Abstract:
A courtesy light fixture for an automotive vehicle includes a housing having a base, a header wall and a supporting portion connecting the header wall to the base. The base includes a plurality of resilient clips which snap onto a support member of a door module. Resilient fingers of the base bear against the support member and urge the base inward to seat the clips against the support. The header wall mounts a lamp receptacle. A seal surrounding the receptacle engages a flange of a lens assembly on a trim panel of the door module so that a lamp in the receptacle is held in a fixed relation with the lens assembly for best illumination of the lighted area. The lens assembly is removable from the trim panel for changing the lamp without removing the trim panel from the door. The resilient fingers yield to take up variations between the trim panel location and the door module support member so the seal always engages the lens housing and flange to maintain the desired lamp position and prevent entry of contaminants or water into the lamp location.

Description:
TECHNICAL FIELD 
     This invention relates to courtesy light fixtures for automotive vehicles and, more particularly, to a door mounted courtesy light fixture and door assembly with novel features. 
     BACKGROUND OF THE INVENTION 
     It is known in the art relating to automotive vehicles to provide courtesy lights for lighting the interior, and sometimes the exterior entryway adjacent the vehicle doors, to aid in entering and leaving the vehicle under nighttime conditions or where exterior illumination is not available. Such courtesy lights are sometimes mounted on the interior of the vehicle door for lighting either the front or rear seat entryways or both. 
     Typically, the light fixture is mounted in a housing attached to the backside of an interior trim panel and connected with wiring provided on the associated door module and installed at the time of assembly of the trim panel to the door, for example, during vehicle assembly. Because of the positioning of the fixture behind a panel opening, it is sometimes necessary to remove the trim panel in order to replace a burned out electric lightbulb. Also, in some cases, variations in the distance between the lightbulb and the interior lens, due to tolerances between the door and trim panel, cause the amount of illumination be reduced from that desired and available when the lamp is properly located relative to the lens. 
     SUMMARY OF THE INVENTION 
     The present invention provides novel courtesy light fixture and door assemblies which together overcome many of the problems of prior art courtesy light fixture arrangements. 
     A feature of the invention is provision of a housing including a base that is snap attached to a support member of an associated door module or panel. The housing further includes a tubular connecting portion extending laterally from the base to a header wall formed on an inner end of the tubular connecting portion. A lamp receptacle including a lamp socket and associated conductors is centrally mounted on the header wall for receiving an electric lamp or lightbulb of any suitable type. A rubber seal is mounted around the lamp receptacle to enclose and protect the lamp and socket against entry of contaminants and water. Electrical conductors lead to a connector for connecting the lamp receptacle with electrical wiring provided on the associated door module at the time of installation of the light fixture housing onto the door module. Thus, all electrical portions of the assembly are completed upon buildup of the door module prior to installation of a trim panel on the door. 
     An associated interior trim panel for mounting on the inner side of the door may be provided with a lens housing mounted on or integrally formed in the trim panel and having a recessed portion with an outer wall that engages the rubber seal of the light fixture housing upon installation of the trim panel to the vehicle door. A lens assembly is removably secured to the lens housing in the trim panel by any suitable means, for example, by a tab at one end of an extended decorative body engaging a slot for retaining one end of the lens assembly which is then pivoted into position and retained by a snap fastener captured by the lens body to avoid loss. The lens assembly includes a central light transmitting lens portion with a light guide extending from the central portion to an inner flange which also engages the seal of the light fixture housing upon installation of the trim panel to the door. 
     The light fixture housing and trim panel mounting are such as to provide an interference fit of the assembly which assures contact of the lens flange and housing surfaces with the rubber seal of the housing and urges the housing toward the support member on which it is mounted. Resilient fingers are provided in the side mounting base of the light fixture housing which provide a resilient connection allowing the housing position to be adjusted by contact with the trim panel so that the rubber seal is continuously urged inward against the light guide flange and the outer wall of the lens housing in spite of variations in the tolerances of the components making up the door module and trim panel assembly or variations in trim panel location occasioned by various conditions during the service life of the vehicle. 
     These and other features and advantages of the invention will be more fully understood from the following description of certain specific embodiments of the invention taken together with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings: 
     FIG. 1 is an exploded pictorial view illustrating the construction and mounting of a courtesy light fixture to an associated door module support member and interior trim panel including a removable lens assembly; 
     FIG. 2 is a cross-sectional view taken vertically through the completed door assembly; 
     FIG. 3 is a cross-sectional view similar to FIG. 2 of a modified embodiment of courtesy light fixture and door assembly according to the invention; and 
     FIG. 4 is an exploded pictorial view of the door assembly of FIG.  3 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIGS. 1 and 2 of the drawings in detail, numeral  10  generally indicates a vehicle door assembly including a door module having a support member  12 , an interior trim panel  14 , and a courtesy light fixture  16  mounted between the support  12  and panel  14 . The support member  12  is an elongated member of metal, or other suitable material, having edge recesses  18  adapted for receiving resilient clips to be subsequently described. However, the member  12  could also be formed as a panel having slots suitably placed for receiving the clips. Alternatively, the support member could take any other suitable configuration adapted for mounting the light fixture  16 . 
