Abstract: A lamp assembly with an integrated Light Emitting Diode support frame is described. An electrically conductive lead frame is encapsulated in between the interior and exterior surfaces of a lamp housing. Surface mounted LED light sources and associated drive components are attached to the lead frame, and thus to the housing. A positive terminal and a negative terminal are formed from the lead frame on the inside to the outside of the housing, so that electricity may be transmitted from an external source to the LED light sources on the inside of the housing. The LED light sources are energized by the conductive lead frame formed into or onto the housing, thus eliminating the need for a separate printed circuit board with a conductive lead frame.

Abstract: The subject invention relates to an automotive front lamp assembly with a reflector and a light source and relates to a manufacturing defect that causes a substantial amount of glare when light from the light source strikes it. The subject invention utilizes at least one glare prevention to cover or prevent the formation of the sink. In an exemplary embodiment, the glare prevention feature comprises a rib or half-sphere with a convex surface that has a sharp radius. The convex surface spreads out the light that reflects off it over a large area in order to prevent glare. In another embodiment of the subject invention, the glare prevention feature comprises a rib with a substantially perpendicular surface and an angled or curved surface. This embodiment prevents glare by redirecting most of the light that strikes its surfaces so that it is not emitted out of the front lamp assembly.

Abstract: The present invention comprises a lamp assembly with a boot hermetically cohered to the housing. The housing comprises a thermoplastic polymer and the boot comprises a thermoplastic elastomer. The boot is cohered to the housing by welding. According to one embodiment, the boot is sonic or vibration welded to the housing. The present invention may be used in the production of a wide range of lamp assemblies, including vehicle headlamp assemblies.

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: The present invention comprises a bending lamp apparatus and method of use. A first filament is energized as a vehicle begins to turn so as to provide illumination in the direction of the turn. As the turn becomes more severe, a second filament is energized such that an additional area is illuminated in the direction of the turn.

Abstract: The subject invention comprises an adaptive front lighting system (“AFS”) utilizing at least one light emitting diode (“LED”) as a light source and a means for moving the LED to achieve AFS functionality. An exemplary embodiment of the subject invention comprises a plurality of LEDs positioned and located on a LED carrier. The LED carrier is mechanically connected to at least one actuator that causes the LED carrier and LEDs to move. A controller is used to cause the actuator to move the LEDs. In this manner, this exemplary embodiment adjusts the light beam and creates the desired light beam pattern. Other exemplary embodiments of the subject invention pivotally connect the LEDs to the lens and to each other and utilize the actuator and controller to adjust the light beam. Another exemplary embodiment positions the LEDs in a spherical surface and connects them to the actuator by an extension in order to adjust the light beam.

Abstract: The present invention comprises a pivot stud with an axis of rotation in the horizontal plane for use within a visual optical aim light assembly. The axis of rotation of the pivot stud defines an axis of rotation about which the light assembly may be rotated so as to properly aim the visual optical aim light assembly. The pivot stub does not allow rotation about planes other than the horizontal plane. According to one embodiment, the pivot stud comprises a ball and socket of a generally ellipsoid shape.

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: An adjustable rear lamp is disclosed to allow the adjustment of a lamp housing within the lamp cavity of an automobile's body frame. A threaded bolt is inserted into an opening in the sheet metal of an automobile. A nut is attached to the threaded bolt. The threaded bolt surrounds a threaded shaft, and one end of the threaded shaft is attached to the lamp housing. The nut and threaded bolt may be rotated, engaging the threaded shaft and moving the threaded shaft into or out of the lamp cavity. The movement of the threaded shaft and the lamp housing allows the lamp housing to be positioned precisely within the lamp cavity.

Abstract: The subject invention comprises a thin lamp assembly having a lens and a lamp housing heat staked and sealed together. The subject invention further comprises the method of assembling the thin lamp assembly. In one embodiment, the lens has a plurality of plastic stakes and a lens rib located around the lens' periphery. Further, the lamp housing has a plurality of receiving holes around its outer periphery and a lamp housing rib around its inner periphery. In this embodiment, a sealant is placed on the lamp housing and the plastic stakes are inserted into the receiving holes so that the lens rib and lamp housing rib form a seal channel to contain the sealant and the lens is flush with the lamp housing. A heat source is then used to heat treat the plastic stakes to form a plurality of mushroom caps that act to attach the lens to the lamp housing.

