Abstract:
A configurable lamp assembly has a set of lamp-lens modules and a set of power modules. Each of the various lamp-lens modules can connect to one of the various power modules to provide a variety of lamp assemblies providing various illumination patterns operable from a number of supply voltages.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is related to design patent application entitled “Lighting Fixture”, application Ser. No. 29/427,741 filed on Jul. 21, 2012 by Calvin and Wilkinson. 
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     JOINT RESEARCH AGREEMENT 
     Not applicable 
     SEQUENCE LISTING 
     Not applicable 
     FIELD OF THE INVENTION 
     The present invention relates to the field of lamp assemblies, and in particular to lamp assemblies for aircraft and vehicles. 
     BACKGROUND OF THE INVENTION 
     Currently, for aircraft and vehicle lighting, there are various voltages and light emission types and patterns required depending upon application. Lamp assemblies may also be required to operate in hazardous environments. 
     Designers and installers of lamp assemblies are required to specify, stock, supply, and install many different lamp assembly types in order to achieve the required illumination spectrum, pattern and voltage. 
     SUMMARY OF THE INVENTION 
     The configurable lamp assembly has a set of lamp-lens modules and a set of power modules. Each of the various lamp-lens modules can connect to one of the various power modules to provide a variety of lamp assemblies providing various output spectrums, and illumination patterns, operable from a number of power supply frequencies and voltages. 
     In one embodiment a lamp-lens module and a power-module fit together to form a configurable lamp assembly. The lamp-lens module has a first side with a lens and one or more lamps while the second side has a lamp PCA connector; and is configured to join with the power module. A lamp PCA connector is on the second side and connects to a power module connector on the power module thus supplying power to the lamp-lens module. In this disclosure “PCA” refers to “printed circuit assembly”. 
     The power module has a first side exposing the power module connector which is adapted to connect with the lamp-lens module lamp PCA connector. The second side of the power module has an external connector which receives electrical power and control signals from an external source. A gasket fits between the lamp-lens second side and power module first side, the gasket seals the lamp-lens module and the power module together forming a common-internal-environment. This seal forms a hermetically sealed cavity of the lamp-lens and the power module. An external-port connects the common internal environment with an external ambient environment. A moisture-barrier and vent permit gaseous communication between the common internal environment, and the outside ambient environment while preventing liquid exchange. 
     A removable fastener system holds the lamp-lens module together with the power module, capturing the gasket between the lamp-lens module and the power module. The removable fastener system enables interchangeability of the lamp-lens module with the power module. This interchangeability enables different types of lamp-lens modules to be connected to different types of power modules. Thus several combinations of lamp-lens modules and power modules are possible to accommodate different power sources and illumination requirements. 
     In other embodiments, the configurable lamp assembly has an inter-module thermal-medium between the lamp-lens module second side and the power module first side to conduct heat from the lamp-lens module to the power module. In this embodiment, the power module is designed to dissipate heat and reduce the temperature of the lamp-lens module. The inter-module thermal-medium can further act to seal the common internal environment from the external ambient environment. 
     Other embodiments of the configurable lamp-lens module have a plurality of lamps. Some lamps emit visible light, while other lamps emit infrared light. Lamp-lens modules can emit either visible, infrared or both types of light as well as other spectrums. Depending upon application, a lamp-lens module may emit one selected spectrum or selectively emit different spectrums upon command from an external source. 
     In another embodiment, the power module is characterized by a heat sink. This heat sink is sturdy enough to accommodate a hard point on the power module for mounting the configurable lighting assembly to vehicles. Different types of mounting assemblies can use this hard point to attach the power-module, and thus the entire configurable lamp assembly to a vehicle. 
     Some embodiments of the lamp-lens module project a spot light beam, while other embodiments of the lamp-lens module project a flood light beam. Still other embodiments of the lamp-lens module can be designed to project beams meeting specific dispersion requirements and profiles. 
     Yet other embodiments have a spark arrestor in or at the external port. The spark arrestor allows the configurable lamp assembly to be used in a hazardous environment where there is a danger of an explosive atmosphere. In such cases, any spark or possible ignition source is quenched before it can exit the common internal environment of the configurable lamp assembly. This feature enables the configurable lamp assembly to be used in environments requiring explosion proof fixtures. 
     In one embodiment the lamp-lens module has a lamp housing, and one or more lamps mounted on a lamp PCA. The lamp PCA fits into the lamp housing and a lamp PCA thermal medium between the lamp PCA and the lamp housing transfers heat from the lamp PCA to the lamp housing. A lens fits to the lamp housing and permits light from the lamp to exit the first side of the lamp-lens module. The lamp housing opposite the lens is the second side of the lamp-lens module that connects to the power module with a lamp PCA connector. 
