INTEGRATED IN-SURFACE LENS ASSEMBLY
A seamless lighting arrangement for a vehicle panel. The vehicle panel has an inside surface and an outside surface. The vehicle panel has a light aperture extending from the inside surface of the vehicle panel to the outside surface of the vehicle panel. Connected to the inside surface of the vehicle panel is a bracket. The seamless lighting arrangement further includes a lens with a bracket connection portion that connects to the bracket and a transmission portion positioned within the light aperture of the vehicle panel. The lens further includes a light unit fixedly connected to the lens. The light unit has a projector port for emitting light from a light source. The light transmission portion of the lens has a light input surface region formed on an inside surface of the lens and a light output surface region formed on an outside surface of the lens.
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This application claims priority U.S. Provisional Patent Application No. 63/330,845, filed Apr. 14, 2022, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTIONThe present invention relates to an integrated in-surface lens assembly.
BACKGROUND OF THE INVENTIONIn the field of automotive lighting design, lighting units are connected to various vehicle body panels for illuminating various areas both inside and outside of the vehicle. The lighting units are often quite large and require numerous components that need to be assembled together using several assembly steps. It is an object of the invention to provide a lighting unit that minimizes the number of components that need to be assembled, thereby reducing the complexity and number of assembly steps. It is further an object of the invention to provide a design flexible solution integrating an “in-surface sealing clear lens” to a larger “opaque” panel (i.e., not light transmitting). This “in-surface sealing clear lens” assembly is positioned and affixed to a panel opening made in the larger panel surface allowing: 1) protection of the light source and 2) projected light to be transmitted to the ground or surrounding area around an automotive vehicle or vehicular mobility unit.
SUMMARY OF THE INVENTIONThe present invention is directed to a seamless lighting arrangement for a vehicle panel. The vehicle panel can be any type of exterior or interior panel, including, but not limited to bumper fascia, rocker panels, quarter panels, spoilers door panels, mirror housings, instrument panels, headliners, interior door panels, etc. The vehicle panel has a light aperture extending from an inside surface of the vehicle panel to an outside surface of the vehicle panel. Connected to the inside surface of the vehicle panel is a bracket at a location near the light aperture. The seamless lighting arrangement further includes a lens with a bracket connection portion that connects to the bracket and a transmission portion positioned within the light aperture of the vehicle panel. The lens further includes a light unit fixedly connected to the lens. The light unit has a projector port for emitting light from a light source. The light transmission portion of the lens has a light input surface region formed on an inside surface of the lens and a light output surface region formed on an outside surface of the lens.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring now to the
Connected to the inside surface 14 of the vehicle panel 12 is a bracket 20 that is used to connect the lens 28 with the light unit 32 to the inside surface 14 of the vehicle panel. The bracket 20 has a flange 22 that connects the bracket 20 to the inside surface 14 using adhesives, welding, fastener clips, snap lock features or fasteners depending on the needs of a particular application. It is also within the scope of this invention for some embodiments to include a backet that is integrally molded to the inside surface 14 of the vehicle panel.
The lens 28 includes a housing 25 that connects to both the bracket 20 and the light unit 32. As shown in
The lens 28 of the seamless lighting arrangement 10 also has a transmission portion 30 positioned within the light aperture 18 of the vehicle panel 12. The lens 28 further includes the light unit 32 fixedly connected to the lens 28. The light unit 32 has a projector port 34 for emitting light from a light source 36, which is a light emitting diode, halogen bulb or incandescent bulb. The light transmission portion 30 of the lens 28 has a light input surface region 38 formed on an inside surface 40 of the lens 28 and a light output surface region 42 formed on an outside surface 44 of the lens 28. The light output surface region 42 of the light transmission portion 30 extends through the light aperture 18 from the inside surface 14 of the vehicle panel 12 to the outside surface 16 of the vehicle panel 12. The light transmission portion 30 is the area of the lens 28 that light is transmitted or refracted through as the light is projected from the light source 36 through the lens 28 and light aperture 18 to a desired area.
The light unit 32 further includes a housing 33 that has a light tube 46 extending from the projector port 34 that connects at a distal end 48 to the lens 28 at the light input surface region 38 of the transmission portion 30. At the distal end 48 of the light tube 46 there is also a flange 23 extending from the housing 33 of the light unit 32 that is used to align and connect the light unit 32 to the lens 28. The flange 23 is connected to the lens 28 using welding, adhesives, or other connections. The flange 23 also defines the boundary of the light input surface region 38.