     The trim panel  14  is illustrated as a molded panel member having a recessed lens housing  20  molded integrally with the panel  14 . Alternatively, the lens housing could be formed as a separate member attached to the trim panel by any suitable means. The lens housing may include a peripheral lip  22  and a recessed outer wall  24 . The outer wall  24  includes a central opening  26  and the lip  22  defines a mounting surface surrounding the open inner edge of the recess on which an associated lens assembly  28  is mounted. 
     In the illustrated embodiment, the courtesy light fixture  16  is located adjacent the rear edge of an associated vehicle door so that the lens housing  20  forms a longitudinally extending recess which is open toward its rear end at an interior edge of the door assembly  10 . The lens housing  20  includes a slot  30  located at the end of the outer wall  24  and a snap receiving opening  32  formed in the trim panel  14  adjacent the opposite end of the lens housing  20 . Lens assembly  28  is formed with a longitudinally extended decorative body  34  having a curved outer end terminating in an angle clip  36  that is receivable within the slot  30  for installation of the lens assembly on the lens housing  20 . A captured snap fastener  38  is provided at the forward end of the body  34  for snap fitting into the opening  32  in order to retain the lens assembly  28  in position on the lens housing  20  with the edges of the body  34  engaging the lip  22  on the lens housing. 
     Centrally, the lens assembly includes a light transmitting lens  40  which connects laterally outwardly (relative to the interior of the door assembly) with a light retaining light guide  42 . The light guide terminates outwardly in a flange  44  which, in assembly, is generally aligned with the central opening  26  of outer wall  24  of the lens housing and extends within and adjacent the edges of the central opening  26  in the outer wall  24 . 
     The courtesy light fixture  16  preferably includes a molded plastic housing  46  having a base  48 , which may be rectangular, and includes a plurality of, in this case four, resilient clips  50  having prongs  52 . The prongs  52  are adapted to snap over the edges of the recesses  18  of the support member  12  so as to hold the base  48  in position on the door module support member  12  prior to final assembly. 
     A tubular connecting portion  54  extends laterally inwardly, relative to the vehicle door from the base  48  to a header wall  56  including a vertically extending flange  58 , forming together a generally flat mounting surface  60 . A conventional lamp receptacle  62  of any suitable type is snap fitted, or otherwise attached, onto a central portion of the header wall  56 . Electrical conductors  64  extend from the lamp receptacle  62  through the flange  58  to an electrical connector  66  mounted on the opposite or outside of the flange  58 . Connector  66  is connectable with a mating connector  68  that is connected with wiring  70  mounted on the door module support member  12 . The wiring extends through a support slot  72  in the housing base  48  and an associated clip  74  to feed electrical power to the lamp receptacle  62  when the assembly is installed on the door module support member  12 . 
     At the inner end of the light fixture  16 , a rubber or other form of seal  76  is mounted on surface  60  of the header wall, surrounding the lamp receptacle  62 . In assembly, the seal  76  engages both the edges of the outer wall  24  of the lens housing  20  adjacent the central opening  26  and the flange  44  of the light guide  42 . The flange  44  extends flush with the outer wall  24  inside the central opening  26 . The seal thereby prevents the entry of contaminants and water from inside the door assembly as well as through the recess formed by the lens housing  20  in the interior door panel. An electrical lightbulb or lamp  78  is seated in the lamp receptacle  62  and extends within the light guide  42  in position relative to the lens  40  for properly illuminating the entry portion adjacent the rear end of the front door on which the courtesy lamp is mounted. The curved rear portion  80  of the decorative body  34  of the lens assembly  28  is preferably formed as a reflector to indicate to the drivers of on-coming vehicles the open position of the vehicle door. 
     It is recognized that design and assembly tolerances in the construction of the vehicle door module and associated panels, including the interior trim panel  14 , must be accounted for in order to maintain engagement of the seal  76  with the wall  24  and flange  44  as required to prevent entry of water and other contaminants into the light guide chamber within which the lamp  78  is located. FIG. 2 illustrates in solid lines the relative position of the support member  12  at the limit of its dimensional tolerance or spacing from the inner wall  24  of trim panel  14 . In most instances, the relative distance will be less than the maximum indicated by the solid lines. Dashed lines  12  indicate a relative position of the support member  12  at a minimum distance from the lens housing inner wall  24 . The light fixture housing  24  accommodates these differences by the provision of resilient fingers  82 . These engage the support member  12  at all times to urge the housing seal  76  inwardly against the outer wall  24  and flange  44  under all dimensional conditions within the design and manufacturing tolerances existing in the assembly. 
