Abstract:
The present invention comprises a lamp assembly with an integral circuit to provide electrical connectivity to the lamp and methods of making the lamp assembly. The integral circuit in one embodiment is constructed from a conductive polymer. The polymer may be injection molded, and the lamp assembly housing and integral circuit may be manufactured using a two-shot injection molding process. The present invention may be used in the production of a wide range of lamp assemblies, including vehicle headlamp assemblies.

Description:
BACKGROUND OF THE INVENTION 
     Lay persons have conducted at-home medical inspections for many years. Virtually every sick child has been subjected to a flashlight being thrust into its mouth as a parent attempts to ascertain the absence or presence of clinical signs of various ailments. These same flashlights are used to conduct inspections of the child&#39;s ears. Of course, at-home medical inspections are not limited to inspections of another individual. Individuals commonly grab the nearest flashlight and position themselves in odd positions in front of a mirror in order to perform self-inspections, such as to view a sore throat, for example. Unfortunately, the presence of the flashlight, while necessary to be able to see anything in the dark recess of a throat, presents a cumbersome obstacle to the vision of the individual performing the inspection. 
     The growing concern with various forms of skin cancer has presented additional difficulties, as it is necessary to look at virtually every inch of one&#39;s skin if a thorough inspection is to be conducted. Not only does this present difficulty in areas of the back, shoulders and head, but inspection in various private areas is virtually impossible. 
     Various hand held instruments for use by physicians or dentists during examination of a patient have been known for many years. It has also been known to use micro-cameras and micro-video cameras in the performance of surgical procedures. These devices, however, tend to be extremely complicated and expensive to manufacture. Moreover, it is often difficult for a layperson to use these devices in a manner that allows for the self inspection of the type needed in searching for signs of skin cancer and other diseases. 
     More recently, the decrease in expense and the continuing miniaturization of components has allowed for expanded uses of micro-cameras and micro-video cameras. For example, these devices may be used in surveillance systems and home security systems. It is even known to use micro-cameras and micro-video cameras mounted in glasses or mounted onto one&#39;s head so as to record what one is seeing. These devices are particularly popular for use by tourists and individuals involved in other recreational activities such as sky-diving and amusement rides. These devices are not acceptable for self inspections, in part, because a light source is still required for inspection of certain areas. 
     It is desirable, therefore, to provide a device which allows for illumination of an object while capturing an image of the object. It is desired that the device be easy for lay persons to use, especially when conducting inspections of themselves or others for diagnosis of medical conditions. It is further desired that the device be easily configured for a variety of such inspections. Moreover, it is desired that the device be of simple and inexpensive construction. It would be further advantageous if the device were capable of transmitting the images captured to a remote location. 
     BRIEF SUMMARY OF THE INVENTION 
     In accordance with the present invention, a combination light and camera is provided which overcomes the disadvantages of the prior art by providing an easy to use camera and light suitable for personal inspections. In one embodiment, a miniature video-camera is embedded in the lens of a hand-held flashlight. Video signals from the miniature video-camera may be viewed on a television set by using a standard RCA plug. Alternatively, a miniature transmitter may be used to transmit the video signals to a remote viewing location. The present invention also comprises a variety of lens forms which may be used in conjunction with the combination camera and light to aid in performing personal inspections. In certain configurations, the present invention is useful as a hand-held personal inspection device, capable of providing a video record of where a flashlight is aimed. 
     The invention provides a device which allows for illumination of an object while capturing an image of the object. A device according to the present invention is easy for lay persons to use and to configure for use, especially when conducting inspections of themselves or others for diagnosis of medical conditions. The present invention is also simple and inexpensive to manufacture and can easily be configured to transmit images captured to a remote location for viewing and/or recordation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side plan view in accordance with an exemplary embodiment of the present invention. 
         FIG. 2  is a front plan view of the embodiment of the invention shown in FIG.  1 . 
         FIG. 3  is a laid open top plan view of the transmitter of the embodiment of the invention shown in FIG.  1  and FIG.  2 . 
