microprocessor 254 inside the lamp 100.
Thus, referring to FIG. 9, the capacitive proximity switch 108
includes the electrode 132, the circuit(s) 250, and the terminal
set 144.
[0044] Optionally, the PCB 128 may include one or more reflector
mounting through-holes 260.
Electrode
[0045] The electrode 132 provides a conductive pathway between the
remote sensing location 172 (see FIGS. 1-4 and 19) and the
circuit(s) 250. Referring to FIG. 10, the electrode 132 includes a
first end 270 opposite a second end 272. In the embodiment
illustrated, the electrode 132 includes first and second bends 274
and 276. The first bend 274 defines a sensing portion 280 that
extends from the first end 270 to the first bend 274. The second
bend 276 defines an anchor portion 282 that extends from the second
end 272 to the second bend 276. An intermediate portion 284 extends
between the first and second bends 274 and 276.
[0046] Referring to FIG. 3, the intermediate portion 284 is
configured to pass through the support grommet 136 and position the
sensing portion 280 inside the recess 170 formed in the back facing
surface 162 of the lens 120. The lens 120 protects the sensing
portion 280, which is sensitive to the electric field 112 (e.g.,
generated by the finger 114) in its vicinity. Because the sensing
portion 280 is positioned behind the lens 120, the lamp 100 may be
sealed and may not contain through-holes through which materials
(e.g., liquids and/or debris) may enter the interior 190 of the
housing 124 and potentially damage internal components of the lamp
100.
[0047] Referring to FIG. 10, the sensing portion 280 has a front
facing surface 285 with a surface area configured such that the
electric field 112 (see FIGS. 1 and 3) of the finger 114 (see FIGS.
1 and 3) may induce the capacitive signal in the electrode 132. The
electrode 132 conducts the capacitive signal to the circuit(s) 250
(see FIGS. 9 and 15). By way of a non-limiting example, the surface
area of the sensing portion 280 may be 15 mm.sup.2 to 50 mm.sup.2.
Referring to FIG. 3, the thickness of the lens 120 at the recess
170 (which is opposite the remote sensing location 172) is
configured to allow the electric field 112 (e.g., emitted by the
finger 114) to adequately and consistently induce the capacitive
signal in the electrode 132.
[0048] Referring to FIG. 9, the anchor portion 282 of the electrode
132 is configured to be inserted inside the through-slot 246 of the
PCB 128. Referring to FIG. 3, the intermediate portion 284 is
configured to extend away from the forward-facing side 230 of the
PCB 128 toward the remote sensing location 172. The intermediate
portion 284 may extend through the channel 222 (see FIGS. 6 and 16)
formed in the housing 124. Optionally, referring to FIG. 9, a
contact portion 286 of the intermediate portion 284 adjacent the
anchor portion 282 may extend along the PCB 128 and be attached
(e.g., soldered) thereto. For example, the contact portion 286 may
be soldered to the solder pad 256 and form an electrical connection
therewith. In the embodiment illustrated, the intermediate portion
284 includes a curved portion 288 that extends from the contact
portion 286 to the first bend 274.
[0049] The electrode 132 may be constructed from metal that is easy
to solder to the solder pad 256. For example, the electrode 132 may
be constructed from thin (e.g., less than 0.15 mm) and flexible
metal (e.g., brass, bronze, and the like). Referring to FIG. 3, the
electrode 132 may be plated with a material (e.g., tin) that
facilitates soldering.
Support Grommet
[0050] Referring to FIG. 3, the support grommet 136 guides and
holds the electrode 132 as the electrode 132 passes through the
reflector 140. The support grommet 136 may be constructed from an
electrically non-conductive material (e.g., silicon rubber) and the
reflector 140 may be constructed from an electrically conductive
material (e.g., metal). Thus, the support grommet 136 may insulate
the electrode 132 from the reflector 140.
[0051] The sensing portion 280 of the electrode 132 is sandwiched
between the support grommet 136 and the lens 120. Elastic pressure
provided by the support grommet 136, biases the sensing portion 280
of the electrode 132 against the lens 120. In other words, the
support grommet 136 presses the electrode 132 against the lens 120
and provides secure positioning of the electrode 132 with respect
to the lens 120.
