Patent Description:
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 <CIT>; <CIT>; <CIT> and <CIT>.

Often the repair material needs to be cured with an ultraviolet 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.

Various concerns exist with respect to curing lamps. Typically, cracks are cured on site, so the repair technician needs to be able to transport all necessary equipment to the location of the windshield or other material to be repaired. Also, the repair technician is desirous of repairing the crack in an efficient manner with good results. Many times the lamp is not as long as the crack to be repaired.

Typically, the lamp is moved along the crack to cure the resin along the crack. A lamp which is too small may not cover enough area over the crack to be efficient for the technician. Conversely, a lamp which is too large is wasteful, may not follow the path of the crack, and may be difficult to transport. If the lamp is not appropriately placed over the repair material, the material may not properly cure. <CIT> discloses a curing lamp apparatus for mounting to a work surface according to the preamble of claim <NUM>.

There is a need for further improvements with respect to curing lamps.

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. Attached to the base is one or more lamp segments or elements. If more than one lamp element is provided, the lamp elements are arranged in a line, with a first lamp element connected to the base, and the first lamp element and any other lamp elements moveable relative to each other for placement over a crack to be repaired.

One, two, three, four or more lamp elements are provided. A first bar or arm is hingedly mounted to the base and includes a distal end extending away from the base. A first lamp element is hingedly mounted at the distal end of the first bar. One or more further lamp elements are hingedly connected to each other in a line. The further lamp elements are moveable relative to each other for closely following the pathway of a crack in the work surface to be repaired.

A further aspect of the present invention relates to a curing lamp apparatus for mounting to a work surface wherein a plurality of lamp elements are each hingedly mounted to each other in a line extending from an end of a base mountable to a work surface with a suction cup.

Another aspect of the invention is to include a further suction cup at a distal end of the lamp element or line of elements.

Another aspect of the present invention relates to a method of using a curing lamp apparatus including the steps of mounting a base of the lamp apparatus to a surface to be repaired, rotating a first lamp element of the lamp apparatus relative to a base to position the first lamp element over a first portion of a crack in the surface, and rotating a second lamp element of the lamp apparatus relative to the first lamp element to position the second lamp element over a second portion of the crack in the surface. The method preferably includes rotating further lamp elements in a line relative to the base to follow the pathway of a crack in the work surface to be repaired.

A further method relates to positioning the lamp element or elements over the crack, rotating the lamp element(s) away from the crack for inspection or repair, then rotating the lamp element(s) over the crack for curing of the repair material.

The lamp apparatus and method of the present invention further concerns a folding lamp apparatus with a plurality of lamp elements separately hinged in a line, and with the lamp apparatus being mountable to the surface to be repaired.

On the top of each lamp element are pivot joints that are connected by links and a fastener at each pivot joint. These pivot joints are tightened to have enough tension so that the segments can be adjusted and remain in the position in which each is arranged. The segment positions are arranged to follow the shape of the crack to be repaired.

Referring now to <FIG> and <FIG>, a lamp apparatus <NUM> in accordance with one preferred embodiment of the present invention is shown. Lamp apparatus <NUM> includes a base <NUM> including a first suction cup <NUM> used for mounting lamp apparatus <NUM> to a windshield or other surface <NUM> to be repaired. Extending from base <NUM> is an arm <NUM> having a distal end <NUM> including at least one lamp element <NUM>. In the preferred embodiment, two or more lamp elements <NUM> are provided. As shown four lamp elements 16a, 16b, 16c, 16d are shown.

Each lamp element <NUM> projects ultraviolet (UV) light onto the windshield <NUM>. Lamp apparatus <NUM> and the UV light it provides is used to cure repair material positioned in a crack <NUM> in windshield <NUM>. One UV source is LED bulbs.

Base <NUM> includes a mount <NUM> for defining a first hinge point <NUM> between base <NUM> and arm <NUM>. Arm <NUM> can be pivotally moved relative to base <NUM> about first hinge point <NUM>. Tensioning fastener <NUM> allows arm <NUM> to be clamped or held more tightly or less tightly to base <NUM> to control the ease of rotation. Tension in the hinge mount can be adjusted through the use of a screwdriver or other tool. Enough tension is desired so that the lamp elements <NUM> generally stay in the position placed by the user.

