Vehicle lamp base having integrally formed spring to bias reflector

Abstract

A vehicle lamp capsule 32 having a base 34 having a spring 5 which, when lamp capsule 32 is installed, biases an inner surface of a vehicle lamp reflector 12. Spring 5 is monolithically formed with base 34 along with at least one reflector-locating structure on the base such as circumferentially extending exterior locating surface 44 and/or retaining keys 42. Base 34 and spring 5 may be molded of a plastics material. In other embodiments base 34 and spring 5 are made in one piece of sheet metal. The spring 5 formed unitary with the lamp base 34 meets regulatory requirements and avoids a risk of dislodgement of a conventional separate piece-part metal spring which could cause an electrical short when the lamp is installed in the field. The lamp capsule 32 is suitably an H13-style lamp.

Claims

1. An automotive lamp capsule (32) adapted to be received in a vehicle lamp reflector (12) mounted to a vehicle chassis, the lamp capsule comprising: a lamp base (34); a light source (38) having an envelope defining an optical axis (39) extending from a proximal end adjacent the lamp base to a distal end, and wherein electric leads (90) for the light source extend from the envelope through the proximal end; the base (34) having a wall (43) defining a passageway (45) for the electrical leads (90) to be received therein to form an electrical pathway for connection to an external power supply to energize the light source; and a retainer (36) interconnecting the light source (38) and the base (34); wherein the wall (43) of the base further defines a circumferentially extending exterior locating surface (44) configured to abut an interior socket surface (24) of the automotive lamp reflector (12), the wall of the base further comprising a spring (5) formed monolithically with the wall, said spring (5) extending radially beyond the exterior locating surface (44).

2. The lamp capsule of claim 1, wherein the lamp base comprises retaining keys (42) extending radially from the lamp base (20).

3. The lamp capsule of claim 2, wherein the retaining keys (42) are formed monolithically with the wall of the lamp base.

4. The lamp capsule of claim 1, wherein the exterior locating surface (44) extends axially in a direction of the optical axis (39).

5. The lamp capsule of claim 4, wherein the spring is formed within an aperture (6) defined in the wall (43), the spring attached to one side of the aperture and extending therefrom transverse to the lamp optical axis (39).

6. The lamp capsule of claim 5, wherein the lamp base (34) and spring (5) are molded of a plastics material.

7. The lamp capsule of claim 1, wherein the wall (43) of the base is generally tubular.

8. The lamp capsule of claim 1, wherein the retainer (36) is formed as a separate component from the base (34) and comprises attachment structure (70; 76) formed to couple to the base.

9. The lamp capsule of claim 1, wherein the spring (5) defines a curved beam.

10. The lamp capsule of claim 1, wherein the spring (5) defines a cantilevered beam.

11. The lamp capsule of claim 1, wherein a distal end of the spring (5) defines a nose (8) extending radially outward of the wall exterior locating surface (44).

12. The lamp capsule of claim 1, wherein the wall (43) defines an aperture (6), the spring (5) being disposed in the aperture.

13. The lamp capsule of claim 12, wherein the spring (5) is attached at a lateral side of the aperture (6).

14. The lamp capsule of claim 13, wherein the spring (5) is cantilevered in the aperture.

15. The lamp capsule of claim 13, wherein a distal end of the spring (5) defines a nose (8) extending radially outward of the wall exterior locating surface (44).

16. The lamp capsule of claim 14, wherein a distal end of the spring (5) defines a nose (8) extending radially outward of the wall exterior locating surface (43).

17. The lamp capsule of claim 1, wherein the lamp base (34) is molded of a plastics material.

18. The lamp capsule of claim 1, wherein the lamp base (34) is formed of a sheet metal.

19. The lamp capsule of claim 1, wherein the light source (38) further comprises a filament configured to emit light when energized, the envelope defining an enclosed volume within which the filament is disposed.

