Patent Publication Number: US-10323815-B2

Title: Rear-loading clip for a light module

Description:
BACKGROUND 
     In many conventional vehicle designs, an inner lens is attached or mounted to a light frame module, such as a bezel. However, the clips or fasteners by which the inner lens is attached to the light frame module remain exposed to the exterior environment because the inner lens is mounted to the light frame module from the front side. Therefore, “cover up” methods are needed, which include a black-shot molding onto the inner lens or hiding the fasteners or clips behind a second bezel. These solutions may not be feasible with a limited packaging space. 
     The “background” description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description which may not otherwise qualify as conventional art at the time of filing, are neither expressly nor impliedly admitted as conventional art against the present disclosure. 
     SUMMARY 
     Embodiments described herein include the following aspects. 
     (1) An inner lens for a light module includes a first plurality of clips positioned on a lower surface of the inner lens configured to engage with a corresponding first plurality of protrusions of a light frame module; and a second plurality of clips positioned on an upper surface of the inner lens configured to engage with a corresponding second plurality of protrusions of the light frame module. The inner lens is configured to be mounted to the light frame module to a rear back side of the light frame module. 
     (2) The inner lens of (1), wherein each of the first plurality of clips has a U-shaped extended end with a hollow central region configured to receive a respective first protrusion of the first plurality of protrusions of the light frame module. 
     (3) The inner lens of either (1) or (2), wherein the U-shaped extended end of said each of the first plurality of clips is configured to bend and lock the first protrusion into place after fully receiving the first protrusion of the first plurality of protrusions. 
     (4) The inner lens of any one of (1) through (3), wherein the first plurality of clips is configured to fully engage with the first plurality of protrusions simultaneously. 
     (5) The inner lens of any one of (1) through (4), wherein each of the first plurality of clips is formed as an integral component of the inner lens. 
     (6) The inner lens of any one of (1) through (5), wherein each of the first plurality of clips is made of a flexible material relative to the inner lens. 
     (7) The inner lens of any one of (1) through (6), wherein each of the second plurality of clips has a first extended end with a first hollow central region. 
     (8) The inner lens of any one of (1) through (7), wherein each of the second plurality of clips further includes a second extended end with a second hollow central region, and wherein the second extended end extends into the first hollow central region. 
     (9) The inner lens of any one of (11) through (8), wherein each of the second hollow central regions of the second plurality of clips is configured to receive a respective second protrusion of the second plurality of protrusions of the light frame module. 
     (10) The inner lens of any one of (1) through (9), wherein the second extended end of said each of the second plurality of clips is configured to bend and lock the second protrusion into place within the second hollow central region after fully receiving the second protrusion of the second plurality of protrusions within the second hollow central region. 
     (11) The inner lens of any one of (1) through (10), wherein the second plurality of clips is configured to fully receive the second plurality of protrusions simultaneously within the respective second hollow central regions. 
     (12) The inner lens of any one of (1) through (11), wherein each of the second plurality of clips is formed as an integral component of the inner lens. 
     (13) The inner lens of any one of (1) through (12), wherein each of the first extended ends of the second plurality of clips is made of a rigid material relative to the inner lens. 
     (14) The inner lens of any one of (1) through (13), wherein each of the second extended ends of the second plurality of clips is made of a flexible material relative to the first extended ends of the second plurality of clips. 
     (15) The inner lens of any one of (1) through (14), wherein the first plurality of clips differs from the second plurality of clips. 
     (16) The inner lens of any one of (1) through (15), wherein the upper surface of the inner lens includes one or more of the first plurality of clips and one or more of the second plurality of clips. 
     (17) The inner lens of any one of (1) through (16), wherein the lower surface of the inner lens includes one or more of the first plurality of clips and one or more of the second plurality of clips. 
     (18) The inner lens of any one of (1) through (17), wherein the light frame module comprises a bezel. 
     (19) The inner lens of any one of (1) through (18), wherein the first plurality of clips and the second plurality of clips are not visible from the exterior of the light module when the inner lens is mounted to the light module. 
     (20) The inner lens of any one of (1) through (19), wherein a first number of the first plurality of clips and a second number of the second plurality of clips positioned on the inner lens are determined to meet or exceed a vibration validation standard. 
     The foregoing paragraphs have been provided by way of general introduction, and are not intended to limit the scope of the following claims. The described embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
         FIG. 1  illustrates a front-end of an exemplary motor vehicle according to one embodiment; 
         FIG. 2  illustrates a top view of a motor vehicle according to one embodiment; 
         FIG. 3  illustrates a partial view of an inner lens for a light module according to one embodiment; 
         FIG. 4  illustrates an exemplary light frame module according to one embodiment; 
         FIG. 5  illustrates a light module in which the inner lens is engaged with the light frame module according to one embodiment; 
         FIG. 6  illustrates a complete inner lens and an exemplary placement of first clips and second clips according to one embodiment; and 
         FIG. 7  illustrates a functional block diagram of a vehicle lamp assembly according to one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     The following descriptions are meant to further clarify the present disclosure by giving specific examples and embodiments of the disclosure. These embodiments are meant to be illustrative rather than exhaustive. The full scope of the disclosure is not limited to any particular embodiment disclosed in the specification, but rather is defined by the claims. 