[0052] Referring to FIGS. 11 and 12, the support grommet 136 has a
channel portion 300 connected to a spacer portion 302. The channel
portion 300 has a front portion 304 opposite a rear portion 306.
The front portion 304 may be offset rearwardly with respect to the
spacer portion 302. The rear portion 306 includes first and second
outwardly extending stop walls 310A and 310B configured to help
prevent the channel portion 300 from moving forwardly with respect
to the reflector 140 (see FIGS. 3, 4, 13, 14, and 17-20).
[0053] The channel portion 300 has a through-channel 312 configured
to allow the intermediate portion 284 (see FIGS. 3, 9, and 10) of
the electrode 132 (see FIGS. 3, 4, 9, 10, and 20) to pass
therethrough. The channel portion 300 extends from a front opening
314 (see FIG. 11) formed in the front portion 304 to a rear opening
316 (see FIG. 12) formed in the rear portion 306. The front opening
314 (see FIG. 11) may be larger than the rear opening 316 (see FIG.
12). Thus, the through-channel 312 may be tapered. Referring to
FIG. 11, a curved edge portion 318 may be formed at an intersection
of a lower portion of the front opening 314 and the front portion
304.
[0054] Referring to FIGS. 11 and 12, the spacer portion 302 has a
front facing surface 320 opposite a rear facing surface 322.
Referring to FIG. 3, the sensing portion 280 of the electrode 132
is positioned against the front facing surface 320 (see FIGS. 11
and 12). The spacer portion 302 is compressible between the sensing
portion 280 and the reflector 140. The spacer portion 302 biases
the sensing portion 280 against the lens 120. In the embodiment
illustrated, the first bend 274 may be substantially 90 degrees.
Thus, referring to FIG. 11, the through-channel 312 may extend at
approximately 90 degrees with respect to the front facing surface
320.
[0055] Optionally, referring to FIG. 12, the rear facing surface
322 of the spacer portion 302 may include a recess 324 positioned
adjacent the channel portion 300. However, this is not a
requirement.
Reflector
[0056] Referring to FIG. 3, the reflector 140 is mounted inside the
interior 190 between the lens 120 and the PCB 128. Referring to
FIG. 13, in the embodiment illustrated, the reflector 140 has a
peripheral portion 330 framing a recessed portion 332. Referring to
FIG. 17, the peripheral portion 330 is configured to be positioned
adjacent the inwardly facing surface 193 of the sidewall 192 of the
housing 124.
[0057] Referring to FIG. 14, in the embodiment illustrated, the
reflector 140 has rearwardly extending first and second arms 336A
and 336B. The first arm 336A has a first recess or through-hole
340A configured to receive the first tab 220A (see FIGS. 6 and 16)
and the second arm 336B has a second recess or through-hole 340B
configured to receive the second tab 220B (see FIGS. 6, 16, and
17). Referring to FIG. 17, when the tabs 220A (see FIGS. 6 and 16)
and 220B are received inside the through-holes 340A and 340B,
respectively, the reflector 140 may be characterized as being
snapped into the housing 124.
[0058] Referring to FIG. 4, the reflector 140 has one or more
rearwardly extending mounting projections 350 each configured to be
received inside the one of the reflector mounting through-hole(s)
260 (see FIGS. 4 and 9) of the PCB 128. The reflector 140 has
rearwardly opening apertures 352G and 352F (see FIG. 14) configured
to receive the mounting pegs 196G and 196H (see FIGS. 6 and 16),
respectively, of the housing 124 after the mounting pegs 196G and
196H have passed through the mounting through-holes 236G and 236F
(see FIG. 9), respectively, of the PCB 128.
