Abstract:
A curing lamp apparatus mounts to a work surface with a suction cup. A base is mounted to the suction cup. A flexible neck extends from the base to the lamp head. The lamp head includes a lamp element with first and second UV light sources which emit UV light at different wavelengths. A control circuit is located in the base. A heat sink is provided on the lamp head including a conductive plate and projecting pins. A protective housing encloses the plate and pins. A timing circuit controls the light source for automatic shut off. External or internal power is provided for the control circuit.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit from U.S. Provisional Patent Application Ser. Nos. 61/310,465, filed Mar. 4, 2010, and 61/411,784, filed Nov. 9, 2010, the disclosures of which are hereby incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to curing lamps for curing repair material used to repair cracks in windshields or other glass or plastic materials. 
     BACKGROUND OF THE INVENTION 
     When a windshield or other glass or plastic material becomes cracked, a resin or other repair material can be used to repair the crack. Various repair bridges or devices with resin injectors are known for applying repair resin to the crack including devices shown in U.S. Pat. Nos. 5,565,217; 5,776,506; 6,139,300 and 6,302,670. 
     Often the repair material needs to be cured with an ultraviolet (UV) light source. Lamps including a UV light source are known which are positioned adjacent to the windshield or other surface, close to the crack to cure the repair material positioned in the crack. An example lamp is shown in U.S. Pat. No. 7,131,752. A common wavelength for curing lamps is 365 nanometers. 
     There is a need for further improvements with respect to curing lamps. 
     SUMMARY OF THE INVENTION 
     The present invention includes a curing lamp apparatus for mounting to a work surface including a suction cup engageable with the work surface, and a base mounted to the suction cup. A lamp head extends from the base and includes a lamp element. The lamp element includes a first UV light source emitting UV light at a first wavelength, and a second UV light source emitting UV light at a second wavelength. 
     A further aspect of the present invention relates to a curing lamp apparatus for mounting to a work surface including a suction cup engageable with the work surface, and a base mounted to the suction cup. A lamp head extends from the base and includes a lamp element for emitting UV light. In one embodiment, a flexible neck connects the lamp head to the base. The flexible neck allows bending and rotation about the neck. 
     In a further aspect, the lamp head includes a heat sink. In one implementation, the heat sink includes a plate and projecting pins. A housing surrounds the heat sink. 
     In a still further aspect, the lamp element includes a substrate including a plurality of dies which include LED emitting structures. A reflector mounts to the substrate. A lens covers the reflector. 
     Another aspect of the present invention relates to a method of repairing a structure comprising applying resin to a crack on a first side of the structure to be repaired; and mounting a base of a lamp apparatus to a second side of the structure, wherein the second side is opposite to the first side. The method further comprises directing UV light from a lamp element connected to the base through the structure to cause curing of the resin in the crack. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a first perspective view of a curing lamp in accordance with one embodiment of the present invention. 
         FIG. 2  is an opposite side perspective view of the curing lamp shown in  FIG. 1 . 
         FIG. 3  is another opposite side perspective view of the curing lamp shown in  FIG. 1 . 
         FIG. 4  is a side view of the curing lamp of  FIG. 1 . 
         FIG. 5  is an opposite side view of the curing lamp of  FIG. 4 . 
         FIG. 6  is an end view of the curing lamp of  FIG. 4 . 
         FIG. 7  is an opposite end view of the curing lamp of  FIG. 6 . 
         FIG. 8  is a top view of the curing lamp of  FIG. 4 . 
         FIG. 9  is another perspective view of the curing lamp of  FIG. 1 , showing the lamp head rotated relative to the base about the neck, and showing the curing lamp mounted to a windshield being repaired. 
         FIG. 10  is an exploded bottom perspective view of the curing lamp of  FIG. 1 . 
         FIG. 11  is an exploded top perspective view of the curing lamp of  FIG. 1 . 
         FIG. 12  is a top perspective view of the top cover of the base. 