20. The lamp capsule of claim 2 in combination with the vehicle reflector (12), the reflector (12) having a neck (2) adjacent a reflective surface (16), the neck defining a bore (48) communicating from an exterior region (14) exterior to the reflector toward an interior region adjacent the reflective surface (16), the lamp capsule (32) having axially oriented camming surfaces (40) defined on respective retaining keys (42), the retaining keys (42) being disposed in an axial direction spaced from the spring (5), whereby the lamp capsule (32) is configured to be introduced into the bore (48) of the reflector neck (2) from the exterior region and retained therein at an axial position in register with corresponding cam surfaces (24, 26) formed on the vehicle reflector.

Description

BRIEF DESCRIPTION OF FIGURES

(1) The above-mentioned and other features of this disclosure, and the manner of attaining them, will become more apparent and better understood by reference to the following description of embodiments described herein taken in conjunction with the accompanying drawings, wherein:

(2) FIG. 1 (Prior Art) is a cross-sectional view of a vehicle headlamp system partially broken away;

(3) FIG. 2 (Prior Art) is a perspective view of a vehicle reflector 12;

(4) FIG. 3 (Prior Art) is a perspective view, partially broken away, of an H13-style lamp capsule 32 having separate piece-part metal spring 52;

(5) FIG. 4 (Prior Art) is a perspective view of a lamp capsule 32;

(6) FIG. 5 (Prior Art) is an elevational view, partially broken away, of another lamp capsule base 34 for H8-16 style lamps having separate piece-part metal spring 52;

(7) FIG. 6 is a perspective view of lamp base 34 showing molded spring 5 formed with wall 43;

(8) FIG. 7 is a perspective view, partially broken away, of lamp capsule 32 with base 34 of FIG. 6;

(9) FIGS. 8-9 are top perspective views of FIG. 6, FIG. 9 being broken away;

(10) FIG. 10 is a rear cross-sectional view of FIG. 6 showing spring beam 5;

(11) FIGS. 11-12 are perspective views of another embodiment of lamp base 34 showing spring 5 formed with wall 43 of sheet metal such as for H8-16 style lamps;

(12) FIG. 13 is a perspective view, partially broken away, of FIG. 11;

(13) FIG. 14 is a perspective view of lamp capsule 32 with base of FIG. 11; and

(14) FIG. 15 is a front elevational view of lamp capsule 32 of FIG. 14.

DETAILED DESCRIPTION INCLUDING BEST MODE OF A PREFERRED EMBODIMENT

(15) It may be appreciated that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The embodiments herein may be capable of being practiced or being carried out in various ways. Also, it may be appreciated that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting as such may be understood by one of skill in the art.

(16) The automotive headlamp 32 disclosed herein is suitable for use on a motor vehicle, particularly in the reflector cavity for the vehicle forward lighting such as the vehicle headlamp or fog lamp (collectively be referred to herein as a vehicle headlamp) which is used to illuminate a road surface. The type of motor vehicle may include, but is not limited to, a land vehicle such as a passenger sedan, a sport utility vehicle, a minivan, a truck (light or heavy truck) and a recreational vehicle (e.g., ATV, motorcycle, snowmobile). Alternatively the motor vehicle may also include water vehicles (e.g. boats, jet-skis, personal water craft) and air vehicles (e.g. planes, helicopters).

(17) FIG. 1 to FIG. 4 show a prior art lamp capsule 32 as known in U.S. Pat. No. 5,855,430 (Coushaine) of the present Applicant's assignee, which is incorporated by reference in its entirety as if fully set forth herein. FIG. 1 shows a cross sectional view of a preferred embodiment of a vehicle headlamp system partially broken away. Like reference numbers designate like or corresponding parts throughout the drawings and specification. The vehicle headlamp system 10 is assembled from an optical reflector 12, lamp capsule 32, and gasket 64. Additional mounting, aiming, sealing, venting, and similar headlamp features may be selected or used according to designer choice as known in the art.