The light unit 32 is configured to receive command signals from an external controller that is located remotely from the light unit 32 and the seamless light arrangement 10. This allows the light unit 32 to be smaller since it is not necessary to have additional circuitry in the light unit 32. Furthermore, a single controller can control multiple light units. However, it is within the scope of this invention for the controller to be located on the light unit 32 itself.
Referring now to
The lens 328 further includes a transmission portion 331 that extends from the shoulder 329 and is positioned within the light aperture 318 of the vehicle panel 312. An outer surface of the transmission portion 331 is flush with an outer surface 316 of the vehicle panel 312 to create a seamless look with no change in depth between the outer surface of the light transmission portion 331 and the outer surface 316 of the vehicle panel 312. In order to ensure that that a consistent flush mount occurs, the connection between the bracket 320 and the light unit 332 must be consistent and reproducible. Therefore, snap tangs 348a, 348b are provided on the light unit 332 for connecting the light unit 332 to the bracket 320. The snap tangs 348a, 348b respectively snap into the fitting aperture 322a, 322b to connect the lighting unit 332 to the bracket 320. The combination of the snap tangs 348a, 348b and fitting aperture 332a, 332b controls the indexing of the lens 328 in the light aperture 318 of the vehicle panel 312. Stated another way the combination of the snap tangs 348a, 348b and fitting aperture 322a, 322b control how far into the transmission portion 330 of the lens 328 is positioned into the light aperture 318, thereby providing a consistently reproducible flush surface between the outer surface 331 of the lens 328 and the outer surface 316 of the vehicle panel 312. The seamless lighting arrangement 300 of the present embodiment is desirable for use in applications where the larger lens described above is not possible due to spatial constraints, but it is still necessary to provide a sealed light unit with a lens outer surface that is flush, or seamless, with the outer surface of the vehicle panel.
Referring now to
The opposing side walls 452a, 452b of the lens 428 form the upright portions of the U-shape of the lens 428. Each of the two opposing side walls 452a, 452b have snap tangs 448a, 448b extending therefrom and engageable with a respective fitting aperture 422a, 422b of the bracket 420. The combination of the snap tangs 448a, 448b and fitting aperture 432a, 432b control the indexing of the lens 428 in the light aperture 418 of the vehicle panel 412 so that datum points of the light aperture 418 align in tolerance with datum points of the transmission portion 430 of the lens 428, the datum points of the light tube 336 and the datum points of the projector port 434. Stated another way the combination of the snap tangs 448a, 448b and fitting aperture 422a, 422b control how far into the transmission portion 430 of the lens 428 is positioned into the light aperture 418, thereby providing a consistently reproducible flush surface between the outer surface 431 of the lens 428 and the outer surface 416 of the vehicle panel 412. Also controlling the alignment of datum points of the light aperture 418, light transmission portion 430 of the lens, light tube 446 and projector port 434 will ensure that a desired projector light pattern from the seamless lighting arrangement 400 is achieved.
The seamless lighting arrangement 400 of the present embodiment is desirable for use in applications where the larger lens described
In application the type of seamless lighting arrangement 10, 100, 300 and 400 implemented can vary depending on the needs of a particular application. Certain applications can have spatial requirements that require type to be used in preference to the other. As explained above the datum points between each of the different components of the arrangement can also dictate which one of the seamless lighting arrangement 10, 100, 200, 300 is chosen.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
Claims
1. A seamless lighting arrangement for a vehicle panel comprising:
- a vehicle panel having an inside surface and an outside surface;
- a light aperture extending from the inside surface of the vehicle panel to the outside surface of the vehicle panel;
- a bracket connected to the inside surface of the vehicle panel, wherein the bracket has two walls and at least one fitting aperture formed on one of the two walls;
- a light unit having at least one snap tang for engaging the at least one fitting aperture to connect the light unit to the bracket, wherein the light unit has a projector port for emitting light and a light tube having a distal end, and
- a lens having a shoulder that connects to the distal end of the light tube at a connection and the lens includes a transmission portion extending into the light aperture of the vehicle panel.
2. The seamless lighting arrangement of claim 1 wherein the connection between the shoulder and the distal end of the light tube is a watertight connection formed using one of welding or adhesives.
3. The seamless lighting arrangement of claim 1 wherein the light tube has a diameter and the shoulder of the lens is less than or equal to the diameter of the light tube.
4. The seamless lighting arrangement of claim 1 wherein the transmission portion and an outside surface of the vehicle panel are flush when the light unit is connected to the bracket.
5. The seamless lighting arrangement for a vehicle panel of claim 1 wherein the light source is controlled by signals received from a controller located remote from the light generator and the seamless light arrangement.
