Abstract: An apparatus and method for testing one or more glass light bulbs assembled into a sub-assembly for cracks. The apparatus comprises a chamber having an enclosed hollow interior and a door that is adapted to open and close to either allow access to the hollow interior or to seal the hollow interior; a test tray assembly having a plurality of compartments for receiving and holding a plurality of glass light bulbs and sub-assemblies to be tested, said tray assembly adapted and dimensioned to be placed into and enclosed by said chamber; a control assembly for controlling the introduction of oxygen into said chamber; and a source of pressurized oxygen connected to said chamber to supply oxygen under pressure to said chamber under the control of said control assembly.

Abstract: A mounting assembly for at least one array of light emitting diodes (LEDs) comprises at least one metal circuit board and mounting bracket. The circuit board has one or more LEDs attached to it and at least one first engaging opening and at least one second engaging opening formed through the circuit board. The first engaging opening is key shaped with a larger portion and a narrowed elongated portion so that engaging surfaces are formed adjacent opposite edges of the narrowed portion. The mounting bracket is formed of a electrically non-conducting material such as plastic with at least one first engaging tab and at least one second engaging tab formed thereon. The first engaging tab is configured to have a narrow portion and a larger portion connected to the outward end of the narrow portion so that there is a gap formed between the edges of the larger portion and the mounting surface.

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: A movable reflector with integrally molded bulb assembly retention features. The movable reflector comprises a bore at the center of the reflector for receiving a bulb assembly and retention features integrally molded on the rear side of the reflector to retain the bulb assembly. The movable reflector further comprises mold voids spaced around the bore adjacent to the retention features and extending through the movable reflector so that the structure of the retention features and the movable reflector may be molded in one injection molding step without additional tool movement.

Abstract: A movable reflector with integrally molded bulb assembly retention features. The movable reflector comprises a bore at the center of the reflector for receiving a bulb assembly and retention features integrally molded on the rear side of the reflector to retain the bulb assembly. The movable reflector further comprises mold voids spaced around the bore adjacent to the retention features and extending through the movable reflector so that the structure of the retention features and the movable reflector may be molded in one injection molding step without additional tool movement.

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 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 license plate lamp utilizing an integrally molded component comprising a base portion, a hollow lens portion, and a light source holder. The light source holder of the molded component is adapted to hold an electrical connector and a light source within the hollow lens portion. The electrical connector provides electrical connection between the light source and the electrical system of the vehicle. The molded component is molded with means to mount the disclosed license lamp to the exterior surface of a vehicle in a manner which allows access to the interior of the disclosed license lamp from inside the trunk of the vehicle.

Abstract: An automotive center high mount stop lamp (“CHMSL”) comprising a housing, a LED array circuit board having at least one LED, a lens/reflector, and a cover. The housing comprises a base and a trapping panel which are joined by a living hinge which allows the trapping panel to be folded over the base. In the folded position the trapping panel serves to secure the LED array circuit board in position without the need for additional means to retain the LED array circuit board. The lens/reflector and cover, respectively, are then fixably attached to the housing.

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: Disclosed is an vertically aimable motor vehicle lamp of a one-piece construction. The lamp includes a housing and mounting bracket joined by at least one integral living hinge positioned at the substantial side of the housing at the housing and bracket interface. The integral living hinges define a line of weakness between them about which the housing is pivotable. The housing includes an integral tab extending radially outwardly from the housing and adjacent to the front of the housing. The integral tab is engaged and operable by a vertical-direction adjuster. Further, the one-piece bracket and housing are suitable for manufacture via injection molding and may, because they are a unitary element, be molded in a single injection.

Abstract: A vehicle lamp assembly comprising a reflector, with three (3) mounting bosses arranged in a triangular fashion on the rear side thereof, a light source and a housing. Three (3) pivot sockets are fixedly attached to each mounting boss, respectively. The vehicle lamp assembly also comprises two (2) ball pivot adjusting screws that are movably secured within two (2) of the three (3) pivot sockets, and an actuator ball pivot that is movably secured within the third pivot socket. An actuator is fixedly attached at one end to the housing and attached at the other end to the actuator ball pivot in a manner that permits linear motion of the actuator. The invention further comprises a vertical adjuster plate and a reflector plate. Movement of the actuator causes the reflector to adjust in both the horizontal and vertical directions, thus allowing the vehicle lamp assembly to produce both low beam and high beam lighting functionality.