     Thus, in all conditions, the prongs  52  of clips  50  will hold the light fixture  16  in position on the support member  12  prior to installation of the trim panel  14 . In most cases, installation of the trim panel  14  will then force the housing  46  outwardly, deforming the spring fingers  82  which maintain the seal  76  in its intended position. The prongs  52  of clips  50  are then forced outward, away from the surface of support member  12 , but the clips  50  continue to align the base on the support member  12 . 
     FIGS. 3 and 4 illustrate an alternative embodiment of courtesy light fixture and door assembly which accomplishes the foregoing and other purposes of the invention in a somewhat different manner. Numeral  84  indicates a door and courtesy light fixture assembly similar to assembly  10  and wherein like numerals indicate like parts. Assembly  84  includes the support member  12 , and a modified trim panel  86  which omits the lens housing  20  of the previous panel. Instead, panel  86  is cut out inside the lip  88  provided to receive a lens assembly  90 . The lens assembly is also modified by being made shorter on the end forward of the lens  40  and provided with pronged fingers  92  which snap into slots  94  in the trim panel to retain the lens assembly  90  in place. The light guide  42  and flange  44  are essentially unchanged. 
     A modified light fixture housing  96  is also provided with a base  98 , connecting portion  100  and header wall  102 . The base  98  is shorter laterally but includes resilient clips  50  with prongs  52  and spring fingers  82  as before for engaging the door support member  12 . Base  98  includes a vertical wall  104  as before which receives in assembly a butyl adhesive sealer  106  engaging a plastic water deflector sheet  108  conventionally mounted inside the door assembly to prevent water entering the door from reaching the trim panel  86  or entering the vehicle passenger compartment. This feature could also be applied in the door assembly  10 , although not previously mentioned. 
     The connecting portion  100  is modified to an L shaped member open on two sides instead of the previous tubular form. The header wall  102  is supported on the inner end of portion  100  and includes a seal  76  as before for engagement by flange  44  of the lens assembly  90 . Outwardly angled L-shaped housing guides  110  extend laterally inward from opposite corners of the header wall  102  to assist in guiding the light guide  42  and flange  44  of the lens assembly  90  and the associated trim panel  86  into their proper positions during assembly of the trim panel and lens assembly onto the door to complete the door assembly  84 . The lamp  78  is received in a different but conventional lamp receptacle  112  which is installed on the header wall  102  by an insert and twist coupling  114  and includes an attached wiring harness  116  that is threaded through a slot  72  in the base for mounting on the support member  12  or other portion of the door assembly as before. 
     Dashed lines in FIG. 3 indicate variations in the position of the trim panel  86 , the attached lens assembly  90  and the connected light fixture housing  96  which occur not only due to manufacturing and assembly tolerances but also to temperature variations, aging and other factors affecting the shape of the trim panel during its service life. These changes are accommodated, as in the previously described embodiment, by the spring fingers  82  which bias the light fixture housing inward away from the support  12  and maintain contact of the seal  76  against flange  44  of the lens assembly under all conditions. 
     The embodiments described above thus provide the following advantages over conventional door mounted courtesy light assemblies. 1) The electric lamp, receptacle and all of the associated wiring are mounted with the housing on the support member  12  and are completely separated from connection with the associated trim panel. 2) Resilient spring fingers in the base of the light fixture housing maintain contact of the seal with the flange  44  of the light guide (and the outer wall of the lens housing in door assembly  10 ) after installation of the inner trim panel. The seal  76  thus prevents entry of contaminants into the lamp chamber under all of the varying tolerance conditions anticipated in design and manufacture of the door assembly as well as due to moving of the trim panel due to temperature changes, aging, and other changes which may occur. 3) The lens assembly  28  is removable by release of the captured snap fastener  38  or the pronged fingers  92  so as to provide access for replacement of the lamp  78  without requiring removal of the trim panel from the door. 
     These features provide an arrangement where all of the electrical assembly and mounting of the light fixture housing may be accomplished in assembly of the door module before the inner trim panel is mounted on the door during vehicle assembly. The arrangement reduces the cost of the door assembly, in that electrical connections are not required to be made at the time of vehicle assembly but are all completed in the door module assembly, when access to the electrical connections is more easily obtained and thus less costly to complete. This advantage is gained while retaining the capability of replacing the electric lamp by merely removing the internal lens assembly without requiring removal or adjustment of the trim panel. 
     While the invention has been described by reference to certain preferred embodiments, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly it is intended that the invention not be limited to the disclosed embodiments, but that it have the full scope permitted by the language of the following claims.