     In another embodiment, the power-module has a power module heat sink. The power module heat sink has a first side with a power module PCA attached to the power module heat sink first side. A power-module-connector attaches to the power module PCA. The power module connector is exposed on the power module heat sink first side so that it can connect with the lamp PCA connector. An external connector connects to the power module PCA, and is exposed on the power module heat sink second side. 
     An external port connects the power module heat sink first side and second side. The power module first side further receives the lamp-lens module second side enabling a gaseous seal between the lamp-lens module and the power module and the connection of the lamp PCA connector to the power module connector. 
     This gaseous seal is accomplished with a gasket adapted to fit between the lamp-lens second side and power module first side. The gasket enables a common-internal-environment between the lamp-lens module and the power module. A moisture barrier vent in the external port of the power module heat sink permits gaseous communication between the common internal environment, and an external ambient environment while preventing liquid exchange. 
     A removable fastener system holds the lamp-lens module together with the power module, capturing the gasket between the lamp-lens module and the power module. The removable fastener system enables a variety of lamp-lens modules to attach to a variety of power modules. The removable fastener system also enables replacement of a failed module and reuse of a good module. 
     The method of constructing a configurable lamp assembly involves providing a selection of lamp-lens modules, each lamp-lens module configured to produce a selected light emission pattern and a selected spectral emission range. Then providing a selection of power modules, each power module adapted to a selected range of power inputs. By remove-ably interfacing together any one of the selection of lamp-lens modules with any one of the selection of power modules a user can form a configured lamp assembly. When this interface includes a gasket or seal, an internal environment is formed. Electrical connections between the two modules allows the transmitting of electrical power and control from the power module to the lamp-lens assembly. Venting gasses between internal environment and an external ambient environment is accomplished with an external port. Blocking the passage of liquids between the internal environment and the external ambient environment is enabled with a moisture barrier. Arresting sparks from passing from the internal environment to the external environment enables use in hazardous environments. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The summary above, and the following detailed description will be better understood in view of the enclosed drawings which depict details of preferred embodiments. Like reference numbers designate like elements. It should however be noted that the invention is not limited to the precise arrangement shown in the drawings. The features, functions and advantages can be achieved independently in various embodiments of the claimed invention or may be combined in yet other embodiments. 
         FIG. 1  shows of an exploded view of an embodiment the lamp-lens module and the power module. 
         FIG. 2  shows a perspective exploded view of an embodiment of the lamp-lens module and the power module. 
         FIG. 3  shows still another exploded view of an embodiment of the lamp-lens module and the power module. 
         FIG. 4  shows a detailed front perspective exploded view of an embodiment of the configurable lamp assembly. 
         FIG. 5  shows detailed rear perspective exploded view of an embodiment of the configurable lamp assembly. 
         FIG. 6  shows a profile detailed exploded view an embodiment of the configurable lamp assembly. 
         FIG. 7  shows a front perspective view of an embodiment of the configurable lamp assembly. 
         FIG. 8  shows a rear perspective view of an embodiment of the configurable lamp assembly. 
         FIG. 9  shows details of an embodiment of the moisture barrier and spark arrestor. 
         FIG. 10  shows an embodiment of a rear view and vent port detail. 
         FIG. 11  shows an embodiment of the lens. 
         FIG. 12  shows hard points on an embodiment of the configurable lamp assembly. 
         FIG. 13  shows how various embodiments of lamp-lens and power modules can be assembled to form various embodiments of the configurable lamp assembly. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that modification to the various disclosed embodiments may be made and other embodiments may be utilized, without departing from the spirit and scope of the present invention. The following detailed description is therefore, not to be taken in a limiting sense. 
       FIG. 1  shows of an exploded view of an embodiment of the configurable lamp assembly  100  showing the lamp-lens module  120  and the power module  160 . The lamp-lens module has a front or first side  122  from which light is emitted. The lamp-lens module back or second side  124  has a portion of the remove-able fastener system  180 . The power module  160  has first or front side  162  with a power module connector  166 . The power module connector  166  supplies power and control signals to the lamp-PCA connector (not shown) on the lamp-lens module  120  second side  124 . The power module second side  164  has an external connector  464  which receives power and control signals from an external source (not shown). While in  FIG. 1  the external connector is depicted as a round, sealed connector, other connector types are possible including wire pig tails. At the rear or second side of the power module  160 , remove-able fasteners  180  mate with remove-able fasteners  180  on the lamp-lens module  120 . In the Figs. the remove-able fasteners  180  are depicted as screws and threaded members. In other embodiments, other types of remove-able fasteners are possible. For example, clips and clamps are a type of remove-able fastener. Note that the concept of remove-able implies that the lamp-lens module is remove-able from the power module even if the fasteners are not remove-able from the modules themselves. 
