Abstract: The present disclosure relates to terminals that are utilized in bulb sockets for automotive lamp assemblies. The embodiments of the bulb sockets disclosed provide for superior alignment, electrical connection, and stabilization of the bulb in the bulb socket. Exemplary embodiments of the terminals contain a cover plate that can be sized to substantially cover a receiver slot and can be positioned in the bulb socket in order to prevent sealing material from entering the bulb accepting portion of the bulb socket.

Abstract: The subject invention relates to automotive lighting assemblies. Specifically, the subject invention relates to a device and method for retaining wires, which provide power to the light source, in the proper orientation. In an exemplary embodiment, a wire retaining cavity is formed by a molded rib on a cover and a molded retention feature with a hook portion on a light source retaining compartment. In this exemplary embodiment, the cover and retaining compartment are integrally connected to one another by a living hinge. The wire retaining cavity is formed once the cover is folded over the retaining cavity bringing the rib into close proximity of the wire retention feature and adjacent to the hook portion of the feature.

Abstract: An automobile lamp assembly including a movable glare shield which is moved into the portion of the beam of light produced by a lamp assembly that is associated with the foreground area, thereby reducing the illumination level in the foreground area. The shield may be rotatably moved out of the blocking position to allow for a full illumination pattern when glare is not present.

Abstract: The subject invention relates to a method of molding an automotive front lamp assembly that prevents the formation of a sink on the reflector by cutting an area into an injection molding tool so that when the reflector is molded, a glare prevention feature is formed in approximately the same location as the sink would have been formed.

Abstract: The subject invention relates to terminals that are utilized in bulb sockets for automotive lamp assemblies. The embodiments of the bulb sockets disclosed provide for superior alignment, electrical connection, and stabilization of the bulb in the bulb socket.

Abstract: An LED lamp assembly comprises a housing having a multi-faceted reflector positioned therein for reflecting light into a light beam. A LED carrier is positioned in front of the reflector and extends vertically from the top to the bottom of the reflector. A plurality of LEDs are positioned on the LED carrier and arranged and disposed to emit light directly on to the reflector, thereby creating the light beam. A light pipe is also positioned within the housing in front of the reflector and in front of the LED carrier. The light pipe extends vertically along the LED carrier from the top to the bottom of the reflector. Accordingly, the LED carrier and light pipe are positioned in the path of the light beam propagated from the reflector.

Abstract: The subject invention relates to terminals that are utilized in bulb sockets for automotive lamp assemblies. The embodiments of the bulb sockets disclosed provide for superior alignment and stabilization of the bulb in the bulb socket so that proper contact is made between the terminals and the bulb without damaging the bulb or the terminals during insertion. The terminal may comprise, among other things, at least one alignment feature, which may include partial spheres, that allows for easy insertion into the bulb socket and substantially ensures proper alignment and positioning within the bulb socket so that a proper connection can be maintained with the bulb and terminal Sealing material may be used to cover wire attachment portions of the terminals and plate portions of the terminals may be used to prevent the sealing material from entering a bulb accepting portion of the socket.

Abstract: A lamp assembly and methods of assembling the lamp assembly are provided. The lamp assembly comprises a printed circuit board (PCB) having a face surface, a rear surface opposite the face surface, electrical traces on the rear surface, and an opening extending from the face surface to the rear surface, and a light emitting diode (LED) emitter having a dome portion, a body, and a plurality of electrical terminals connected to the body, wherein the body of the LED emitter is adjacent the rear surface, the dome portion of the LED emitter extends through the opening in the PCB to the face surface, and the electrical terminals are connected to the electrical traces on the rear surface.

Abstract: A stamped ball socket for attaching a headlamp pod to a mounting bracket comprising a base having an opening which is adapted to accept a fastener. The ball socket further comprising at least two walls extending from the base and at least two lock-in fingers protruding at an angle from the walls. The lock-in fingers and the walls of the ball socket flex to allow a pivot ball to be inserted between the lock-in fingers such that when the pivot ball is fully inserted it is adjustably retained in the ball socket by the lock-in fingers. Additionally, the base, walls, and lock-in fingers of the present invention are integrally formed by stamping a single piece of metal.

Abstract: An adverse weather headlamp assembly that comprises a foreground shield with two sides that taper up from a bottom portion to form a triangular shaped shield. The foreground shield can be movable between a blocking position and a pass-through position. In combination with a cutoff shield, the foreground shield reduces the amount of emitted light that can be reflected off of a wet or icy road in adverse weather conditions in order to reduce glare, while still allowing enough light to be emitted for the driver to adequately see the road.

Abstract: A lamp assembly with a peripheral auxiliary function is described for use with automobile lamps. A moveable shield and a fixed shield are positioned about a light source inside a housing. A first reflective surface and a second reflective surface are formed on the inside of the housing. The moveable shield is moveable between a first position and a second position. In the first position, the moveable shield blocks light from striking the second reflective surface, and a main beam is projected from the lamp assembly. In the second position, the moveable shield blocks light from striking the first reflective surface, and a peripheral beam is projected from the assembly. Thus, the moveable shield may be moved to switch between the main beam and the peripheral beam, creating the ability to alter the functionality of the lamp assembly.

