Abstract: A lamp assembly with an integrated Light Emitting Diode support frame is described. An electrically conductive lead frame is formed onto a lamp housing, or onto the internal surface 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: A LED light source assembly, utilizing a standard electrical socket with an integrated heat sink and an adjustable secondary heat sink structure is described. The LED light source assembly places a LED light source at a similar relative position inside a lamp housing as a traditional incandescent light bulb, to take advantage of traditional reflector geometries. A heat sink is attached to an automobile electrical socket, having a standard shape for traditional incandescent lighting. A LED light source is installed on the heat sink, and receives electricity from the automobile via the electrical socket. A secondary LED heat sink, with a second LED light source, may optionally be affixed to one of several possible attachment points of the LED light source assembly. The addition of a secondary LED heat sink allows the number and position of LED light sources to be varied according to lighting requirements.

Abstract: A lamp assembly with a peripheral auxiliary finction 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: 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 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: An automotive lamp assembly includes a light source and a hyperbolic reflector positioned to reflect light from the light source. A bifocal lens is positioned in front of the light source and hyperbolic reflector such that it receives light emitted from the light source and light reflected off the reflector. The bifocal lens includes a first portion having a focal point at the light source and a second portion having a focal point at a virtual focus of the reflector. When the light source is energized and emits light, direct light from the light source strikes the first portion of the lens and collimates the light substantially parallel to the optical axis. Light from the reflector strikes the second portion of the lens and is collimated substantially parallel to the optical axis. Altogether, the light passing through the bifocal lens provides a desirable light beam for an automotive vehicle.

Abstract: A peripheral beam lamp is described for use with automobile lamps. A light source is positioned within a housing, and the inner surface of the housing has a non-reflective surface and a partially reflective section. Light emitted from the light source may either strike the non-reflective surface or the partially reflective section, or may not strike any part of the inner surface of the housing before being emitted from the lamp assembly. Light striking the non-reflective surface is absorbed, and light striking the partially reflective section is partially reflected, depending on the color of the light and the color of the partially reflective section. Light emitted from the lamp assembly without striking the inner surface of the housing forms a main beam, and the light striking the partially reflective section imparts a color to the lens and lamp assembly, rendering a stylized appearance.

Abstract: A solid state adaptive forward lighting system is described for use with automobile headlamps. A central processing unit receives input from automobile wheel position sensors and incline sensors. The processing unit signals an array of light emitting diodes to selectively operate one or more diodes in the array to produce light. The array of light emitting diodes is provided with a converging lens to selectively change the angle of light projected from the light housing. The invention is thus able to change the angle of light based on the inputs from the sensors. The change in the angle of light enhances the automobile operator's view of the upcoming roadway, regardless of the orientation of the vehicle.

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 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: A mounting plug for pivotably connecting a first component to a second component. The mounting plug comprises a ball stud portion comprising a ball and a post. The post comprises means for attaching the ball stud portion to the first component. The mounting plug further comprises a base and a socket chamber integrally molded on top of the base. The socket chamber is adapted to removably and pivotably retain the ball stud portion. The mounting plug further comprises a channel integrally molded to the base adjacent to the socket chamber, with the channel adapted to allow the ball to be inserted there through and into the socket chamber. The mounting plug further comprises a retainer portion integrally molded below the base. The retainer portion comprises at least one tab integrally molded to the retainer portion and adapted to removably secure the socket portion to the second component.

Abstract: Disclosed is a means and method for attaching an automotive lighting lens to the housing of an automotive lighting assembly while a structural adhesive cures. An automotive lighting assembly has a recessed hollow portion dimensioned to enclose one or more light fixtures and an open end with a peripheral edge. Formed around the periphery of the housing is a sealing groove and a plurality of engaging openings adjacent the groove. The engaging openings have a plurality of protuberances projecting into the opening, the protuberances providing a reduced area of clearance within the engaging opening. A covering lens has an exterior edge and a flange dimensioned to extend into and mate with the sealing groove formed around the edge of the lens.

Abstract: An automotive headlamp assembly comprises a reflector positioned within a housing. The reflector defines a lamp cavity where a light source is positioned. The reflector includes a first portion designed to reflect light in a low beam pattern and a second portion designed to reflect light in a high beam pattern. An actuator is also positioned within the lamp cavity. The actuator is operable to move a light shield in a linear direction parallel to the optical axis of the reflector. In particular, the actuator is operable to move the light shield between a low beam position that exposes the light source to the first portion of the reflector and a high beam position that exposes the light source to both the first portion and the second portion of the reflector.

Abstract: A bifunctional headlamp having a bulb shield operable to project a low beam light pattern or a high beam light pattern. A bulb shield surrounds a bulb inside a housing. The bulb shield is attached to an actuator, which rotates the bulb shield about the bulb. The bulb shield contains projections placed opposite one another on the bulb shield, which serve to selectively shield portions of emitted light from the bulb from reflecting out of the housing. The selective shielding of the light emitted from the housing allows the bifunctional headlamp to utilize one bulb for both a low beam pattern and a high beam pattern. The use of one bulb for two functions reduces complexity and electrical requirements.

Abstract: The present invention comprises a light assembly with LESDs mounted opposite to the reflective side of a reflector. A plurality of reflectors are arranged in an overlapping fashion such that the light emitted from the LESD of one reflector is directed to the reflective surface of an underlying reflector. In this fashion, a number of LESDs may be incorporated into a lighting device in a variety of patterns while maintaining the LESDs and their mountings hidden from view.

Abstract: An apparatus for making a molded article comprises a cavity block, a slide and an actuator. The cavity block includes a mold cavity for forming the molded article and a runner for delivering the polymeric resin to the mold cavity. The slide is positioned adjacent to the cavity block and includes a bore extending through the slide and a gate formed in the slide. The gate of the slide is positioned to connect the runner to the mold cavity by forming a passage from the runner to the mold cavity. The actuator is operable to move the slide to a second position where the gate does not connect the runner to the mold cavity and no continuous passage from the runner to the mold cavity is available through the gate.

Abstract: A lighting assembly comprising a housing having at least one aperture formed therein and a reflector secured to the housing. The reflector comprises at least one reflector cup having a front curved surface. The lighting assembly further comprises at least one light source, such as an LED, positioned in the at least one aperture and secured to the housing. The at least one light source is positioned to emit light toward the at least one reflector cup and the light may then be focused into a collimated beam. A plurality of light sources may be circumferentially spaced around the outer edge of 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 comprises, among other things, alignment features that allow for easy insertion into the bulb socket and ensure proper alignment and positioning within the bulb socket so that a proper connection can be maintained with the bulb and the terminal.

Abstract: A vehicular headlamp in which the radial beam of radiated light is continuously adjustable between a first position and a second position. Semi-cylindrical lamp shields surround a lamp. The lamp shields are attached to gears which operate to rotate the lamp shields radially about the lamp. An actuator is attached to the gears, such the actuator can turn the gears in order to rotate the lamp shields. The actuator is controlled by a circuit which prevents over-rotation. The actuator may move in very small increments, such that the lamp shields may be continuously adjustable between the first position and the second position. The lamp shields are thus continuously adjustable to vary the projected radial beam of the headlamp.

Abstract: A system for adjusting the direction of a light beam from a headlamp assembly comprises a condenser lens which is movable along an arcuate path. As a vehicle turns a corner, the system moves the condenser lens along the arcuate path, so as to direct the light beam in the direction that the vehicle is moving. Because the condenser lens follows an arcuate path, the light beam is not distorted, allowing for greater angular displacement of the light beam.