     In  FIG. 1  when the lamp-lens module  120  connects with the power module  160 , the two members capture a gasket  140 . This gasket  140  seals the lamp-lens module  120  together with the power module  160 , forming an internal common environment  130 . This internal common environment  130 , is separate from the external ambient environment  135 . 
       FIG. 2  shows a perspective exploded view of the configurable lamp assembly  100  with embodiments of the lamp-lens module  120  and the power module  160 . This perspective view shows the lamp-lens PCA connector  220 . When the lamp-lens module  120  connects to the power module  160 , the lamp-lens PCA connector  220  receives power and control from the power module connector  166  of  FIG. 1 . The connection of the lamp-lens module  120  with the power module  160  captures the gasket  140 . The resulting seal between the lamp-lens module  120  and the power module  160  also protects the electrical connection between the lamp-lens PCA connector  220  and the power module connector  166  of  FIG. 1 . Another view of the external connector  464  and remove-able fasteners  180  is also shown. The hard point  800  allows the configurable lamp assembly  100  to be mounted to vehicles or stationary platforms (not shown) in a number of ways. 
       FIG. 3  shows a different perspective exploded view of the configurable lamp assembly  100  with embodiments of the lamp-lens module  120  and the power module  160 . This perspective view shows the power module connector  166  located on the power module first side. When the lamp-lens module  120  connects to the power module  160 , the lamp-lens PCA connector  220  of  FIG. 2  receives power and control from the power module connector  166 . The lamp-lens module first side  122 , gasket  140 , power module first side  162 , and external power connector are also shown. 
       FIG. 4  shows a detailed front perspective exploded view of an embodiment of the configurable lamp assembly. The lamp-lens module has a lamp housing  128 . In one embodiment the lamp housing  128  is a hard plastic or metal and acts as the base for the other components of the lamp-lens module  120 . A lamp PCA  420  holds lamps  422  and other electronic components. The term lamps in this disclosure means any number or type of light emitting device, and in particular, LEDs (light emitting diodes). A lamp PCA thermal medium  424  is a paste, gasket or washer type material that aids in the conduction of heat from the lamp PCA  420  to the lamp housing  128 . The lamp-lens  126  fits into the lamp housing  128  capturing the lamp PCA  420  and lamp PCA thermal medium  424 . The lamp lens  126  is secured to the lamp housing  128  by any of a number of means including adhesives, conformal coatings and encapsulants (not shown). The lamp PCA connector  220  of  FIG. 2  mounts to the side of the lamp PCA  420  opposite the lamps  422  and protrudes out the lamp housing  128  for connection with the power module connector  166  of  FIG. 3 . 
     The power module heat sink  168  holds a number of components of the power module  160 . The power module PCA  165  fits into the power module heat sink first side  167 , while the external connector fits into the power module heat sink second side  169  which is shown more completely in  FIG. 5 . Connections between the external connector  464  and the power module PCA  165  supply power and control signals from external sources to the configurable lamp assembly  100 . The power module connector  166  mounts on the side of the power module PCA  165  facing the lamp-lens module  120  for eventual connection with the lamp PCA connector  220  of  FIG. 2  An external port  452  connects the power module heat sink first side  167  with the power module heat sink second side  169  of  FIG. 5 . The advantages of the external port  452  are described in more detail in conjunction with the following Figs. 
     Gasket  140  and in some embodiments inter-module thermal medium  426   a  or  426   b  seal the lamp-lens module  120  with the power module  160  when the two modules are held together by remove-able fasteners  180 . When fastened together, the two modules  120  and  160  have a internal common environment  130  of  FIG. 1  which is vented to the external ambient environment of  FIG. 1  by the external port  452 . A spark arrestor  454  acts to quench any ignition source which might attempt to leave the internal common environment  130  and ignite a flammable external ambient environment  135 . 
       FIG. 5  shows detailed rear perspective exploded view of an embodiment of the configurable lamp assembly. While similar to the descriptions associated with  FIG. 4  earlier,  FIG. 5  shows the opposite sites of the components. 
       FIG. 6  shows a profile detailed exploded view an embodiment of the configurable lamp assembly  100 .  FIG. 6  provides an alternate view of the construction of the lamp-lens module  120  and power module  160  and the gasket  140  and inter-module thermal medium  426   a  and  426   b . Also more visible in  FIG. 6  is the alignment of the lamp PCA connector  220  with the power module connector  166  which make electrical connection when the modules  120  and  160  are assembled together. 