Abstract: The subject invention relates to automotive head lamp assemblies with a low beam unit and a high beam unit. In an exemplary embodiment, the low beam unit and high beam unit is connected to one another by an adjuster bracket. The adjuster bracket allows for two ball studs to interact with the adjuster bracket. The first ball stud interacts with the adjuster bracket and high beam reflector so that the high beam reflector's vertical axis can be adjusted to make it parallel to the vertical axis of the low beam reflector. The second ball stud interacts with the adjuster bracket and low beam reflector so that both the low beam reflector and high beam reflector are adjusted vertically at the same time and in the same direction.

Abstract: A Catadioptric Light Distribution System that collects and collimates the hemispherical pattern of light emitted by a Lambertian light emitting diode (LED) into a collimated beam directed essentially parallel to the optical axis of the LED. The system comprises a circular condensing lens having a center axis that is aligned with the optical axis of the LED parabolic reflector having circular opening formed therethrough which is centered on the center axis of the parabolic reflector and a double bounce mirror. The light reflected and culminated by the parabolic reflector is directed onto the circular annular double bounce mirror so that this light is collimated in an annular beam which passes around the edge of the condensing lens.

Abstract: The subject invention relates to an assembly and method for attaching a stud to a lamp housing that decreases the overall size of the automotive lamp assembly. The apparatus has a collar molded over a stud. The collar attaches the stud to the lamp housing by being shear welded to the lamp housing. The stud is prevented from rotating about its longitudinal axis, so that it can serve to mount the lamp housing to an automobile.

Abstract: A thin automobile lamp assembly is manufactured by first fixing an elongated printed circuit board (PCB) having a plurality of LEDs to an elongated inner lens before the inner lens and PCB are joined to any other parts. The inner lens is fixed to the PCB by contacting the inner lens and the PCB such that a plurality of stakes on the inner lens extend through a plurality of associated holes on the PCB. The stakes extending through the holes are then melted by a process such as heat staking to fix the PCB to the inner lens. The fixed relationship between the inner lens and the PCB board secures a proper alignment between the lens and the plurality of LEDs on the PCB. Next, the PCB and lens subassembly is joined to a lamp housing, and the entire assembly is secured to an automobile.

Abstract: A lamp assembly with a multi-stage reflector is described for use with automobile lamps. A singular shield is positioned about a light source inside a housing. A first reflective surface and a second reflective surface are formed on the housing. The singular shield is moveable between a first position and a second position. In the first position, the moveable shield blocks light from striking the second reflective surface, and a main beam is projected from the lamp assembly. In the second position, the moveable shield allows light to strike both the first and second reflective surfaces, and a second beam is projected. Thus, the singular shield may be moved to switch between the main beam and the second beam, creating the ability to alter the functionality of the lamp assembly. More than two reflective surfaces and moveable positions may be used, to create a multitude of possible beam patterns.

Abstract: The present invention comprises a light assembly which provides additional light adjacent the main beam of a light. A shield within the light assembly is moved in response to a sensed condition so as to provide a first area of additional illumination at the edge of the light's main beam. In response to a second sensed condition, the shield is moved such that a second area of additional illumination is illuminated in addition to the first area.

Abstract: The present invention comprises a bulb socket assembly. The bulb socket assembly comprises a bulb accepting body portion, a terminal accepting body portion connected to the bulb accepting body portion, at least one terminal positioned in the bulb socket with the terminal's blade end extending into the bulb accepting body portion and its lead end positioned in the terminal accepting body, at least one wire connected to the lead end of the at least one terminal, and a sealing material substantially covering the lead end and the connected wire of the at least one terminal. One embodiment of the bulb socket assembly further comprises a stabilizing feature that allows the socket assembly to firmly grasp bulbs of various sizes. Another embodiment of the bulb socket assembly further comprises a plurality of alignment features to help guide a bulb into proper alignment with a set of terminals.

Abstract: A stamped ball socket for attaching a headlamp pod to a mounting bracket comprising a base having an opening which is adapted to accept a fastener. The ball socket further comprising at least two walls extending from the base and at least two lock-in fingers protruding at an angle from the walls. The lock-in fingers and the walls of the ball socket flex to allow a pivot ball to be inserted between the lock-in fingers such that when the pivot ball is fully inserted it is adjustably retained in the ball socket by the lock-in fingers. Additionally, the base, walls, and lock-in fingers of the present invention are integrally formed by stamping a single piece of metal.

Abstract: The subject invention relates to automotive lighting assemblies. Specifically, the subject invention relates to a device and method for retaining wires, which provide power to the light source, in the proper orientation. In an exemplary embodiment, a wire retaining cavity is formed by a molded rib on a cover and a molded retention feature with a hook portion on a light source retaining compartment. In this exemplary embodiment, the cover and retaining compartment are integrally connected to one another by a living hinge. The wire retaining cavity is formed once the cover is folded over the retaining cavity bringing the rib into close proximity of the wire retention feature and adjacent to the hook portion of the feature.