Arm <NUM> is in the form of a first bar extending from a proximal end <NUM> adjacent to base <NUM> to a distal end <NUM>. First lamp element 16a includes a second bar <NUM> connected at proximal end <NUM> to distal end <NUM> of arm <NUM>. Distal end <NUM> of first bar <NUM> and proximal end <NUM> of second bar <NUM> define a second hinge point <NUM> for lamp apparatus <NUM>. A distal end <NUM> of second bar <NUM> is hingedly mounted to a proximal end <NUM> of another arm <NUM>. Tensioning fasteners <NUM> allows arms <NUM>, <NUM> to be clamped or held more tightly or less tightly to first lamp element 16a to control the ease of rotation.

First bar <NUM> is moveable about first hinge point <NUM> as shown. First hinge point <NUM> defines a hinge axis <NUM> perpendicular to lower suction cup surface <NUM>. Lower suction cup surface <NUM> is perpendicular to longitudinal axis <NUM>, which is perpendicular to windshield <NUM> as shown in <FIG>.

Further lamp elements 16b, 16c, and 16d are connected to each other with arms or bars <NUM> and <NUM>, respectively. Lamp elements 16a-d are similarly constructed. Arms <NUM>, <NUM>, <NUM>, <NUM> are similarly constructed. Hinge points <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> are each defined by tensioning fasteners <NUM>, and further each define respective hinge axes parallel to longitudinal axis <NUM>.

In the preferred embodiment, lamp apparatus <NUM> includes the example movements and positions illustrated in <FIG> and <FIG> in order to provide more flexibility for positioning lamp elements <NUM> over a variety of shapes for crack <NUM> in windshield <NUM>.

Each lamp element 16a-d is pivotally moveable about respective hinge points as shown. Lamp elements 16a-d move independently in the preferred embodiment. Lamp elements 16a-d pivot about respective first and second hinge axes which are all parallel to longitudinal axis <NUM>. In this manner, a variety of positions for lamp elements <NUM> are possible in order to more closely follow a variety of different crack shapes.

Lamp elements 16a-d include a main V-shaped housing <NUM> including an upper surface <NUM> defining fastener openings <NUM> for the tensioning fasteners <NUM> to join to the arms. Bottom surface <NUM> of lamp housing <NUM> defines a V- or U-shaped opening <NUM> to allow light to project on to the surface to be cured. Small rounded feet <NUM> on lower edges <NUM> of bottom surface <NUM> engage the surface to be repaired. Open ends <NUM> of lamp housing <NUM> are provided so as to not obstruct light extending from bulbs <NUM> adjacent to the open ends <NUM>.

Main housing <NUM> includes a longitudinal channel <NUM> for receiving a PC board assembly <NUM> and a hole <NUM> for a fastener <NUM>.

The base <NUM> of lamp apparatus <NUM> includes a main or driver circuit board <NUM>, a switch <NUM>, and a battery <NUM>. The base <NUM> includes two bumpers <NUM> for engaging the windshield <NUM>. The lamp elements 16a-d are pivotally mounted to one another in a line to allow for multiple relative positions so as to allow for the lamp outputs to be positioned closely to a crack on a windshield that may take many shapes, including linear, or curved.

Each lamp element 16a-d includes a PC board <NUM> and at least one UV LED module <NUM> which together form a UV LED PC board assembly <NUM>. As shown, each lamp element 16a-d includes two UV LED modules <NUM>. Electrical connector sockets <NUM> at opposite ends allow for powering of each of the UV LED PC board assemblies <NUM>.

In one embodiment, each of these UV LED PC board assemblies <NUM> is connected by a flexible two-wire assembly <NUM> with connector plugs <NUM> at both ends. The flexible two-wire assemblies <NUM> are used to connect each of the four UV LED PC board assemblies of the lamp elements 16a-d in a serial arrangement. In some arrangements, the wires can be coiled to maintain them in an organized manner.