(18) FIG. 2 shows a perspective view of an optical reflector 12, partially broken away. Reflector 12 is typically mounted to a vehicle chassis. Optical reflector 12 may be made of molded plastic, such as a filled bulk molding material, as known in the art. Reflector 12 has the general form of a concave shell with an exterior (or rear) side 14 and an interior, or forward reflective side, referred to as optical surface 16. Optical surface 16 provides a desired headlamp beam pattern as known in the art. Optical surface 16 may be coated, if necessary, with various reflective and protective layers, not shown.

(19) Extending in a forward direction from the optical surface 16, is an optical axis 18 (Z-axis), generally indicating the direction of the final headlamp beam. It is understood that the reflector 12 may be enclosed on the front side by a clear cover lens (not shown) that may, optionally, include beam directing lens elements. Reflector 12 may be supported by aiming hardware, and enclosed in a housing as is known in the art.

(20) The optical reflector 12 also has an internal wall 20 defining within neck 2 a passage or bore 48 extending axially between exterior surface 14 and optical surface 16. Formed on the internal wall 20 are one or more axial positioning surfaces 22, and one or more planar positioning surface 24. The axial positioning surface 22 then provides a locating surface that the lamp capsule 32 can be positioned against for proper location of lamp capsule 32 in the axial direction 18 (Z-axis direction). The axial positioning surface 22 may be formed as a depression or concavity on an in-leading ramp or camming surface 26 facing in the forward axial direction 18 to thereby locate lamp capsule 32 with reference to optical surface 16. Reflector 12 and neck 2 further define socket region 50 that receives and retains lamp capsule 32. Socket region 50 is located axially spaced from gasket seating surface 28 which comes into abutment with gasket 64 (FIG. 1). Socket region 50 has latching structure comprising wall 20 and positioning surface 22 which provides a cavity having a ledge onto which capsule retaining keys 42 (FIG. 1 and FIG. 4) can be introduced through corresponding slots such as by axial and then slight rotational (so-called eighth-turn or quarter-turn) motion akin to a bayonet latch, for positioning and retention of the lamp capsule, all as is known in the art.

(21) Conventionally, axial positioning surface 22 and lead in ramp 26 are repeated as a pattern in two other locations (a second positioning surface is shown as 22 and a second planar locating surface is shown as 24 the remaining albeit similar surfaces are not shown) around internal wall 20. The in-leading ramps 26, may terminate respectively in notched depressions serving as locating surfaces 22, 22 and a similar one not shown that can then accept radially-extending retaining keys 42 (FIG. 4), which can also be called follower arms 42, extending radially from lamp capsule 32. The three axial positioning surfaces 22 are located approximately equiangularly around internal wall 20.

(22) FIG. 4 shows a perspective view of lamp capsule 32. The lamp capsule 32 may be made with a plastic base 34 of plastic resin, or filled plastic resin. A suitable resin is available under the trade name Amodel A-1145HS, available from the Solvay company, which is a 45% glass-filled, heat stabilized polyphthalamide (PPA) resin. Coupled to plastic base 34 is holder or retainer 36, preferably made of metal or rolled sheet metal, and held in the metal holder 36 is light source 38. The light source 38 has an envelope axis 39 which is an optical axis. The optical reflector 12 is designed to couple and seal with lamp capsule 32. The lamp capsule 32 has an axial locating surface 40 formed on retaining keys 42, a planar locating wall surface 44, a capsule sealing surface 46, and a bias spring 52. An elastomeric gasket 64 (FIG. 1) is received on sealing surface 46. There are numerous base and metal holder designs allowing for accurate positioning of the light source with respect to the lamp capsule.

(23) The base 34 is approximately a plastic tube adapted with coupling, locating and sealing features that then supports a metal holder 36 that supports light source 38. The light source 38 is conventionally a tungsten halogen lamp bulb. With respect to the axial and planar location features described above in the coupling of the capsule to the reflector, the light source and holding method, and features of supporting the light source 38 to retainer 36 for interconnecting to base 34, are all matters of design choice understood by those of skill in the art. Other light source designs and holding methods may be used with the reflector coupling design.