6. The seamless lighting arrangement for a vehicle panel of claim 1 further comprising an inside surface of the lens having a wedge formed on the inside surface of the lens, with at least a portion of the wedge being formed on the light input surface region so that light received from the light projector port is deflected and exits the light output surface region at an angle relative to the direction light is received at the light input surface region.
7. The seamless lighting arrangement of claim 1 wherein the bracket has a flange that that connects the bracket to the inside surface of the vehicle panel using adhesives, welding, fastener clips, snap lock features or fasteners depending on the needs of a particular application.
8. A seamless lighting arrangement for a vehicle panel comprising:
- a vehicle panel having an inside surface and an outside surface;
- a light aperture extending from the inside surface of the vehicle panel to the outside surface of the vehicle panel;
- a bracket connected to the inside surface of the vehicle panel, wherein the bracket has two walls each having a fitting aperture;
- a lens having a U-shape with two opposing walls, a transmission portion and a wedge,
- a snap tang formed on each one of the two opposing walls, wherein each snap tang is configured to engage a respective fitting aperture of the bracket to connect the lens to the bracket such that the transmission portion of the lens is positioned in the light aperture of the vehicle panel, and
- a light unit having a projector port for emitting light and a light tube having a distal end, wherein there is a connection between the distal end of the tube and the wedge of the lens.
9. The seamless lighting arrangement of claim 8 wherein the connection between the distal end of the light tube and the wedge of the lens is a watertight connection formed using one of welding or adhesives.
10. The seamless lighting arrangement of claim 8 wherein the wedge has a surface area that is larger than a perimeter of the light tube.
11. The seamless lighting arrangement of claim 8 wherein the transmission portion and an outside surface of the vehicle panel are flush when the light unit is connected to the bracket.
12. The seamless lighting arrangement for a vehicle panel of claim 8 wherein the light source is controlled by signals received from a controller located remote from the light generator and the seamless light arrangement.
13. A seamless lighting arrangement for a vehicle panel comprising:
- a vehicle panel having an inside surface and an outside surface;
- a light aperture extending from the inside surface of the vehicle panel to the outside surface of the vehicle panel;
- a bracket connected to the inside surface of the vehicle panel;
- a lens with a bracket connection portion that connects to the bracket and a transmission portion positioned within the light aperture of the vehicle panel;
- a light unit fixedly connected to the lens, the light unit has a projector port for emitting light from a light source, wherein the light transmission portion has a light input surface region formed on an inside surface of the lens and a light output surface region formed on an outside surface of the lens.
14. The seamless lighting arrangement for a vehicle panel of claim 13 wherein the transmission portion extends through the light aperture from the inside surface of the vehicle panel to the outside surface of the vehicle panel.
15. The seamless lighting arrangement for a vehicle panel of claim 13 wherein the light source is controlled by signals received from a controller located remote from the light generator and the seamless light arrangement.
16. The seamless lighting arrangement for a vehicle panel of claim 13 wherein the projector port further includes a light tube extending from the projector port and connected at a distal end to the lens.
17. The seamless lighting arrangement for a vehicle of claim 16 further comprising a weld connection between the inside surface of the lens and the distal end of the light tube.
18. The seamless lighting arrangement of claim 16 further comprising a flange extending from a housing of the light unit that is used to align and connect the light unit to the lens, wherein the flange is connected to the lens using welding, adhesives, or other connections.
19. The seamless lighting arrangement for a vehicle panel of claim 13 further comprising a weld connection between the inside surface of the lens and the projector port.
20. The seamless lighting arrangement for a vehicle panel of claim 13 further comprising an inside surface of the lens having a wedge formed on the inside surface of the lens, with at least a portion of the wedge being formed on the light input surface region so that light received from the light projector port is deflected and exits the light output surface region at an angle relative to the direction light is received at the light input surface region.
21. The seamless lighting arrangement of claim 13 wherein the bracket has a flange that that connects the bracket to the inside surface of the vehicle panel using adhesives, welding, fastener clips, snap lock features or fasteners depending on the needs of a particular application.
22. The seamless lighting arrangement of claim 13 further comprising:
- a housing of the lens with two fastener bosses extending from the surface of the housing of the lens;
- a housing of the light unit having two fastener tabs that align and connect with the two fastener bosses extending from the housing of the lens, and
- two fasteners extending through a respective one of the fasteners tabs and engaging a respective one of the fasteners bosses to connect the housing of the light unit to the housing of the lens.
