Vehicle mini lamp

• US 7,658,524 B2
• Filed: 03/10/2005
• Issued: 02/09/2010
• Est. Priority Date: 03/10/2004
• Status: Expired due to Fees

• Current Assignee: Truck-Lite Company LLC (Truck-Lite Holdings 2 Corp.)
• Original Assignee: Truck-Lite Company Incorporated (Truck-Lite)
• Inventors: Wagner, Adam, Johnson, Gary, Schwab, Kurt L., DiPenti, Timothy A., Bartkowski, Robert C., Ehrlich, Rodney
• Primary Examiner(s): Lee; Jong-Suk (James)
• Assistant Examiner(s): MACCHIAROLO, LEAH SIMONE
• Application Number:
  US11/077,919
• Publication Number:
  US 20050207176A1
• Time in Patent Office: 1,797 Days
• Field of Search: 362/153, 362/153.1, 362/154, 362/227, 362/362, 362/364, 362/470, 362/485, 362/487, 362/493, 362/496, 362/498, 362505-507, 362540-546, 362/800, 362/548, 362/549
• US Class Current: 362/545
• CPC Class Codes: B60Q 1/0088 Details of electrical connections B60Q1/305 takes precedence; electrical connection of the light source itself F21S41/192, F21S43/195
• CPC Class Codes: B60Q 1/2623 Details of the fastening means
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• CPC Class Codes: B60Q 1/32 for indicating vehicle sides , e.g. clearance lights
• CPC Class Codes: F21V 31/04 Provision of filling media
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

The present invention is a small vehicle lamp comprised of: a generally cylindrically-shaped housing with an axial bore therethrough and forming a top opening and a bottom opening; a lens disposed on the top surface of the housing; a circuit board within the axial bore of the housing; at least one LED mounted on and electrically connected to the circuit board; a resistor disposed on the circuit board; a first cable wire and a second cable wire passing through the bottom opening of the housing and in electrical contact with the circuit board; and an potting compound disposed within the housing bore, in which the epoxy covers the resistor and circuit board and at least partially covers the LED and the cable wires. The lamp is configured such that it has a low profile and can be part of a system in which a plurality of the lamps are used on a vehicle.

Claims

1. A device comprising:

a generally cylindrically-shaped housing having an outer surface, an inner surface, a top end, a bottom end, and with an axial bore therethrough, said axial bore forming a top opening and a bottom opening;

a lens having a top surface, said lens being disposed on said top end of said housing;

a circuit board disposed within said axial bore of said housing, said circuit board having a top surface, a bottom surface, and electrical circuitry disposed thereon;

at least one LED mounted on and electrically connected to said circuit board, forming a first electrical connection;

a resistor disposed on and in electrical contact with said circuit board, forming a second electrical connection;

a first cable wire and a second cable wire contained within a cable, said first cable wire and said second cable wire passing through said bottom opening of said housing and in electrical contact with said circuit board, forming a third electrical connection and a fourth electrical connection;

an attachment member disposed substantially around said housing, said attachment member having an upper surface and a recess adapted to receive said lens and create a flush meeting between said top surface of said lens and said upper surface of said attachment member, said attachment member being adapted to permanently or non-permanently secure said vehicle lamp to a mounting structure; and

a mounting structure having a first wall, a second wall and a third wall, said second and third walls extending perpendicularly from said first wall and being spaced apart to define a channel therebetween, said first wall having an aperture adapted to received said housing such that said cylindrically-shaped sidewall extends within said channel, wherein said mounting structure protects said vehicle lamp from damage, said mounting structure being made of a material selected from a group consisting of aluminum, A36 steel, plastic, wood, and fiberglass.