(24) Conventionally, positioned along lamp capsule 32 is at least one axial locating surface 40, or three. The axial positioning surface 22 of reflector 12 mates face to face with the axial locating surface 40 of lamp capsule 32. When surfaces 22 and 40 are seated one to the other, lamp capsule 32 is then properly positioned with respect to the optical surface 16 along the optical axis 18 (Z direction). The lamp capsule 32 axial positioning surfaces 40 are the lower (exterior side) facing surfaces of three retaining keys 42, extending orthogonal to lamp axis 39 from lamp capsule 32. When lamp capsule 32 is inserted in reflector 12, each arm 42 passes inward sufficiently to slide up on a corresponding in-lead ramp 26, formed on reflector 12. By rotating lamp capsule 32, the arms 42 are cammed up ramps 26, thereby advancing lamp capsule 32 along the optical axis (Z direction) while compressing gasket 64. Once arms 42 reach the inner ends of the in-lead ramps 26, the axial locating surfaces 40 abut the positioning surfaces 22, which may be formed with retaining depressions or slots, and are held in place by the resilient compression of gasket 64.

(25) With particular reference to FIG. 1 and FIG. 4, also positioned along lamp capsule 32 is a wall 43 having on its exterior a locating surface 44. Wall 43 extends circumferentially and extends axially along lamp axis 39. The planar positioning surface 24 of reflector 12 mates face to face with wall locating surface 44. When the planar positioning surface 24 and the wall locating surface 44 are properly seated one to the other, lamp capsule 32 is then properly positioned in the X and Y directions with respect to the optical axis 18 (Z direction). The capsule locating surface 44 has a cylindrical face formed on an exterior side of base 34 and extending axially parallel to the optical axis 18. The planar positioning surface 24 of the reflector and the wall locating surface 44 of plastic base 34 are formed to be conformal with each other when lamp capsule 32 is properly positioned in reflector 12.

(26) Positioned along lamp capsule 32 is sealing surface 46. The capsule sealing surface 46 allows lamp capsule 32 to be sealed to the gasket 64, and thereby close off the reflector passage 48. Capsule sealing surface 46 is a ring shape, whose normal is approximately parallel to the optical axis 18. The ring, which may be circular or otherwise, extends around lamp capsule 32 so as to follow along and to mate with the gasket 64 which is also mated to the corresponding reflector sealing surface 28.

(27) Conventionally, retainer 36 can have holding cup 80, which may be sheet metal, formed to engage light source 38. Where light source 38 is a filament lamp having light-emitting coil and press seal 88, retainer 36 can engage press seal 88. Holding cup 80 is supported by pedestal 74 having mounting feet 76 and optionally attached to clip ring 66. Clip ring 66 may be formed of sheet metal and has mounting tongues 70 which mount into an upper region of plastic base 34 such as by retention in notch 69. Optionally retainer 36 or pedestal 74 mounts directly to base 34 at an upper region thereon. A respective mounting foot 76 abuts atop a respective retaining key 42 to connect to base 34 and for stability. In known constructions, retainer 36 may be received somewhat internally within a cavity of base 34 forming passageway 45, or somewhat atop an upwardly-facing lip of base 34.

(28) Conventionally, base 34 and wall 43 define a cavity or passageway 45 for electrical leads 90 from light source 38 to be received therein to then form an electrical pathway with electrical lugs 92 located in a lower region of base 34 which is typically narrower than the upper region of base 34 supporting the wall. The lower region of base 34 thus provides mechanical and electrical connection to a wiring connector supplying power from the vehicle.

(29) Conventionally lamp capsule 32 includes a bias spring 52. The spring bias 52 is positioned to act between the internal wall 20 and the lamp capsule 32 so as to press between the reflector and the lamp capsule 32 in a direction orthogonal to the lamp axis 18. FIG. 3 shows a perspective view of a conventional spring 52.