[0059] Referring to FIG. 13, the reflector 140 has one or more
light reflecting portions 360A-360D each having a reflective
sidewall 362 that extends between front and a rear-openings 364 and
366. The front opening(s) 364 are positioned within the recessed
portion 332. Each of the light reflecting portion(s) 360A-360D is
positioned such that at least one of the light source(s) 252 (see
FIGS. 9 and 15) shines light through the rear opening 366 and onto
the reflective sidewall 362. In the embodiment illustrated, the LED
252A (see FIG. 9) shines light into the rear opening 366 of the
light reflecting portion 360A, the LEDs 252B and 252C (see FIG. 9)
shine light into the rear opening 366 of the light reflecting
portion 360B, the LEDs 252D and 252E (see FIG. 9) shine light into
the rear opening 366 of the light reflecting portion 360C, and the
LED 252F (see FIG. 9) shines light into the rear opening 366 of the
light reflecting portion 360D. The reflective sidewalls 362 of the
light reflecting portions 360A-360D reflect the light forwardly and
out through the lens 120 (see FIGS. 2-5 and 19). The reflective
sidewalls 362 of the light reflecting portions 360A-360D may
collimate or otherwise direct the light generated by the light
source(s) 252 (see FIGS. 9 and 15) in a desired direction. In the
embodiment illustrated, in each of the light reflecting portions
360A-360D, a reflective wall 368 extends from the reflective
sidewall 362 and into the path of the light generated by one or
more of the light source(s) 252 (see FIGS. 9 and 15). The
reflective wall 368 is configured to help direct the light in the
desired direction.
[0060] Referring to FIG. 18, the peripheral portion 330 of the
reflector 140 includes a notch or opening 370 in which the channel
portion 300 of the support grommet 136 may be mounted. Referring to
FIG. 14, one or more sidewalls 372 may extend rearwardly alongside
the opening 370. In the embodiment illustrated, the sidewall(s) 372
include first and second sidewall portions 374A and 374B that
extend along opposite sides of the opening 370. The first and
second sidewall portions 374A and 374B may help maintain the
support grommet 136 (see FIGS. 3, 4, 11, 12, and 18-20) inside the
opening 370. Referring to FIG. 12, the first and second stop walls
310A and 310B of the channel portion 300 of the support grommet 136
are configured to abut the first and second sidewall portions 374A
and 374B (see FIG. 14), respectively, and help prevent the channel
portion 300 from moving forwardly with respect to the reflector 140
(see FIGS. 3, 4, 13, 14, and 17-20).
Terminal Set
[0061] Referring to FIG. 9, the terminal set 144 includes two or
more pins or contacts 380A-380C. In the embodiment illustrated, the
terminal set 144 includes the three substantially identical
contacts 380A-380C. One of the contacts 380A-380C may be configured
to deliver power to the circuit(s) 250, another of the contacts
380A-380C may be a ground, and the last of the contacts 380A-380C
may provide output information to the vehicle 104 (see FIG. 1). For
example, the last contact may indicate whether the lamp 100 is on
or off. The microprocessor 254 may provide the output information
to the last contact.
[0062] In the embodiment illustrated, each of the contacts
380A-380C is generally L-shaped. Thus, the contacts 380A-380C each
have first and second legs 382 and 384 connected together by a bent
portion 386. Opposite the bent portion 386, the first leg 382 has a
first free end 390. Opposite the bent portion 386, the second leg
384 has a second free end 392.
[0063] The first legs 382 of the contacts 380A-380C are configured
to extend forwardly toward the PCB 128 along the stop walls
214A-214C (see FIG. 6), respectively. The first free ends 390 of
the contacts 380A-380C are configured to be received inside the
plated through-holes 244A-244C, respectively, and to form an
electrical connection therewith. Referring to FIG. 8, the first
legs 382 of the contacts 380A-380C are configured to extend through
the through-channels 210A-210C, respectively, to position the
second legs 384 inside the connector 212. Thus, the second free
ends 392 of the contacts 380A-380C are positioned with the
connector 212. The connector 212 is configured receive the
electrical connector (e.g., a plug), which receives the second free
ends 392 of the contacts 380A-380C and forms an electrical
connection therewith. The electrical connector (not shown) may be
configured to form a seal with the connector 212 that prevents
materials (e.g., liquids and/or debris) from entering the interior
190 (see FIGS. 3, 4, 6, 16, and 17) through the through-channel(s)
210A-210C. As mentioned above, the electrical connector (not shown)
may be connected (e.g., via a wire) to a circuit (not shown) inside
the vehicle 104 (see FIG. 1). The circuit (not shown) in the
vehicle 104 (see FIG. 1) may include a processor (not shown)
configured to receive the indication from the last contact.