         FIG. 13  is a side view of the top cover of the base. 
         FIG. 14  is an end view of the top cover of the base. 
         FIG. 15  is a top perspective view of the bottom portion of the base. 
         FIG. 16  is a top view of the bottom portion of the base. 
         FIG. 17  is a side view of the bottom portion of the base. 
         FIG. 18  is an end view of the bottom portion of the base. 
         FIG. 19  is a perspective view of the lamp substrate. 
         FIG. 20  is a front view of the lamp substrate of  FIG. 19 . 
         FIG. 21  is an enlarged view of a portion of the lamp substrate of  FIG. 20 . 
         FIG. 22  is an example use of the curing lamp on a windshield being repaired. 
         FIG. 23  is a first perspective view of another embodiment of a curing lamp in accordance with the present invention. 
         FIG. 24  is an opposite side perspective view of the curing lamp shown in  FIG. 23 . 
         FIG. 25  is another opposite side perspective view of the curing lamp shown in  FIG. 23 . 
         FIG. 26  is a side view of the curing lamp of  FIG. 23 . 
         FIG. 27  is an opposite side view of the curing lamp of  FIG. 26 . 
         FIG. 28  is a top view of the curing lamp of  FIG. 23 . 
         FIG. 29  is an exploded top perspective view of the curing lamp of  FIG. 23 . 
         FIG. 30  is an exploded bottom perspective view of the curing lamp of  FIG. 23 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to  FIGS. 1-21 , a lamp apparatus  10  for curing repair resin in accordance with one preferred embodiment of the present invention is shown. Lamp apparatus  10  includes a base  12  including at least one suction cup  14  used for mounting lamp apparatus  10  to a windshield or other surface to be repaired. Extending from base  12  is a neck  16  terminating in a lamp head  18 . Lamp head  18  includes a lamp element  20  for emitting UV (ultraviolet) light on the windshield. The UV light is used to cure repair material positioned in a crack within the windshield.  FIG. 9  shows the lamp apparatus  10  mounted on a windshield  100  adjacent a break  102 . 
     Suction cup  14  secures base  12  to the windshield as desired by the user. Suction cup  14  defines a longitudinal axis  28 . Suction cup  14  includes a bottom  24  which creates a sealing surface with the windshield. Knobs  26  allow for opposite sides of suction cup  14  to be pulled toward base  12 . Such action is useful to mount suction cup  14  to the windshield. Such action is also useful to remove suction cup  14  from the windshield. 
     Base  12  includes a top cover  32  and a bottom portion  34  which form an enclosed housing. Airflow slots  36  are provided within base  12 . Base  12  includes the control circuitry for lamp apparatus  10 . A switch  38  allows for user control from an exterior of base  12 . Base  12  also includes a power connector  40  for connecting to an external power supply, or a battery charger. Disposed within base  12  is a rechargeable battery  42 . A PCB  44  with the control circuitry is also contained within base  12 . Conductors extend from PCB  44  through neck  16  to lamp head  18  for controlling lamp element  20 . 
     Neck  16  allows for relative movement between base  12  and lamp head  18 . In the illustrated embodiment, neck  16  can be rotated about longitudinal axis  48 . Neck  16  can also be bent relative to axis  48 . With such flexibility, lamp head  18  can be placed into a variety of positions relative to base  12 . Compare  FIGS. 2 and 9  which show rotation of lamp head  18  relative to base  12 . In one embodiment, neck  16  includes Loc-Line® fittings which allow for rotation of head  18 , or bending movement, or both. 
     Lamp head  18  includes a housing  56  which holds lamp element  20 . Lamp head  18  also includes a heat removal device, such as a heat sink  60 , for use in cooling lamp element  20 . Heat sink  60  includes a base  62  and projecting pins or rods  64 . A heat sink housing  66  surrounds base  62  and rods  64  to protect from damage, and to protect the user from any sharp edges. Heat sink housing  66  defines a cage around rods  64  to protect the heat sink and allow for airflow to contact the heat sink to promote cooling. 