       FIG. 7  and  FIG. 8  show a front perspective view and rear perspective view respectively of an embodiment of the configurable lamp assembly  100 . These views show one embodiment of the external connector  464  connected to an external power control source  466 .  FIG. 8  also indicates the hard point  800  which can support the entire configurable lamp assembly  100  in a variety of applications. Various types of mounting assemblies can mount to the hard point  800  and then be fitted to various types of vehicles. 
       FIG. 9  shows details of an embodiment of the moisture barrier  456  and spark arrestor  454 , while  FIG. 10  shows an embodiment of a rear view of the external port  452  detail. The external port  452  allows gaseous exchange between the internal common environment  130  with the external ambient environment  135 , both of  FIG. 1 . When the configurable lamp assembly is mounted on a high performance aircraft for example, steep climbs or dives will rapidly change the pressure difference between the internal and external environments. The external port  452  allows this pressure difference to quickly equalize. The spark arrestor  454  acts to prevent an ignition source inside the configurable lamp assembly  100  from reaching the external ambient environment  135 . The narrowness of the external port  452  passages also aid in spark arresting. The moisture barrier  456  acts to allow gaseous exchange between the two environments  130  and  135  but reduces or prevents the passage of liquid. The moisture barrier  456  is interposed between the two environments  130  and  135  inside the spark arrestor  454 . The moisture barrier  456  can be single or multiple pieces of material and can also be described as a waterproof/breathable fabric. The design and construction of waterproof/breathable fabrics is known to those skilled in the art. When used in conjunction with the spark arrestor  454 , the moisture barrier acts to further aid in the arrest of sparks. 
       FIG. 11  shows an embodiment of the lens  126  which also includes individual reflectors for one or more lamps. The choice of lens type together with reflector combinations can enable a variety of beam profiles. While spot light and flood light beams are well known, other custom lenses can provide custom beam patterns for specific uses. 
       FIG. 12  shows hard points  800  on an embodiment of the configurable lamp assembly  100 . The hard points  800  can be tapped directly into the body of the power module or be inserts. Inserts can be useful when the body of the power module is a softer metal or plastic. The inserts can be a harder material which can withstand repeated assembly and disassembly. While holes with inserts are shown in  FIG. 12 , the ribs of the power module in  FIG. 12  can also be considered as hard point and be adapted for mounting purposes. 
       FIG. 13  shows how various embodiments of Lamp-lens modules  1320   a ,  1320   b ,  1320   c , and  1320   d  and Power Modules  1360   a ,  1360   b , and  1360   c  can be assembled to form various embodiments of the configurable lamp assembly  100 . Lamp-lens module  1320   a  represents a lamp-lens module with a flood light dispersion beam of infrared light as indicated by dashed lines. Lamp-lens module  1320   b  represents a lamp-lens modules with a spot light type beam of infrared light. Lamp-lens module  1320   c  represents a visible flood light indicated by solid lines, while  1320   d  represents a visible spot light. Note that these four lamp-lens module examples represent only a fraction of the possibilities. For example other spectrums, light output levels and dispersions are possible. Combinations of switchable visible and infrared light are also possible for overt/covert applications. 
     The power modules  1360   a ,  1360   b , and  1360   c  represent different power modules. For example power module  1360   a  might be for 12 volt DC only, while power module  1360   b  might be for 120 volts AC. Still others might be rated for higher power levels, other voltages, other frequencies or extreme environments and temperatures. 
     The interchangeability of various lamp-lens modules with various power modules provides the advantage of a modular kit approach. By stocking a limited type of modules, a technician can create numerous versions of configurable lamp assemblies by mixing and matching lamp-lens modules with power modules. Repair material costs can also be reduced when one module can be replaced without scrapping the entire configurable lamp assembly. 
     Using the examples of  FIG. 13 , a user provides a lamp-lens module configured to produce a selected light emission pattern, light intensity and a selected spectral emission range. The lamp-lens is chosen from the available choices  1320   a ,  1320   b ,  1320   c  or  1320   d . The user then provides a power module adapted to a selected range of power inputs. The power module is chosen from the available choices of  1360   a ,  1360   b , or  1360   c . The user then interfaces the two modules together to form a completed configurable lamp assembly. The power module transmits power to the lamp-lens assembly, while the venting system allows gaseous venting between the internal common environment inside the assembly and the external ambient environment. The moisture barrier enables the blocking of liquids between the internal environment and the external ambient environment, while the spark arrestor enables the arresting of sparks from passing from the internal environment to the external environment. 
     The user can then attach the configurable lamp assembly to a vehicle or stationary site by mounting the configurable lamp assembly to a mounting adapter by the hard points and then to the user application, or mount the assembly directly. 
     Although this invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this invention. Rather, the scope of the present invention is defined only by reference to the appended claims and equivalents thereof. 
     