     In the interest of clarity, not all of the features of the implementations described herein are shown and described in detail. It will be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions will be made in order to achieve the developer&#39;s specific goals, such as compliance with application- and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. 
     Embodiments described herein provide lighting modules having one or more solid state light sources. As used herein, a solid state light source refers to a type of light source using an electroluminescence phenomenon in which a material emits light in response to passage of an electric current or in response to a strong electric field. Examples of light sources include, but are not limited to semiconductor light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), polymer light-emitting diodes (PLEDs), and monolithic light-emitting diodes (MLEDs). Lighting modules described herein can also include one or more bulb sources, such as a halogen light source or a high intensity discharge (HID) light source. 
       FIG. 1  illustrates a front-end of an exemplary motor vehicle  100 . Motor vehicle  100  includes two headlamp assemblies  105   a  and  105   b . Headlamp assemblies  105   a  and  105   b  include low beam headlamps  110   a  and  110   b  (also referred to as a lower or dipped beam) and high beam headlamps  115   a  and  115   b  (also referred to as a main or driving beam). Typically, the low beam headlamps  110   a  and  110   b  are used whenever another vehicle is on the road directly ahead of motor vehicle  100  and/or whenever another vehicle is approaching motor vehicle  100  from an opposite direction. 
       FIG. 2  illustrates a top view of motor vehicle  100 . A front end  210  and a back end  220  are illustrated. In addition to lighting functions, motor vehicle  100  illustrates signaling functions. Front lamp assemblies  215   a  and  215   b  represent signaling functions, such as a combination turn signal and parking lamp or a combination parking lamp and a daytime running lamp (DRL). Each of the front lamp assemblies  215   a  and  215   b  can be separate from headlamp assemblies  105   a  and  105   b  or they can be incorporated into the same assembly module. 
       FIG. 2  also illustrates rear lamp assemblies  225   a  and  225   b . Rear lamp assemblies  225   a  and  225   b  represent signaling functions, such as a combination brake lamp and tail lamp or a combination tail lamp and a turn signal lamp. Each of the rear lamp assemblies  225   a  and  225   b  can include separate modules for each signaling lamp function or they can be incorporated into the same assembly module. 
     Most states, countries, or regions which utilize motor vehicles have various requirements and standards that a vehicle must adhere to in order to legally use roadways. For example, Federal Motor Vehicle Safety Standard (FMVSS) No. 108 specifies various maximum and minimum photometric intensity values (based on angle) for headlamps on vehicles operated within the Unites States. In addition to these requirements, the Insurance Institute for Highway Safety (IIHS) in the United States has its own set of tests and ratings (Headlight Test and Rating Protocol) for headlamp performance. The IIHS tests and ratings seek to encourage manufacturers to improve the illumination performance in actual on-road use. IIHS evaluations have shown that the on-road illumination provided by vehicle headlamps varies widely. In addition, IIHS has rated the majority of headlamps in a poor category (e.g. insufficient illumination, excessive glare, etc.). 
       FIG. 3  illustrates a partial view of an inner lens  300  for a light module. A first clip  310  is positioned on a lower side of the inner lens  300 . The first clip  310  has a hollow central region  320 , which is configured to receive a first protrusion of a light frame module (illustrated in  FIG. 5 ). The first clip  310  has a U-shape, wherein the two ends of the first clip  310  are formed as an integral component of the inner lens  300 . The first clip  310  is made of a flexible material, relative to the inner lens  300 . This allows the first clip  310  to flex/bend as the first protrusion is inserted into the hollow central region  320  of the first clip  310 . 
     A second clip  330  is positioned on an upper side of the inner lens  300 . The second clip  330  has a first extended end with a first hollow central region  340 . The second clip  330  has a U-shape, wherein the two ends of the second clip  330  are formed as an integral component of the inner lens  300 . The U-shaped portion of the second clip  330  is made of a rigid material, similar to or the same as the inner lens  300 . 
     The second clip  330  also has a second extended end  350  which extends into the first hollow central region  340 . The second extended end  350  is made of a flexible material, relative to the U-shaped portion of the second clip  330 . The second extended end  350  has a second hollow central region  360 , which is configured to receive a second protrusion from the light frame module. 
     The first clip  310  and the second clip  330  are configured to receive protrusions from a light frame module.  FIG. 4  illustrates an exemplary light frame module  400 , such as a bezel. A first protrusion  410 , such as a bezel standoff is shaped and positioned on the light frame module  400 , such that it engages with the first clip  310  from the inner lens  300 . When the first protrusion  410  is inserted into the first hollow central region  340  of the first clip  310 , the first clip  310  is pushed or flexed upward. When the first protrusion  410  is further inserted into the first hollow central region  340 , the first clip  310  springs back to its original position and the first protrusion  410  becomes locked into place by the first clip  310 . 