         FIG. 4  is a partial laid open top plan view of the flashlight of the embodiment of the invention shown in FIG.  1  and FIG.  2 . 
         FIG. 5  is a side plan view of an alternative embodiment of the present invention without a transmitter. 
         FIG. 6  is a partial laid open top plan view of the embodiment of the invention shown in FIG.  5 . 
         FIG. 7  is a laid open side plan view of one embodiment of a lens in accordance with the present invention. 
         FIG. 8  is a laid open side plan view of an alternative embodiment of a lens in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     An exemplary embodiment of the present invention is described in reference to FIG.  1 . Referring to  FIG. 1 , a side plan view of one embodiment of the invention is shown. Flashlight  100  comprises on-off button  102 , battery section  104 , and lens section  106  at the forward end of flashlight  100 . In this embodiment, lens section  106  comprises a means for emitting a light beam in a generally forward path. Transmitter  108  is attached to lens section  106  and includes antenna  110  and on-off button  112  which controls miniature video-camera  116  shown in FIG.  2 . Transmitter  108  is a wireless transmitter capable of transmitting images captured by video-camera  116  to a remote location. Wireless transmitter  108  may be of the type model S130356 and video-camera  116  may be of the type S130351, both commercially available from Intplus, S.L. of Sevila, Spain. 
     Those of skill in the relevant art will realize, however, that a number of alternative cameras and transmitters exist. According to one embodiment, the camera and transmitter comprise a single unit, such as is available in camera transmitter model AVX434S2, commercially available from Supercircuits, Inc. of Liberty Hill, Tex. Moreover, the camera may be a still camera or a video camera. These and other alternative embodiments being within the scope of the present invention. The salient feature of the camera is that it is of a reduced size, as will be discussed below. 
       FIG. 2  is a front plan view of flashlight  100 . Lens section  106  comprises lens  114 . Miniature video-camera  116  is embedded in lens  114 . The output of miniature video-camera  116  is provided to transmitter  108  by wire  118 . Because it is of a reduced size, miniature video-camera  116  may be placed directly in the beam of light produced by flashlight  100  without unduly interfering with the beam of light emitted by flashlight  100 . Accordingly, flashlight  100  may be positioned extremely close to an object to be imaged, without loss of illumination. Additional benefits resulting from the placement of miniature video-camera  116  within lens  114  will be discussed below. 
       FIG. 3  is a laid open top plan view of transmitter  108 . Transmitter  108  comprises on-off button  120  which controls power to transmitter  108 . Power for transmitter  108  is supplied by battery  122 . Battery  124  supplies power to miniature video-camera  116 . 
     Referring to  FIG. 4 , which is a partial laid open top plan view of flashlight  100 , battery  126  supplies power to light emitting device  128  and is controlled by on-off button  102 . Those of skill in the art will realize that for certain applications a battery operated device is not needed. Accordingly, power may alternatively be provided by hard wiring the device into another power source or through the provision of a plug for connecting to a power source. Moreover, the camera, transmitter and light emitting device may share a common power source. These and other variations being within the scope of the present invention. 
     Also shown in  FIG. 4  is reflector  130 . Reflector  130  in this embodiment works in conjunction with light emitting device  128  and lens  114  to project a beam of light in a generally forward direction. The present invention may be practiced with a wide variety of means for projecting light in a generally forward direction. For example, a reflector may not be desired for a particular application. Alternatively, a parabolic or other shaped reflector may be used. Moreover, light emitting device  128  may be a candescent bulb, an incandescent bulb or light emitting diode. These and other embodiments being within the scope of the present invention. 
     An alternative embodiment of the invention is shown in FIG.  5 . In this embodiment, flashlight  500  comprises battery section  502 , lens section  504  and miniature video-camera  506 . Referring now to  FIG. 6 , miniature video-camera  506  is powered by battery  510  as controlled by on-off button  508 . Light source  510  is powered by battery  512  and controlled by on-off button  514 . Video output from miniature video-camera  506  is available at RCA plug  516  through wire  518 . 