       
         
               
             
               
               
             
           
               
                   
               
               
                 Glossary 
               
             
          
           
               
                 Ref 
                   
               
               
                 Number 
                 Name 
               
               
                   
               
               
                 100 
                 Configurable Aircraft and Vehicle Lamp Assembly 
               
               
                 120 
                 Lamp-lens Module 
               
               
                 122 
                 Lamp-lens Module First Side 
               
               
                 124 
                 Lamp-lens Module Second Side 
               
               
                 126 
                 Lens 
               
               
                 128 
                 Lamp Housing 
               
               
                 130 
                 Common Internal Environment 
               
               
                 135 
                 External Ambient Environment 
               
               
                 140 
                 Gasket 
               
               
                 160 
                 Power Module 
               
               
                 162 
                 Power Module First Side 
               
               
                 164 
                 Power Module Second Side 
               
               
                 165 
                 Power Module PCA 
               
               
                 166 
                 Power Module Connector 
               
               
                 167 
                 Power module heat sink first side 
               
               
                 168 
                 Power module heat sink 
               
               
                 169 
                 Power module heat sink second side 
               
               
                 180 
                 Removable Fastener System 
               
               
                 220 
                 Lamp PCA connector 
               
               
                 420 
                 Lamp PCA 
               
               
                 422 
                 Lamp 
               
               
                 424 
                 Lamp PCA thermal Medium 
               
               
                  426a 
                 Inter-Module Thermal Medium 
               
               
                  426b 
               
               
                 452 
                 External Port/Vent port 
               
               
                 454 
                 Spare Arrestor 
               
               
                 456 
                 Moisture Barrier 
               
               
                 464 
                 External Connector 
               
               
                 466 
                 External Power/Control Source 
               
               
                 800 
                 Hard Point 
               
               
                 1360a 
                 Direct current 
               
               
                 1360b 
                 Alternating Current 
               
               
                  1320b, d 
                 Spot light Beam 
               
               
                  1320a, c 
                 Flood Light Beam 
               
               
                  1320c, d 
                 Visible Light/Lamp 
               
               
                  1320a, b 
                 Infrared Light/Lamp