       FIG. 4  illustrates just one first protrusion  410  for simplicity. However, a plurality of first protrusions  410  are present on the light frame module  400 , which are configured and positioned to engage with a corresponding plurality of first clips  310  on the inner lens  300 . When the inner lens  300  is mounted to the light frame module  400 , the plurality of first clips  310  are configured to fully engage with the plurality of first protrusions  410  simultaneously. 
     A second protrusion  430  is illustrated on the light frame module  400 . The second protrusion  430  is shaped and positioned on the light frame module  400 , such that it engages with the second clip  330  from the inner lens  300 . When the second protrusion  430  is inserted into the second hollow central region  360  of the second clip  330 , the second extended end  350  of the second clip  330  is pushed or flexed upward. When the second protrusion  430  is further inserted into the second hollow central region  360 , the second extended end  350  of the second clip  330  springs back to its original position and the second protrusion  430  becomes locked into place by the second extended end  350  of the second clip  330 . 
       FIG. 4  illustrates just one second protrusion  430  for simplicity. However, a plurality of second protrusions  430  are present on the light frame module  400 , which are configured and positioned to engage with a corresponding plurality of second clips  330  on the inner lens  300 . When the inner lens  300  is mounted to the light frame module  400 , the plurality of second clips  330  are configured to fully engage with the plurality of second protrusions  430  simultaneously. 
       FIG. 5  illustrates a light module  500  in which the inner lens  300  is engaged with the light frame module  400 . The first clip  310  of the inner lens  300  is fully engaged with the first protrusion  410  of the light frame module  40 X). The second clip  330  of the inner lens  300  is fully engaged with the second protrusion  430  of the light frame module  400 . Just one first clip  310  engaged with the first protrusion  410  and just one second clip  330  engaged with the second protrusion  430  are illustrated for simplicity. However, multiple first clips  310  are engaged with multiple first protrusions  410  and multiple second clips  330  are engaged with multiple second protrusions  430  when the inner lens  300  is fully engaged with the light frame module  400 . 
     The number of first clips  310  engaged with corresponding first protrusions  410  and the number of second clips  330  engaged with corresponding second protrusions  430  can depend in part on adequately securing the inner lens  300  with the light frame module  400 , such that vibrations are eliminated. In one embodiment, the numbers of first clips  310  and the numbers of second clips  330  are determined such that a vibration validation standard is met or exceeded. 
       FIG. 6  illustrates a complete inner lens  300  and an exemplary placement of first clips  310  and second clips  330 .  FIG. 6  illustrates six first clips  310  and four second clips  330 . However, this is illustrated as just one example. There could be the same number of first clips  310  and second clips  330 , or there could be fewer first clips  310  than second clips  330 . The number of first clips  310  and the number of second clips  330  can vary with each particular type and design of inner lens  300  and light frame module  400 . 
     In other examples, there can be a mixture of first clips  310  and second clips  330  on an upper surface  610  of the inner lens  300  and/or a mixture of first clips  310  and second clips  330  on a lower surface  620  of the inner lens  300 . The number and placement of first clips  310  and second clips  330  can vary with each particular type and design of inner lens  300  and light frame module  400 , and/or the number and placement can vary to achieve a vibration validation standard. 
     Light module  500  can be used for any vehicle lamps or reflectors, such as front lamp assemblies  215   a  and  215   b  and/or rear lamp assemblies  225   a  and  225   b.    
       FIG. 7  illustrates a functional block diagram of a vehicle lamp assembly  500  of vehicle  100 . Vehicle lamp assembly  500  includes a control circuit  705  and a solid state light source module  710 . One or more optional light source modules  720  include additional solid state light source modules and/or a laser light source module. An input signal  725  is connected to the control circuit  705 . The input signal  725  can be a switch to initiate or close power to one or more of the solid state light source module  710  and the optional light source module(s)  720 . Other types of input signals  725  are contemplated by embodiments described herein. 
     It should be noted that while  FIG. 7  illustrates control circuit  705  as included within vehicle lamp assembly  500 , control circuit  705  could also be located apart from vehicle lamp assembly  500 . Moreover, a single control circuit  705  can be employed for both a right and left vehicle lamp assembly such that the solid state light source module  710  and the optional light source module(s)  720  are driven in a synchronized manner. 
     Embodiments described herein provide several advantages. The inner lens  310  is designed in such a way that it can be mounted to a rear back side, i.e. the interior unexposed side of the light frame module  400 . This is advantageous because the first clips  310  and the second clips  330 , as well as the respective first protrusions  410  and second protrusions  430  are hidden from an exterior view of the light module  500  when the light module  500  is mounted onto a vehicle. In addition, the first clips  310  and the second clips  330 , as well as the respective first protrusions  410  and second protrusions  430  are compact and therefore, can fit into a small profile light module  500 . 
     While certain embodiments have been described herein, these embodiments are presented by way of example only, and are not intended to limit the scope of the disclosure. Using the teachings in this disclosure, a person having ordinary skill in the art can modify and adapt the disclosure in various ways, making omissions, substitutions, and/or changes in the form of the embodiments described herein, without departing from the spirit of the disclosure. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. The accompanying claims and their equivalents are intended to cover such forms or modifications, as would fall within the scope and spirit of the disclosure.