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 is disclosed. The system 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 and which is configured to receive an collimate a portion of the light from the LED defined by a central cone of light centered around the optical axis. A parabolic reflector having circular opening formed therethrough is centered on the center axis of the parabolic reflector and is positioned around the LED to receive and redirect the light which does not form the cone that impinges upon the condensing lens in a collimated annular beam in a direction away from the condensing lens.

Abstract: The subject invention relates to automotive headlamp assemblies with a sign light shield. In an exemplary embodiment, the sign light shield can be raised or lowered by an actuator into or out of a reflecting position that allows the sign light shield to reflect light emitted from a light source through the upper portion of a lens. In another embodiment, the headlamp assembly can comprise two cutoff shields mounted to a rotatable shaft, where one of the cutoff shields has a sign light shield mounted directly to it and the other cutoff shield does not have a sign light shield. An actuator rotates the shaft until the sign light shield is in a position that will allow it to reflect light out of the upper portion of the lens or until the sign light shield is in a position where it cannot reflect any light.

Abstract: A sealing bulb boot for use in a vehicular lighting assembly comprising a boot with a lip running along its outer perimeter and a hole at its approximate center. The hole in the boot is generally circular in configuration with at least one notch which allows a conventional tabbed locking mechanism of a light source, which requires an approximate quarter turn to lock the light source to the reflector, to pass therethrough. The outer lip of the sealing bulb boot presses around a portion of the housing of the lighting assembly. A seal is also created around the inner portion of the sealing bulb boot upon the insertion of the light source through the hole at the center of the boot and the turning of the light source to engage the light source's locking mechanism.

Abstract: An automotive lighting assembly cooling system includes a heat pipe with an evaporation area proximate to a heat generating component, such as a Light Emitting Diode (LED), and a condensing area located remote from the evaporation area. Evaporation of fluid within the heat pipe transfers heat away from the heat generating component. The efficiency of the cooling system in one embodiment is increased by including fins associated with the condensing area and placing the fins in an area where air flow external to a moving vehicle assists in cooling the fins.

Abstract: An adjustable rear lamp is disclosed to allow the adjustment of a lamp housing within the lamp cavity of an automobile's body frame. A threaded bolt is inserted into an opening in the sheet metal of an automobile. A nut is attached to the threaded bolt. The threaded bolt surrounds a threaded shaft, and one end of the threaded shaft is attached to the lamp housing. The nut and threaded bolt may be rotated, engaging the threaded shaft and moving the threaded shaft into or out of the lamp cavity. The movement of the threaded shaft and the lamp housing allows the lamp housing to be positioned precisely within the lamp cavity.

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 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: The subject invention comprises a headlamp moisture control system that comprises at least one desiccant and at least one valve. The desiccant comprises an interior desiccant surface that forms an intake passageway and an exterior desiccant surface that forms at least one exhaust passageway. Further, the exterior desiccant surface area has a surface area that is greater than the interior desiccant surface area. The at least one valve can comprise an intake valve and an exhaust valve or it can comprise a combination valve. In either embodiment, the at least one valve prevents the desiccant from constantly being exposed to air that contains moisture. The moisture control system prevents moisture from entering a headlamp assembly during the cooling of a headlamp by only allowing air to enter the headlamp assembly through the intake passageway over the interior desiccant surface.

Abstract: A standalone gradient detector system, utilizing a gradient detector with a several photodetectors, is disclosed. A lamp emits light toward a screen. The light strikes the photodetectors on a photodector array, which communicate the light intensity to a gradient circuit. The gradient circuit compares the intensity values from each photodetector with the intensity value for the photodetector immediately adjacent, and computes a gradient value. The maximum gradient value is displayed using a display device, and the position of the photodetector with the maximum gradient value is indicated by an adjacent light source. The gradient of an automobile headlamp may thus be found easily, assisting in headlamp positioning during headlamp and vehicle manufacture.