A two-wire assembly <NUM> connects the driver circuit board <NUM> and passes through a hole <NUM> in the base <NUM> to the first UV LED PC board assembly <NUM> in the first lamp element 16a.

In one embodiment, the driver circuit board <NUM> is powered by a rechargeable lithium ion three-cell <NUM> volt battery <NUM>.

On the end lamp segment there is a distal suction cup <NUM> to help keep the line of segments stable and in their arranged positions. Suction cup <NUM> includes an arm <NUM> and a handle <NUM>.

After the crack repair is completed, the lamp elements <NUM> are folded up in a storage position to be able to store the lamp assembly in a tool box or on a shelf.

In use, lamp apparatus <NUM> is attached to the windshield <NUM> by first suction cup <NUM>. After the cup is attached to the glass, a suction cup lever <NUM> is flipped downward to set the suction cup securely to the windshield. In the illustrated embodiment, there are two rubber bumpers <NUM> on the underside of the base, opposite the suction cup providing protective support for the base on the windshield.

The second suction cup <NUM> attached to the end lamp element 16d is set after the segments are arranged to align with the shape of the crack.

The lamp apparatus <NUM> includes a charger port <NUM> that connects to the side of the lamp housing. An indicator light <NUM> on the battery charger changes from red to green when the battery is fully charged.

Base <NUM> includes a bottom <NUM> and a cover <NUM>. First suction cup <NUM> includes a mounting post <NUM> connected to suction cup lever <NUM>. A suction cup cover <NUM> is positioned over first suction cup <NUM>.

To operate the lamp apparatus <NUM> once it is in position, the momentary start switch <NUM> is depressed for at least one second and the lamp apparatus <NUM> will operate for five minutes and shut off automatically. The indicator light next to the charging receptacle in the lamp housing will indicate a low battery when the light comes on and stays on. When this indicator is blinking, it indicates the driver circuit is in the <NUM>-minute mode. This mode is achieved by pushing and holding the start button until the indicator light begins to blink and then the start switch is released. The lamp will stay on for <NUM> minutes and turn off automatically. The <NUM> minute cure cycle is used about <NUM>% of the time. On occasion there may be times that the technician wants to cure a break longer and the second time is set at <NUM> minutes. The technician can just let it run out or shut it off after the resin is cured.

The segment height is high enough for the two LEDs in each segment to intersect with each other and the LEDs in the adjacent segments, to provide a consistent line of UV light coverage over the crack being repaired.

Each lamp element <NUM> includes main housing <NUM>, and an interior reflector <NUM>. First links <NUM>, <NUM>, <NUM>, <NUM> connect each lamp segment or element to an adjacent lamp segment or element. Second links <NUM> connect in a pivotal manner to the first links.

In one preferred embodiment the shape of the reflecting sides of the interior reflector is in the form of a mirrored aluminum element <NUM> defining a <NUM>-degree angle between main sides.

Referring now to <FIG>, lamp apparatus <NUM> is shown in a folded position, such as for storage or transport. In the folded position, lamp elements <NUM> are positioned in two rows parallel to each other and base <NUM> due to the various hinge points. Other folded up storage positions are possible.

Claim 1:
A curing lamp apparatus for mounting to a work surface comprising:
a suction cup (<NUM>) defining a longitudinal axis (<NUM>) perpendicular to a suction cup surface (<NUM>) engageable with the work surface;
a base (<NUM>) mounted to the suction cup;
a first bar (<NUM>) having a proximal end (<NUM>) hingedly mounted to the base (<NUM>) and a distal end (<NUM>) extending from the base (<NUM>), and further defining a first hinge point (<NUM>) between the base (<NUM>) and the proximal end of the bar (<NUM>);
said curing lamp being characterised in that it further comprises:
a first lamp element (16a) hingedly mounted to the distal end (<NUM>) of the first bar (<NUM>) and defining a second hinge point (<NUM>), and further defining a third hinge point (<NUM>) between the first lamp element (16a) and a second bar (<NUM>);
a second lamp element (16b) hingedly mounted to a distal end of the second bar (<NUM>) to form a line of lamp elements.