Light retainer assembly and heated light assembly

A light retainer is provided with a grommet having a tubular body with an inner surface providing a cavity with a first inner groove and a second inner groove spaced lengthwise of the body from the first inner groove, the first inner groove configured to receive a heated lens and the second inner groove configured to receive a light. A heated light assembly is also provided with a grommet, a heated lens and a light.

TECHNICAL FIELD

This disclosure pertains to heated lights and heated lamps. More particularly, this disclosure relates to apparatus for supporting a heated lens in front of a light in order to melt snow and ice and remove condensation from lenses of lights and lighting systems for mobile and stationary applications.

BACKGROUND OF THE INVENTION

Techniques are known for heating lamps and lighting systems. One technique involves providing a heating wire on a back surface of a cover element provided over a vehicle light. However, such a system does not necessarily provide thermal protection for overheating. Secondly, such a system does not readily provide a heated lens to a self-contained light assembly, such as an LED light assembly. For example,FIG. 5illustrates a prior art light grommet42that is received within a cylindrical aperture40in a fender panel38of a vehicle36configured to retain a self-contained LED light assembly52between a pair of circumferential and radially inwardly extending flanges44and46. A pair of circumferential and radially outwardly extending flanges48and50trap grommet within aperture40to retain light assembly52securely therein. A power supply (or current source)22, such as a battery and/or alternator powers LED lights in assembly52. Assembly52includes an integrally formed front lens provided over individual LEDs. However, ice or condensation can form over such lens causing obstruction of light there through. A need exists to interchange such a light assembly to provide a heated lens that removes ice and/or condensation from in front of the LED lights, as LED lights do not generally generate as much heat as do traditional incandescent lights. Such a system does not necessarily provide an ability to modify an existing lamp by merely replacing an existing lamp bulb with a new lamp assembly and grommet that heats the lens sufficient to melt snow and/or ice from the lens. Finally, the recent adoption of LED lighting systems, which generate very little heat, increases the problem of snow and ice accumulating on the lens of such a lighting system. Accordingly, improvements are needed to better enable removal of ice, snow and condensation from lenses of lights and lighting systems.

SUMMARY OF THE INVENTION

A heated light is provided with a heating wire in a lens that is supported within a light mounting grommet in front of an LED light assembly in order to defrost and clear moisture and/or ice that can cover the lens with snow, ice, or vapor. By heating the lens, accumulation of snow, ice, or vapor is mitigated or eliminated from a surface of the lens, thereby enabling light to transmit through the lens. Applications include lamps and bulbs on conveyance devices, including vehicles, boats, planes, and trains, as well as sedentary structures, such as lamp posts, street lights, railroad crossing markers and lights, and airport ground and runway lighting systems.

According to one aspect, a light retainer is provided with a grommet having a tubular body with an inner surface providing a cavity with a first inner groove and a second inner groove spaced lengthwise of the body from the first inner groove, the first inner groove configured to receive a heated lens and the second inner groove configured to receive a light.

According to another aspect, a heated light assembly is provided having a grommet, a heated lens, and a light. The grommet has a tubular body with an inner surface providing a cavity with a first inner groove and a second inner groove spaced lengthwise of the tubular body from the first inner groove. The heated lens is carried in the first groove. The light is carried in the second groove.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1-4 and 6illustrate in simplified form a first version of a heated light assembly10. A mounting grommet20made of rubber or some other resilient silicon or synthetic material is provided for mounting a heated lens16over a lamp or light52(seeFIG. 6) or54(seeFIG. 8) in order to provide additional heat for melting any snow and/or ice that would otherwise build up on the light and obstruct light transmission during inclement or winter weather. A current source22, such as a vehicle battery or alternator provides power to operate the heated lens16via a thermostatic control12. Lens16has a heating wire14embedded therein (seeFIGS. 3 and 4) for heating lens16during inclement weather.