Vent Patch
[0064] Referring to FIG. 4, as mentioned above, the vent patch 148
is configured to cover the vent hole(s) 202 (see FIGS. 3, 6, and 7)
formed in the rear portion 182 of the housing 124. In the
embodiment illustrated, the vent patch 148 is generally disk
shaped. However, this is not a requirement. The vent patch 148 may
be attached to the rear portion 182 by an adhesive. The vent patch
148 may be constructed from polytetrafluoroethylene ("PTFE") or
polyolefin.
Method
[0065] FIGS. 15-19 illustrate a method of constructing the lamp
100. Referring to FIG. 15, the electrode 132 (see FIGS. 3, 4, 9,
10, and 20) may be constructed from a strip 400 (e.g., of metal).
The strip 400 may be at least somewhat malleable so that when the
strip 400 is deformed past its elastic deformation limit, the strip
400 remains bent. The strip 400 may have a simple shape (e.g.,
flat, straight, and rectangular) which enables easy, low cost
manufacture compared to other more complex shapes and/or materials
(e.g., a flex circuit).
[0066] Before assembly begins, first and second bends 402 and 404
may be formed in the strip 400. Thus, the strip 400 may be
characterized as being pre-bent, which allows the bends 402 and 404
to be formed more accurately and faster (e.g., using hand operated
jigs or automated machinery) than they could be formed during
assembly. As shown in FIG. 15, the first bend 402 may have a
smaller outside angle (e.g., at least 30 degrees with respect to
flat) than the first bend 274 (see FIGS. 3, 9, 10, and 20) of the
electrode 132 (see FIGS. 3, 4, 9, 10, and 20). By way of
non-limiting examples, the first bend 274 (see FIGS. 3, 9, 10, and
20) may have an outside angle of approximately 90 degrees with
respect to flat and the inside angle of the first bend 402 may be
at least 30 degrees with respect to flat. Thus, the first bend 402
of the strip 400 may be bent into the first bend 274 during the
assembly process. The second bend 404 may have an outside angle of
approximately 90 degrees with respect to flat. The second bend 404
is identical to the second bend 276 (see FIG. 10) of the electrode
132 (see FIGS. 3, 4, 9, 10, and 20).
[0067] The strip 400 has a first end 410 connected to a second end
412 by an intermediate portion 414. After the first and second
bends 402 and 404 are formed, the first end 410 is inserted into
the through-slot 246 of the PCB 128. The second bend 404 prevents
the intermediate portion 414 from slipping into or through the
through-slot 246. The second bend 404 positions the intermediate
portion 414 against the PCB 128 and into contact with the solder
pad 256 to form an electrical connection therewith. Next, the
intermediate portion 414 may be soldered to the solder pad 256. The
intermediate portion 414 may be soldered directly to the solder pad
256 without requiring a special connector of the type required to
form a connection with a flex circuit. Thus, the electrode 132 (see
FIGS. 3, 4, 9, 10, and 20) may be less expensive to implement and
easier to connect to the PCB 128 than a flex circuit. The contacts
380A-380C of the terminal set 144 may be inserted into the plated
through-holes 244A-244C, respectively, before or after the first
end 410 is inserted into the through-slot 246 of the PCB 128.
Optionally, the contacts 380A-380C of the terminal set 144 may be
soldered within the plated through-holes 244A-244C,
respectively.
[0068] Referring to FIG. 16, the PCB 128, with the strip 400
attached thereto, is inserted into the interior 190 of the housing
124. The mounting pegs 196A-196F are positioned within the mounting
through-holes 236A-236F (see FIG. 9), respectively. Optionally, the
mounting pegs 196A-196F may be heat-staked to the PCB 128. The
strip 400 is positioned to extend frontwardly from the PCB 128
through the channel 222 of the housing 124. Thus, as shown in FIG.