     Lamp element  20  includes a substrate  76  or PCB  76  which includes a plurality of dies  78  which emit the desired UV light. The substrate  76  includes tracings  80 . Side notches  82  allow for substrate  76  to mount together with heat sink  60  with fasteners  88  into sockets  90  in heat sink base  62 . A reflector  84  concentrates the light, and a protective lens  86  covers reflector  84 . 
     An array of dies  78  is provided on substrate  76 . (See  FIG. 21 ). Each die emits light at a certain wavelength. In one embodiment, an array of five rows of eight dies are provided. Three rows  280  emit light at 365 nanometers. Two rows  282  emit light at 395 nanometers. In the example embodiment, the rows alternate. In other embodiments, all of the dies  78  emit UV light at the same wavelength. 
     The preferred embodiment includes at least two dies which emit light each at a different wavelength. Both 365 and 395 nanometers wavelengths are considered in the ultraviolet range. One advantage for providing UV light at 395 nanometers is that lamp apparatus  10  can be used from an opposite side of the windshield of an automobile. Compare  FIG. 9  to  FIG. 22 . In  FIG. 9 , lamp apparatus  10  is shown on the same side of the windshield  100  as break  102 . As shown in  FIG. 22 , lamp apparatus  10  is shown on an opposite side of the windshield  100 , from break  102 . Repair bridge  104  is mounted to exterior surface  106  of windshield  100 . Lamp apparatus  10  is mounted to interior surface  108 . 
     Windshield  100  includes an outer layer  110 , a middle layer  112 , and an inner layer  114 . Typically, middle layer  112  is a plastic film layer. In the illustrated example, break  102  occurs within outer layer  110 . Injector  116  of bridge  104  is a repair device used to apply repair resin  120  to break  102 . As shown, injector  116  includes a pressure port  124  and a mechanical probe  126 . Lamp apparatus  10  can be used on either side of windshield  100 . Lamp element  20  includes emission of light at 365 nanometers which works with many resins to cause curing when used on the same side as the break. 
     As noted, lamp element  20  also emits light at a wavelength different from 365 nanometers. With such a construction, lamp apparatus  10  can cure resin through a windshield which includes polyvinylbuterol (PVB) treated to block UV light at 365 nanometers or other certain types of solar protective materials. The PVB layer (e.g., layer  112 ) tends to block light at 365 nanometer wavelengths, but passes the noted 395 nanometer wavelengths. The light blocking properties for layer  112  are beneficial as it reduces sunlight damage to an automobile&#39;s interior. However, the light blocking properties of windshield  100  prevent the 365 nanometer wavelengths from light source  20  of lamp apparatus  10  from reaching the resin to be cured. The 395 nanometer wavelength emitted from lamp element  20  is able to pass through windshield  100  in order to reach the applied resin material to be cured in break  102 . 
     By allowing lamp apparatus  10  to be mounted on an opposite side of windshield  100 , more room is available for the repair technician to access break  102 . Also, curing from the bottom of break  102  allows for the resin to shrink into the crack as it cures. 
     The PCB  44  is equipped with a timer that is programmed to start when switch  38  is pushed and remain on for an appropriate length of cure time. In the example embodiment, five minutes is selected. The timer shuts off the light automatically. When switch  38  is pushed and held in during the five minute cycle, the lamp element  20  shuts off, after approximately 5 seconds. The cycle is started over again when switch  38  is pushed again. The input to the circuit of PCB  44  comes from two different sources. One input is a rechargeable battery, such as an 11.1 VDC lithium ion or lithium polymer battery. The second input is a barrel type DC receptacle jack  40  that can be accessed outside base  12  for an external battery source or a 12 VDC AC/DC converter. In the preferred embodiment, the circuit accepts 9-14 VDC and boosts it to approximately 18.5 volts controlling the current output at 270 milliamps (MA). Jack  40  is used to recharge the battery. 