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: An apparatus and method for testing one or more glass light bulbs assembled into a sub-assembly for cracks. The apparatus comprises a chamber having an enclosed hollow interior and a door that is adapted to open and close to either allow access to the hollow interior or to seal the hollow interior; a test tray assembly having a plurality of compartments for receiving and holding a plurality of glass light bulbs and sub-assemblies to be tested, said tray assembly adapted and dimensioned to be placed into and enclosed by said chamber; a control assembly for controlling the introduction of oxygen into said chamber; and a source of pressurized oxygen connected to said chamber to supply oxygen under pressure to said chamber under the control of said control assembly.

Abstract: A vehicle lamp assembly comprises a lamp housing, a lens, and a closeout sub-assembly. The closeout sub-assembly comprises a closeout and a template attached to the closeout. The closeout sub-assembly is created by forming the closeout around the outer periphery of the template such that the outer portion of the closeout is located adjacent to and outside of the peripheral edge of the template. The vehicle lamp assembly is created by affixing the closeout sub-assembly to the outer periphery of the inner surface of the lens and attaching the lens to the housing such that the closeout sub-assembly is located between the lens and the housing and such that the outer portion of the closeout is located adjacent to and outside of the peripheral edge of the lens.

Abstract: A vehicle lamp assembly comprising a reflector, with three (3) mounting bosses arranged in a triangular fashion on the rear side thereof, a light source and a housing. Three (3) pivot sockets are fixedly attached to each mounting boss, respectively. The vehicle lamp assembly also comprises two (2) ball pivot adjusting screws that are movably secured within two (2) of the three (3) pivot sockets, and an actuator ball pivot that is movably secured within the third pivot socket. An actuator is fixedly attached at one end to the housing and attached at the other end to the actuator ball pivot in a manner that permits linear motion of the actuator. The invention further comprises a vertical adjuster plate and a reflector plate. Movement of the actuator causes the reflector to adjust in both the horizontal and vertical directions, thus allowing the vehicle lamp assembly to produce both low beam and high beam lighting functionality.

Abstract: A vehicle lamp assembly comprises a lamp housing, a lens, and a closeout sub-assembly. The closeout sub-assembly comprises a closeout and a template attached to the closeout. The closeout sub-assembly is created by forming the closeout around the outer periphery of the template such that the outer portion of the closeout is located adjacent to and outside of the peripheral edge of the template. The vehicle lamp assembly is created by affixing the closeout sub-assembly to the outer periphery of the inner surface of the lens and attaching the lens to the housing such that the closeout sub-assembly is located between the lens and the housing and such that the outer portion of the closeout is located adjacent to and outside of the peripheral edge of the lens.

Abstract: A method and apparatus for centerless grinding of one or more tapered sections in a length of wire in which the wire is advanced through a gap formed between a rotating work wheel and regulating wheel, and the gap is adjusted in forming the tapered section by an image detection module upstream of the wheels made up of a linear array of closely spaced pixels beneath a guide slot through which the wire is advanced to sense the position of the wire at close increments and incrementally adjust the gap in strict accordance with the position actually sensed.

Abstract: The practice of joining two thermoplastic resin bodies with widely disparate melting temperatures is enhanced by providing a shallow, roughened surface on at least the higher melting point body. When the parts are clamped together for frictional engagement, the roughened surface increases the local pressure, accelerates the formation of a molten film between the bodies and provides a strengthening mechanical interlock in the welded joint.

Abstract: A center high mount stoplamp is characterized by a linear array of light emitting diodes on a light carrier. A corresponding plurality of lens optics are carried on a lens carrier. A desired distance between the light emitting diodes and the lens optics is established by extensions from the lens carrier having opposing surfaces which interface with back and front sides of the light carrier.