16, the strip 400 may be curved or flexed. The second legs 384 (see
FIGS. 8 and 9) of the contacts 380A-380C are positioned within the
through-channels 210A-210C (see FIGS. 6 and 8), respectively.
[0069] Referring to FIG. 17, the reflector 140 is positioned inside
the interior 190 of the housing 124. The mounting pegs 196G and
196H (see FIGS. 6 and 16) are positioned within the apertures 352G
and 352F (see FIG. 14), respectively, of the reflector 140. Each of
the mounting projection(s) 350 of the reflector 140 is positioned
inside a different one of the reflector mounting through-holes 260
(see FIGS. 4 and 9) of the PCB 128. The strip 400 is positioned
within the opening 370 formed in the peripheral portion 330 of the
reflector 140. The reflector 140 is snapped into the housing 12 by
inserting the tabs 220A and 220B (see FIGS. 6 and 16) inside the
through-holes 340A and 340B, respectively. As mentioned above, the
peripheral portion 330 is positioned adjacent the inwardly facing
surface 193 of the sidewall 192 of the housing 124.
[0070] Referring to FIG. 18, next, the first end 410 of the strip
400 is fed into the through-channel 312 of the support grommet 136.
The first bend 402, which has not yet been bent to form the first
bend 274 (see FIGS. 3, 9, 10, and 20), allows more effective
installation and positioning of the support grommet 136. The
channel portion 300 of the support grommet 136 is positioned in the
opening 370 formed in the peripheral portion 330 of the reflector
140. The rear portion 306 of the support grommet 136 is pushed into
the opening 370 far enough to position the stop walls 310A (see
FIGS. 11 and 12) and 310B against the sidewall portions 374A and
374B (see FIG. 14), respectively. The spacer portion 302 of the
support grommet 136 is positioned against the reflector 140.
[0071] Referring to FIG. 19, finally, the lens 120 is attached to
the housing 124, which bends the strip 400 toward the spacer
portion 302 of the support grommet 136 along the first bend 402.
Referring to FIG. 20, this finishes forming the first bend 274 and
completes the construction of the electrode 132.
[0072] The lens 120 also compresses the support grommet 136 against
the reflector 140. Referring to FIG. 3, the sensing portion 280 is
positioned inside the recess 170 formed in the back facing surface
162 of the lens 120. Thus, the sensing portion 280 faces forwardly
and is positioned on the opposite side of the lens 120 from the
remote sensing portion 172. As mentioned above, the lens 120 may be
sonic plastic welded or vibration welded to the housing 124. The
vent patch 148 may be attached to the housing 124 to cover the vent
hole(s) 202 at any point during the assembly process.
[0073] At this point, assembly of the lamp 100 is complete. The
flexibility of the electrode 132 allows the lamp 100 to be
assembled even when there is variation in a distance between the
PCB 128 (see FIGS. 3, 4, 9, 15, and 16) and the lens 120. In
contrast, a rigid electrode may be too short or too long and could
interfere with assembly of the lens 120.
Alternate Embodiment
[0074] FIG. 21 illustrates an alternate embodiment of a PCB 128',
an electrode 132', a support grommet 136', and a reflector 140'
that may be used with the lens 120 (see FIGS. 2-5 and 19), the
housing 124 (see FIGS. 2-4, 6-8, and 16-20), the terminal set 144,
and the vent patch 148 (see FIGS. 3 and 4) to construct the lamp
100.
[0075] The PCB 128' is substantially similar to the PCB 128 (see
FIGS. 3, 4, 9, 15, and 16). Therefore, only differences between the
PCB 128' and the PCB 128 (see FIGS. 3, 4, 9, 15, and 16) will be
described in detail. As shown in FIG. 21, the PCB 128' differs from
the PCB 128 only with respect to the location and orientation of
the solder pad 256.