23. A seamless lighting arrangement for a vehicle panel comprising:
- a vehicle panel having an inside surface and an outside surface;
- a light aperture extending from the inside surface of the vehicle panel to the outside surface of the vehicle panel;
- a bracket connected to the inside surface of the vehicle panel;
- a lens with a bracket connection portion that connects to the bracket and a transmission portion positioned within the light aperture of the vehicle panel;
- a light unit fixedly connected to the lens, the light unit has a projector port for emitting light from a light source, wherein the light transmission portion has a light input surface region formed on an inside surface of the lens and a light output surface region formed on an outside surface of the lens;
- a light tube extending from the projector port and connected at a distal end to the lens, and
- a flange extending from a housing of the light unit that is used to align and connect the light unit to the lens, wherein the flange is connected to the lens using welding, adhesives, or other connections.
24. The seamless lighting arrangement for a vehicle panel of claim 23 wherein the transmission portion extends through the light aperture from the inside surface of the vehicle panel to the outside surface of the vehicle panel.
25. The seamless lighting arrangement for a vehicle panel of claim 23 wherein the light source is controlled by signals received from a controller located remote from the light generator and the seamless light arrangement.
26. The seamless lighting arrangement for a vehicle of claim 23 wherein the connection between the flange and the lens is a weld connection between the inside surface of the lens and the distal end of the light tube.
27. The seamless lighting arrangement for a vehicle panel of claim 23 further comprising an inside surface of the lens having a wedge formed on the inside surface of the lens, with at least a portion of the wedge being formed on the light input surface region so that light received from the light projector port is deflected and exits the light output surface region at an angle relative to the direction light is received at the light input surface region.
28. The seamless lighting arrangement of claim 23 wherein the bracket has a flange that that connects the bracket to the inside surface of the vehicle panel using adhesives, welding, fastener clips, snap lock features or fasteners depending on the needs of a particular application.
29. The seamless lighting arrangement of claim 23 further comprising:
- a housing of the lens with two fastener bosses extending from the surface of the housing of the lens;
- a housing of the light unit having two fastener tabs that align and connect with the two fastener bosses extending from the housing of the lens, and
- two fasteners extending through a respective one of the fasteners tabs and engaging a respective one of the fasteners bosses to connect the housing of the light unit to the housing of the lens.
30. A seamless lighting arrangement for a vehicle panel comprising:
- a bracket for connection to a vehicle panel;
- a lens with a bracket connection portion that connects to the bracket and a transmission portion of the lens;
- a light unit fixedly connected to the lens, the light unit has a projector port for emitting light from a light source, wherein the light transmission portion has a light input surface region formed on an inside surface of the lens and a light output surface region formed on an outside surface of the lens.
31. The seamless lighting arrangement for a vehicle panel of claim 30 wherein the projector port further includes a light tube extending from the projector port and connected at a distal end to the lens.
32. The seamless lighting arrangement for a vehicle of claim 31 further comprising a weld connection between the inside surface of the lens and the distal end of the light tube.
33. The seamless lighting arrangement of claim 31 further comprising a flange extending from a housing of the light unit that is used to align and connect the light unit to the lens, wherein the flange is connected to the lens using welding, adhesives, or other connections.
34. The seamless lighting arrangement for a vehicle panel of claim 31 further comprising a weld connection between the inside surface of the lens and the projector port.
35. The seamless lighting arrangement for a vehicle panel of claim 30 further comprising an inside surface of the lens having a wedge formed on the inside surface of the lens, with at least a portion of the wedge being formed on the light input surface region so that light received from the light projector port is deflected and exits the light output surface region at an angle relative to the direction light is received at the light input surface region.
36. The seamless lighting arrangement of claim 30 wherein the bracket has a flange that that connects the bracket to the vehicle panel using adhesives, welding, fastener clips, snap lock features or fasteners depending on the needs of a particular application.
37. The seamless lighting arrangement of claim 30 further comprising:
- a housing of the lens with two fastener bosses extending from the surface of the housing of the lens;
- a housing of the light unit having two fastener tabs that align and connect with the two fastener bosses extending from the housing of the lens, and
- two fasteners extending through a respective one of the fasteners tabs and engaging a respective one of the fasteners bosses to connect the housing of the light unit to the housing of the lens.
Type: Application
Filed: Apr 3, 2023
Publication Date: Oct 19, 2023
Applicant: Magna Exteriors Inc. (Aurora)
Inventors: Daniel Vander Sluis (Rochester Hills, MI), Patrick Gerrity (Dearborn, MI), Oliver Pace (Clarkston, MI)
Application Number: 18/130,055