An electrical wiring harness (not shown) from the vehicle provides power to operate the light and heat the light assembly in an effort to remove presence of ice in the form of snow, graupel, hail or frost from a lens surface on the tail light assembly. Optionally, heated lamp10can be any of a number of lamps or lights, including side marker lights, head lights, cab lights, brake lights, or any other form of light on any type of conveyance or vehicle including ATVs, snowmobiles, boats, planes, cars, trucks, trains and other forms of transportation requiring a lens heater for removing accumulated snow and/or ice on operating lights associated with the conveyance. Furthermore, heated lamp10can be used on other lighting systems including sedentary structures, such as lamp posts, street lights (seeFIGS. 7 and 8), railroad crossing markers and lights, and airport ground and runway lighting systems. Furthermore, the embodiments depicted inFIGS. 9-17can also be used on such lighting systems.

In one case, heating wire14ofFIGS. 1 and 3comprises a Nichrome heating wire (or Nichromium wire) with a thermistor physically crimped to one end of the wire to provide an electrically conductive connection. As shown inFIGS. 3 and 4, wire14is physically press-fit into a complementary groove24formed in inner surface21of lens16. Optionally, a PTC thermistor alloy resistance wire can be substituted for wire14and thermostatic control12(ofFIG. 1). Thermostatic control12can also be provided by a thermistor (or thermal resistor). Further optionally, one or more conductive traces made from Indium Tin Oxide (ITO), a heat resistant film, can be deposited as a thin film directly onto surface21of lens16, or is deposited onto a layer that is subsequently adhesively affixed onto such surface. One suitable optional wire is sold as PTC Thermistor Alloy Resistance wire, sold by Senphus, Jiangyin Senphus Electrical Material Co., Ltd., No. 8, Taoyuan Rd., Chengchang Industrial Park, Huangtu Town, Jiangyin City, Jiangsu Province, China. Optionally, the thermistor can be replace with any form of thermostat, or with a thermocouple, or resistance temperature detector (RTD) and associated control circuitry, or other thermostat capable of limiting maximum heat output and providing thermostatic control to activate heat delivery from wire14to lens16. Lens can be either plastic or glass, or some other suitable optically transmissible material. Lens16can also be clear, or can be tinted a color, such as red, yellow, or blue, and includes a light-transmitting portion18.

Grommet20ofFIGS. 1 and 2includes a retention ring30that is secured via snap-fit or via fasteners to an inner surface of grommet body20, inboard of flange34. Grommet20is retained to a vehicle in an aperture that is trapped between flanges32and34. An LED light (not shown) is then retained between flanges26and28by urging the rubber flange26and inserting the LED light therein. Grommet20has a first radially-extending groove on an inner surface and configured to receive a heated lens, and a second radially-extending groove on spaced axially on an inner surface from the first groove and configured to receive a light or lamp module, such as an LED light. An outer surface19of lens16mates with ring30and an inner surface21of lens16is provided proximate flange28. Furthermore, grommet20includes a pair of radially-extending grooves on an outer surface and spaced axially apart to receive a flange provided by an aperture in a structure to which the grommet is mounted. For example, a sheet metal aperture on a bumper is received between flanges32and34to retain the grommet, LED lamp, and heated lens to the vehicle.

FIG. 6further illustrates details of heated light assembly10including thermostatic control12, current source22, mounting grommet20, and LED lamp52. An electrical connector assembly58enables mating and demating of current source22from lamp52and heating wire14. Lamp52is urged past flange26, in assembly, between flanges26and28. Lens16is assembled between flanges28and30. Finally, flanges32and34capture a rim flange of a structural aperture to retain the light assembly10to the structure, such as a vehicle.

In the case of a street light ofFIG. 7, a lamp housing54has a cylindrical outer shape that fits in the second groove provided by flanges26and28(seeFIG. 8), thereby providing a heated lens over an LED street light that is protected from accumulation of snow and/or ice during inclement or winter weather. A heated lens16is retained between flanges28and30. Individual LED lights56pass light through heated lens16even during inclement weather.