2. A method for assembling a vehicle mini lamp comprising the steps of:

affixing a plurality of electrical components to a circuit board, said circuit board having a top surface and a bottom surface, wherein said circuit board is comprised of a plurality of traces disposed on said top surface and said bottom surface, and said electrical components are selected from a group of components consisting of a resistor, a plurality of cable wires, and at least one LED, each of said electrical components electrically interconnected via said traces;

positioning said electrical components and said circuit board within a housing, wherein said housing is comprised of an inner surface, an outer surface, a top surface, a bottom surface, and an axial bore therethrough, said axial bore forming a top opening and a bottom opening;

affixing a lens to said housing; and

positioning said housing within an attachment member, said attachment member having a aperture therein adapted to receive said housing and an upper rim surface extending outwardly from said aperture and being substantially flush with said upper surface of said lens, said attachment member being adapted to attach said vehicle lamp to a vehicle such that said vehicle lamp has a low profile in relation to said vehicle.

3. The method of claim 2, wherein said lens is selected from a group consisting of:

a red lens, emitting a generally red light from said vehicle mini lamp;

or a yellow-amber lens, emitting a generally yellow-amber light from said vehicle mini lamp;

or a clear lens and said at least one LED emits red light, emitting red light from said vehicle mini lamp;

or said at least one LED emits yellow-amber light, emitting yellow-amber light from said vehicle mini lamp.

4. The method of claim 2, wherein said inner surface of said housing is tapered or further comprised of a ledge, said tapered inner surface or said ledge of said housing being adapted to receive and support said circuit board.

5. The method of claim 2, wherein said lens is securely connected to said housing by a method selected from a group comprised of high frequency welding, hot gas welding, ultrasonic welding, hot plate welding, vibrational welding, an adhesive, a snap-fit, threaded engagement, and using a fastener, said fastener selected from a group comprised of a snap-ring, at least one rivet, and at least one screw.

6. The method of claim 2, wherein said circuit board is further comprised of a plurality of throughholes, each of said plurality of throughholes being plated with an electrically conductive material to allow electrical continuity between said electrical circuitry on said top surface and said electrical circuitry on said bottom surface.

7. The method of claim 6, wherein said at least one LED is further comprised of a plurality of leads, each of said plurality of throughholes of said circuit board adapted to receive one of said plurality of leads of said at least one LED and allow said at least one LED to be electrically connected to said bottom surface of said circuit board, but positioned above said top surface of said circuit board.

8. The method of claim 2, wherein said at least one LED is electrically connected to said top surface of said circuit board.

9. The method of claim 2, wherein said at least one LED is further comprised of a plurality of leads, each of said plurality of leads electrically connected to said top surface of said circuit board and creating a space between said at least one LED and said circuit board, and wherein said resistor is electrically connected to said top surface of said circuit board and disposed in said space between said at least one LED and said circuit board.

10. The method of claim 2, wherein said resistor is electrically connected to said bottom surface of said circuit board.

11. The method of claim 2, wherein said affixing step is selected from a group comprised of soldering, clinching, or an adhesive.

12. The method of claim 2, wherein said vehicle mini lamp is further comprised of a cable seal, said cable seal disposed on said first cable wire and said cable wire within said housing and creating a sealed chamber within said housing.

13. The method of claim 2, wherein said vehicle lamp is one of a plurality of vehicle mini lamps mounted to a mounting structure and interconnected to one light source via a splitter assembly, said splitter assembly comprised of a connector wire connected to a power source, said connector wire comprised of a third cable wire and a fourth cable wire, a splitter housing, a plurality of cables, each of said plurality of cables containing said first cable wire and said second cable wire, and a plurality of splices within said housing, wherein a first of said plurality of splices connects said third cable wire of said connector wire to said first cable wire of each of said plurality of cables and a second of said plurality of splices connects said fourth cable wire of said connector wire to said second cable wire of each of said plurality of said cables, such that each of said plurality of vehicle lamps operates parallel to one another.