     Referring now to  FIGS. 10-21 , additional details of lamp apparatus  10  are shown. Suction cup  14  mounts to bottom portion  34  of base  12  with screws  200  which pass through apertures  202  in bottom  34  into sockets  204  of suction cup  14 . Bottom portion  34  of base  12  further defines a side aperture  206  for switch  38 . A second side aperture  208  in recess  209  in bottom portion  34  aligns with power connector  40  mounted on PCB  44 . PCB  44  mounts with screws  210  which are received in sockets  212  in bottom portion  34  after passing through apertures  214 . 
     Base  12  defines a pocket for holding battery  42  above PCB  44 . Bottom portion  34  includes a front rib  220  and a rear rib  222  which capture ends of battery  42 . Side ribs  224 ,  226  include a middle channel  228 . Top cover  32  includes a front tab  230  which is received in a slot  232  of bottom portion  34 . Top ribs  234 ,  236  with middle channels  237  cooperate with side ribs  224 ,  226  for positioning of the battery. A fastener  238  passes through aperture  240  of bottom portion  34  and into a socket  242  of top cover  32 . A front wall  244  of bottom portion  34  includes an aperture  246 . Front aperture  246  receives an end of neck  16  and allows for electrical cables to pass out of base  12  and into neck  16  for passage to lamp head  18 . 
     Neck  16  includes a first connector  248 , a female/male connector  250 , a male/male connector  252 , and a second connector  254 . Both first and second connectors  248 ,  254  are threaded for threadably mounting to base  12  and lamp head  18 , respectively. Each of the elements of neck  16  includes one of the mating ball and socket connection ends which allow for three-dimensional bending movement, and rotation about the neck axis  48 . More elements can be added if a longer neck  16  is desired. 
     Lamp head  18  includes a bulkhead plate  260  with an aperture  262  for receiving neck  16 . Bulkhead plate  260  mounts with screws  266  through apertures  268  into sockets  270  of base  62  of heat sink  60 . Housing  56  mounts with fasteners  280  through apertures  282  into sockets  272  also on base  62  of heat sink  60 . 
     Heat sink housing  66  includes a body  170 , with an open bottom  172  with a protective flange  174 . Open ends  176  are provided on body  170 . Sides  178  connect bottom  172  to top  180 . Sides include first openings  179 . Top  180  includes second openings  182 . 
     Referring now to  FIGS. 23-30 , a lamp apparatus  310  for curing repair resin in accordance with another preferred embodiment of the present invention is shown. Lamp apparatus  310  is similar in many respects to lamp apparatus  10 . Lamp apparatus  310  includes a base  312  including at least one suction cup  314  used for mounting lamp apparatus  310  to a windshield or other surface to be repaired. Extending from base  312  is a flexible neck  316  terminating in a lamp head  318 . Lamp head  318  includes a lamp element  320  for emitting UV light on the windshield. Lamp element  320  emits light at least two wavelengths like lamp element  20 . 
     Base  312  includes a top cover  332  and a bottom portion  334  which form an enclosed housing for battery  342 . Battery  342  and base  312  have a different shape relative to base  12  and battery  42  noted above. Base  312  closely surrounds battery  342  and the control circuitry. 
     Base  312  includes similar control circuitry for controlling lamp element  320 . A PCB  344  with a control circuit is contained within base  312 . Bottom portion  334  of base  312  includes a side aperture  408  in a recess  409  which aligns with a power connector  340  mounted on PCB  344 . PCB  344  also includes an indicator light  345 . When battery power becomes low (under 9 volts), indicator light  345  comes on and remains on until the battery is charged again. 
     Lamp head  318  includes a housing  356  which holds lamp element  320 . Lamp head  318  also includes a heat sink  360  like heat sink  60  and a heat sink housing  366  to protect heat sink  360  from damage, and to protect the user from any sharp edges. Heat sink housing  366  includes a body  380  with various openings  382  to allow for airflow.