(30) A conventional separate piece-part metal spring 52 is shown in FIG. 3 showing a detail cut-away of lamp capsule 32, such as similar to embodiments of lamps sold by Osram Sylvania Inc. designated as the H13-style and sold under the registered trade name Sylvania. The bosses 11, also called shelf surfaces, support separate metal spring 52, such as by bracing it at its two opposed terminal ends and also at two intermediate regions adjacent the projecting nose of the spring.

(31) In an alternate conventional construction of lamp capsule 32 illustrated in FIG. 5, showing a detail cut-away view of base 34 sectioned above the spring (in a direction towards the narrow proximal end of base 34 having the electrical contact lugs 92), the plastics material portion of base 34 does not have retaining keys 42 molded into it, but rather retaining keys 42 are formed of sheet metal, typically in one integral part monolithically formed with sheet-metal retainer 36, and the resulting part mated to the plastics material lower portion of base 34 containing electrical contact lugs 92 for making contact with an external power supply.

(32) In present embodiments shown in FIGS. 6-15, and having particular regard to the foregoing description of overall construction of a lamp capsule and operation of the lamp capsule in the reflector, like reference numerals connote like structure and operation of parts, the difference to the prior art lamp capsules 32 discussed hereinabove residing in the difference of the construction of the bias spring.

(33) FIGS. 6-10 show base 34 molded of a plastics material and having spring 5 molded integrally into wall 43 of the base. The spring 5 is molded monolithically with base 34. Such monolithic molding of spring 5 with the remaining portions of wall 43 can be said to result in a unitary part. Spring 5 on base 34 is molded with at least one reflector-locating structure also on base 34, such as circumferential exterior locating surface 44 or retaining keys 42, or optionally both locating surface 44 and retaining keys 42. Monolithic molding of spring 5 on base 34 with locating surface 44 can advantageously reduce misalignment or tolerance between the outer peripheral position of spring 5 and locating surface 44 which locates capsule position into reflector 12. Preferably, retaining keys 42 are also molded as part of tubular wall 43. Cavity or passageway 45 in wall 43 accommodates electrical leads 90. The wall 43 defines a circumferentially extending exterior locating surface 44, as described hereinabove. Spring 5 is formed in an aperture 6 defined in wall 43. Spring 5 can be configured as a curved beam. Spring 5 is preferably formed as a cantilevered beam, connected at one lateral side, being a proximal beam end, of aperture 6; thus, the distal end of spring 5 is a free end. Alternatively a beam forming spring 5 could be formed as a film or bulge from wall 43, connected at more than one side of the beam.

(34) As shown in FIG. 7, light source 38 can be a filament lamp. Such filament lamps have an envelope wall, typically made of glass, defining an enclosed volume within which the light-emitting filament is located. Such a lamp can have a press seal 88 closing the enclosed volume, and electric leads 90 for the light source extend from the enclosed volume through press seal 88. Such electric leads 90 connect to electrical contact lugs located within a passageway at a lower region of base 34. Alternatively it is understood that light source 38 could be formed as a solid-state light source such as one or more light-emitting diodes (LEDs) located within a spatial envelope and which are arranged with respect to an optical axis 39 and are supplied by analogous electric leads 90, but without a press seal 88; in such an arrangement, a retainer 36 would be suitably adapted to support an LED light source, as is understood by the ordinary worker in the art.

(35) FIGS. 7-10 show that spring 5 can be flush or approximately flush with an interior surface of wall 43 where a cavity or passageway 45 for electrical leads is defined, thus avoiding an interference with electrical leads disposed therein. Advantageously, Applicant's embodiments avoids the conventional support bosses 11 (contrast FIGS. 3, 5).