14. A low profile vehicle lamp assembly comprising:

a cylindrically-shaped housing having a top end, body with an interior portion, outer surface and a lens portion covering said top end, said housing adapted to fit within an opening in a surface such that said lens portion is substantially flush with the surface and said body is positioned behind said surface, said lens having an annular lip that extends beyond said outer surface of said cylindrically-shaped housing, said lip being substantially flush with said surface;

circuitry disposed within said interior portion of the housing;

at least one light source being electrically connected to said circuitry; and

a mounting structure having a first wall, a second wall and a third wall, said second and third walls extending perpendicularly from said first wall and being spaced apart to define a channel therebetween, said first wall having an aperture adapted to receive said housing, wherein said mounting structure protects said vehicle lamp from damage.

15. A low profile vehicle lamp assembly comprising:

a cylindrically-shaped housing having a top end, body with an interior portion, outer surface and a lens portion covering said top end, said housing adapted to fit within an opening in a surface such that said lens portion is substantially flush with the surface and said body is positioned behind said surface, said lens having an annular lip that extends beyond said outer surface of said cylindrically-shaped housing, said lip being substantially flush with said surface;

circuitry disposed within said interior portion of the housing;

at least one light source being electrically connected to said circuitry; and

an attachment member having a aperture therein adapted to receive said housing and an upper rim surface extending outwardly from said aperture and being substantially flush with said lens, said attachment member being adapted to attach said vehicle lamp to a vehicle such that said vehicle lamp has a low profile in relation to said vehicle.

16. A low profile vehicle lamp assembly comprising:

a housing having a top end, body with an interior portion and a lens portion covering said top end;

circuitry disposed within said interior portion of the housing;

at least one light source being electrically connected to said circuitry; and

an attachment member having a aperture therein adapted to receive said housing and an upper rim surface extending outwardly from said aperture and being substantially flush with said lens portion, said attachment member being adapted to attach said vehicle lamp to a vehicle such that said vehicle lamp has a low profile in relation to said vehicle.

17. The low profile vehicle lamp assembly of claim 16 further including a mounting structure having a first wall, a second wall and a third wall, said second and third walls extending perpendicularly from said first wall and being spaced apart to define a channel therebetween, said first wall having an aperture adapted to receive said attachment member wherein said mounting structure protects said vehicle lamp from damage.

18. The vehicle lamp of claim 16, wherein said attachment member attaches to a wall of a vehicle.

19. The vehicle lamp of claim 16, wherein said attachment member attaches to a portion of a mounting structure.

20. The vehicle lamp of claim 16, wherein said lens is selected from a group consisting of:

a red lens, emitting a generally red light from said vehicle lamp;

a yellow-amber lens, emitting a generally yellow-amber light from said vehicle lamp;

or a clear lens and said at least one light source emits red light, emitting red light from said vehicle lamp;

or said at least one light source emits yellow-amber light, emitting yellow-amber light from said vehicle lamp.

21. The vehicle lamp of claim 16 further comprising a circuit board having said circuitry mounted thereon.

22. The vehicle lamp of claim 21, wherein said housing includes an inner surface being tapered or including a ledge, said tapered inner surface or said ledge of said housing being adapted to receive and support said circuit board.

23. The vehicle lamp of claim 21, further including a resistor electrically connected to said circuit board.

24. The vehicle lamp of claim 16, wherein said housing is made of a material selected from a group consisting of polycarbonate plastic and acrylic, and wherein said lens is made of a material selected from a group consisting of polycarbonate plastic, acrylic, and glass.

25. The vehicle lamp of claim 16, wherein said vehicle lamp is further comprised of a potting compound for filling at least a portion of said housing.

26. The vehicle lamp of claim 16, wherein said upper rim surface of said attachment member is arcuate and said lens is generally arcuate to form a generally flush surface.

27. The vehicle lamp of claim 16, wherein said attachment member is formed from a flexible material.

28. The vehicle lamp of claim 16 wherein said attachment member is formed from rigid material.

29. The vehicle lamp of claim 16, wherein said vehicle lamp is adapted for use as a clearance lamp, a side marker lamp, or an identification lamp.