     The present invention further comprises means for directing light to and from an object to be imaged. Alternative means are shown in  FIGS. 7 and 8 . Referring to  FIG. 7 , lens  700  is designed to provide illumination to an area to be inspected through tip  702 . Tip  702  is much smaller than lens  114  of flashlight  100 . Thus, tip  702  may easily fit within smaller orifices such as an individual&#39;s throat so as to inspect the throat of the individual. Alternatively, tip  702  may be used to look within an individual&#39;s ear. Of course, tip  702  and other smaller sized lenses can be used to look within cracks and crevices to look for lost items or for doing structural inspections. 
     Base  704  of lens  700  is designed to focus the light coming from lens  114  into tip  702 . Accordingly, base  704  expands from tip  702  to a circumference about the size of lens  114 . Inset  708  of base  704  is designed to fit within lens section  106  so as to provide optical communication between lens section  106  and lens  700 . Thus, light beams emitted from flashlight  100  pass into and through lens  700 . Moreover, when lens  700  is inserted into lens section  106 , miniature video-camera  116  at the forward end of flashlight  100  extends into recess  710  allowing base  704  to fit flush against lens  114 . Thus, optical communication is provided between lens  700  and miniature video-camera  116 . 
     The location of miniature video-camera  116  within lens section  106  allows for a single lens to be used which both directs light to the area to be viewed, and allows for the emitted or reflected light to be returned to miniature video-camera  116 . This is a significant advantage, as a variety of lens shapes can be easily fit within lens section  106  depending on the desired application. Moreover, the size of the lens is reduced, as it need only be sized to fit over lens section  106 . Furthermore, because the camera is within the emitted light beam, the device may be placed very close to an object to be imaged without loss of illumination. Of course, at close range it may be desired to reduce the illumination level of the emitted light beam. In these situations, a dimmer switch may be utilized, such use being within the scope of the present invention. 
     In order to pass light, such that the performance of miniature video-camera  506  is not significantly degraded, lens  700  must be manufactured from a material that exhibits high clarity. Moreover, it is advantageous if lens  700  is manufactured from a material that can be easily disinfected and has high tensile strength. One such material is available in the form of cast acrylic block such as poly methyl methacrylate, commercially available from Industrial Plastic Supply, Inc. of Anaheim Calif. The block may be fashioned into the desired lens shape by milling and polishing. Lens  700  thus passes the emitted light beam, directing it toward the object to be imaged, and passes reflected or emitted light from the object to be imaged to miniature video-camera  116 . 
       FIG. 8  shows an alternative lens. Base  804  of lens  800  is designed to focus the light coming from lens  114  into tip  802 . Accordingly, base  804  expands from tip  802  to a circumference about the size of lens  114 . Lens  800  is designed to provide illumination to an area to be inspected through tip  802 . Tip  802  is somewhat smaller than lens  114  of flashlight  100 , but significantly larger than tip  702  of lens  700 . Thus, tip  802  is useful for inspecting areas such as the back and shoulders of an individual. Tip  802  may also be sized such that it is useful for vaginal and rectal inspections. 
     Continuing with the description of lens  800 , inset  808  of base  804  is designed to fit within lens section  106 . When lens  800  is inserted into lens section  106 , miniature video-camera  116  extends into recess  810  allowing base  804  to fit flush against lens  114 . 
     Those of skill in the art will realize that as described herein, the present invention provides significant advantages over the prior art. The invention provides a device which allows for illumination of an object while capturing an image of the object, even at very close range. The present invention is easy for lay persons to use and to configure for use, especially when conducting inspections of themselves or others for diagnosis of medical conditions. The present invention is also simple and inexpensive to manufacture and can easily be configured to transmit images captured to a remote location for viewing and/or recordation. Other objects and features of the present invention will be apparent to those of skill in the art in consideration of the above description, the accompanying drawings, and the following claims. 
     While the present invention has been described in detail with reference to certain exemplary embodiments thereof, such is offered by way of non-limiting example of the invention, as other versions are possible. It is anticipated that a variety of other modifications and changes will be apparent to those having ordinary skill in the art and that such modifications and changes are intended to be encompassed within the spirit and scope of the invention as defined by the following claims.