[0076] The electrode 132' is substantially similar to the electrode
132 (see FIGS. 3, 4, 9, 10, and 20). Therefore, only differences
between the electrode 132' and the electrode 132 (see FIGS. 3, 4,
9, 10, and 20) will be described in detail. As shown in FIG. 21,
the electrode 132' extends from the PCB 128' and through the
reflector 140' along a substantially horizontal (front to back)
travel path. In contrast, referring to FIG. 3, the electrode 132
extends from the PCB 128 and through the reflector 140 along both a
vertical and horizontal travel path.
[0077] Referring to FIG. 21, the support grommet 136' is
substantially similar to the support grommet 136 (see FIGS. 3, 4,
11, 12, and 18-20). Therefore, only differences between the support
grommet 136' and the support grommet 136 (see FIGS. 3, 4, 11, 12,
and 18-20) will be described in detail. The support grommet 136'
may be implemented as a block of compressible material against with
the sensing portion 280' of the electrode 132' rests. Thus, the
support grommet 136' may omit the channel portion 300 (see FIGS.
11, 12, and 18).
[0078] The reflector 140' is substantially similar to the reflector
140 (see FIGS. 3, 4, 13, 14, and 17-20). Therefore, only
differences between the reflector 140' and the reflector 140 (see
FIGS. 3, 4, 13, 14, and 17-20) will be described in detail. In the
reflector 140', an opening 370' is formed in a recessed portion
332' of the reflector 140' instead of in a peripheral portion 330'
of the reflector 140'. Like in the reflector 140 (see FIGS. 3, 4,
13, 14, and 17-20), the peripheral portion 330' frames the recessed
portion 332'.
[0079] The foregoing described embodiments depict different
components contained within, or connected with, different other
components. It is to be understood that such depicted architectures
are merely exemplary, and that in fact many other architectures can
be implemented which achieve the same functionality. In a
conceptual sense, any arrangement of components to achieve the same
functionality is effectively "associated" such that the desired
functionality is achieved. Hence, any two components herein
combined to achieve a particular functionality can be seen as
"associated with" each other such that the desired functionality is
achieved, irrespective of architectures or intermedial components.
Likewise, any two components so associated can also be viewed as
being "operably connected," or "operably coupled," to each other to
achieve the desired functionality.
[0080] While particular embodiments of the present invention have
been shown and described, it will be obvious to those skilled in
the art that, based upon the teachings herein, changes and
modifications may be made without departing from this invention and
its broader aspects and, therefore, the appended claims are to
encompass within their scope all such changes and modifications as
are within the true spirit and scope of this invention.
Furthermore, it is to be understood that the invention is solely
defined by the appended claims. It will be understood by those
within the art that, in general, terms used herein, and especially
in the appended claims (e.g., bodies of the appended claims) are
generally intended as "open" terms (e.g., the term "including"
should be interpreted as "including but not limited to," the term
"having" should be interpreted as "having at least," the term
"includes" should be interpreted as "includes but is not limited
to," etc.). It will be further understood by those within the art
that if a specific number of an introduced claim recitation is
intended, such an intent will be explicitly recited in the claim,
and in the absence of such recitation no such intent is present.
For example, as an aid to understanding, the following appended
claims may contain usage of the introductory phrases "at least one"
and "one or more" to introduce claim recitations. However, the use
of such phrases should not be construed to imply that the
introduction of a claim recitation by the indefinite articles "a"
or "an" limits any particular claim containing such introduced
claim recitation to inventions containing only one such recitation,
even when the same claim includes the introductory phrases "one or
more" or "at least one" and indefinite articles such as "a" or "an"
(e.g., "a" and/or "an" should typically be interpreted to mean "at
least one" or "one or more"); the same holds true for the use of
definite articles used to introduce claim recitations. In addition,
even if a specific number of an introduced claim recitation is
explicitly recited, those skilled in the art will recognize that
such recitation should typically be interpreted to mean at least
the recited number (e.g., the bare recitation of "two recitations,"
without other modifiers, typically means at least two recitations,
or two or more recitations).
[0081] Accordingly, the invention is not limited except as by the
appended claims.
* * * * *