FIG. 9illustrates another version of a round heated vehicle tail light assembly110, similar to the assembly depicted inFIGS. 1-4 and 6, but in greater detail generated to scale from engineering drawings and depicting a grommet in centerline sectional view for supporting an LED light assembly and a heated lens covering the LED light assembly to enable heat removal of snow and/or ice that would otherwise build up on the LED light and obstruct light output. More particularly, a round resilient rubber, or synthetic rubber mounting grommet120retains a heated lens116optically in front of an LED light (or lamp assembly)152. Lens116is retained in assembly between a pair of first and second circumferential flanges128and130extending generally radially inwardly from an inner surface143. Lamp52is retained in assembly between a pair of the second flange128and a third circumferential flange126extending generally radially inwardly from the inner surface143. A cavity151(seeFIGS. 10 and 11) is provided within grommet120having a first inner groove129and a second inner groove127spaced lengthwise of the body from the first inner groove129.

As shown inFIG. 9, a rim flange, or bezel,134is formed on a radial outer edge of grommet120. Rim flange134has an angled end portion that cooperates with an angled flange132to form a receiving groove137that receives in urged relation, during assembly, a cylindrical structural rim167on a structure, such as a vehicle bumper or body. Rim167terminates in a radially inwardly extending leg169that defines an aperture140through which most of light assembly110is received. In assembly, leg169passed behind flange132which traps and retains grommet120(and assembly110) onto cylindrical rim167. A heating wire114is received within a groove in an inner surface of light-transmitting portion118of lens116. A circumferentially spaced apart array of nipples135are provided about an outer surface of grommet, behind flange132. Nipples135are resiliently urged within aperture140during assembly to further facilitate retention during assembly.

FIG. 10is a centerline sectional view of the grommet120ofFIG. 9. Grooves127and129are provided between pairs of flanges126,128and128,130, respectively. A clearance groove139is provided in flange128along with a longitudinal groove127(in inner surface143) and a radial groove144(in flange126) to enable routing of electrical wires to heat the lens, in assembly. Circumferential groove137is formed between flanges134and132, outwardly (in an axial direction) of an array of nipples135.FIG. 11is a front view of grommet, or light retainer120ofFIG. 10more clearly depicting groove141and cavity151

FIG. 15is a simplified centerline sectional view of the round heated vehicle tail light assembly ofFIG. 9with a light wiring harness and lens heating element wiring harness depicted in assembly within the grommet. Grooves, or cavities127and141are shown in grommet120to provide clearance for electrical wires170in assembly.

FIG. 15further depicts a heating element wiring harness170provided in series with a light wiring harness172and a connector assembly174for supplying electrical power (current) to both the LED light and the heated lens ofFIGS. 6-19 and 24. Both ground and tail light wires split out of a wiring harness adapter to provide ground and tail light connectors for powering the heated lens, as well as power the LED light from the vehicle power (battery and/or alternator). One branch from the wiring adapter provides plugs for the heater, and the other branch provides plugs to the LED light. Each branch is formed by a Y-branch, or electrical splitter.

FIG. 16a perspective view of the grommet, or light retainer120ofFIGS. 9-15. Circumferential grooves127and129are shown formed between flange pairs126,128and128,130, respectively. Bezel134forms a radial outermost edge of grommet120. In one version, grommet120is used to retain a tail light and a heated lens together. In another case, grommet120retains a front light or a side marker light together with a heated lens.

FIG. 17illustrates in perspective view yet another version of an oval grommet for a heated tail light assembly, similar to the version depicted inFIGS. 9-16. Grommet, or light retainer220has circumferential grooves227and229that are shown formed between flange pairs226,228and228,230, respectively. Bezel234forms a radial outermost edge of grommet220. In one version, grommet220is used to retain a tail light and a heated lens together. In another case, grommet220retains a front light or a side marker light together with a heated lens.

In compliance with the statute, embodiments of the invention have been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the entire invention is not limited to the specific features and/or embodiments shown and/or described, since the disclosed embodiments comprise forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.