(36) Base 34 and spring 5 can be molded as one unitary part, molded of conventional glass-filled resin such as the resin available under the trade name Amodel A-1145HS, available from the Solvay company, which is a 45% glass-filled, heat stabilized polyphthalamide (PPA) resin. The spring 5 can suitably have the dimensions shown in FIG. 10, which is a sectional view taken above spring 5. At the distal end of the spring-beam, the spring 5 has a radially outwardly facing protuberance or nose 8. The nose 8 may be thicker, in a width direction transverse optical axis 39, then the thickness of the beam along most of its length that defines spring 5. The nose 8 extends radially outward of the exterior locating surface 44 of wall 43. An overall diameter from an outer surface of nose 8 to the opposite side of exterior locating surface 44 is about 27.5 mm. Therefore the outermost surface of nose 8 of spring 5, in rest or neutral position, extends about 0.8 or 1 mm beyond outer surface 44 adjacent to aperture 6 and spring 5. Spring 5 may be curved, preferably continuously curved, along its length. Spring 5 may be suitably radiused at transition regions at its distal end to form nose 8, such as by having a relief radius. The outwardly-facing surface of nose 8 is suitably radiused to smoothly engage relevant surfaces of reflector 12, such as with an outwardly-convex radius of about 2 mm, as shown. Spring 5 may be curved along its length at a radius of about 11.75 mm centered on the internal cavity or center of exterior surface 44, as shown. Applicants herein determined that when spring 5 was molded as described herein and was then deflected at about 1.08 mm, the deflection force was generally at least about 11.7 N, thus satisfying, and exceeding, the lower regulation limit of 9 N. One of ordinary skill in the art using no more than conventional knowledge understands to choose suitable dimensions of length, width and height of the beam forming integral-molded spring 5 to achieve a desired deflection force.

(37) In an embodiment shown in FIGS. 11 to 15, a portion of base 34 is formed of a sheet material, with spring 5 formed of one piece with the sheet material that forms wall 43 and outer surface 44. This construction is useful in lamps conventionally designated as the H8-16 style. The sheet material may suitably be sheet metal, a material similar to that of metal retainer 36 to retain light source 38. As shown in FIG. 13 showing in detail a cross-sectional view cut transverse to optical axis 39 just above the spring beam, spring 5 may suitably be flush with inner surface of wall 43 to provide clearance in passageway 45 for electrical leads 90 (not shown). To assemble lamp capsule 32, base 34 is coupled to a lower socket portion to connect electrical contact lugs 92 (see FIGS. 14-15), and formed to make mechanical and electrical connection to a wire connector supplying power from the vehicle.

(38) While a preferred embodiment of the present disclosure has been described, it should be understood that various changes, adaptations and modifications can be made therein without departing from the spirit of the disclosure and the scope of the appended claims. The scope of the disclosure should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents. Furthermore, it should be understood that the appended claims do not necessarily comprise the broadest scope of the disclosure which the applicant is entitled to claim, or the only manner in which the disclosure may be claimed, or that all recited features are necessary.

(39) The following is a non-limiting list of reference numeral used in the specification: 2 reflector neck 5 spring (FIGS. 6-15) 6 aperture (FIGS. 6-15) 8 nose of spring 5 10 vehicle headlamp system 11 boss (shelf) (FIG. 3) 12 reflector 14 exterior of reflector 16 inner optical surface of reflector 18 axis (optical) 20 internal wall 22 axial positioning surface 22 axial positioning surface 24 radial positioning surface 26 lead-in ramp (camming portion) 28 gasket seating surface 32 lamp capsule 32 lamp capsule (FIGS. 1, 4) 34 base of lamp capsule 34 base of lamp capsule (FIGS. 1, 4) 36 retainer 38 light source 39 light source axis 40 axial locating surface (cammed surface) 42 retaining key (follower arm) 43 wall 44 lamp capsule outer locating surface 45 passageway (cavity) 46 capsule (gasket) seating surface 48 bore of neck 50 socket 52 separate piece-part bias spring (FIGS. 1, 3, 4) 64 gasket 66 clip ring 69 mounting notch 70 tongue 74 pedestal 76 mounting foot 80 cup 88 press seal 90 electrical lead 92 electrical contact lug