Patent Description:
<CIT> describes a front cover for vehicle lighting fixture, a method of manufacturing the front cover, and an electric heating structure in which part of the surface of the front cover opposed to the light source comprises a heating element having a three-dimensional curved surface. The heating element comprises a mesh pattern having intersections of a large number of grids formed of conductive metallic filaments.

<CIT> describes a vehicle lighting device in which a process of manufacturing the wire heater to be transferred to a lamp lens is described, with a transfer process of transferring the wire heater to the lamp lens. In this process an adhesive is adhered to an interior face of the lamp lens, and an electrically conductive paste for the heater of the wire pattern is transferred to an interior face of the front part of the lamp lens.

<CIT> describes a lamp assembly which includes a housing forming an interior space, and having a first portion and a second portion. A light source is disposed within the interior space and positioned to direct light through the first portion. An electrically resistive coating is disposed on the first portion of the housing, and is operable to heat the first portion to create a positive temperature gradient in which the first portion exhibits a higher temperature than the second portion so that moisture within the interior space condenses on the second portion and not the first portion.

<CIT> describes a vehicular lighting fixture heater installed on a lamp lens which is constituted of a base film, an adhesive installed at one face of the base film, and a conductive line heater which is installed at the other face of the base film and which generates heat by being supplied with current.

Disclosed are examples of a lamp or lens assembly for a vehicle that include aspects for deicing the lens. According to the invention, the assembly includes a lamp positioned in a housing with a light transmissive lens coupled to the housing in front of the lamp. According to the invention, the light transmissive lens defines a curved cross-section with a curvature extending across the lens. According to the invention, the lamp assembly includes one or more electrically conductive traces positioned on a surface of the lens, the electrically conductive traces extending across and curving with the curvature of the light transmissive lens. According to the invention, the assembly includes a first coating covering the one or more electrically conductive traces, the first coating covering a portion of the lens surface leaving a separate second portion uncovered. According to the invention, the electrically conductive traces extend outwardly away from the surface of the lens and have a thickness of at least <NUM>.

In another aspect, the electrically conductive traces are optionally positioned on an inside surface of the lens. According to the invention, the electrically conductive traces have a cross-section that is taller than it is wide. In another aspect, the curvature of the light transmissive lens optionally defines a concave interior surface, and optionally a convex exterior surface. In another aspect, the electrically conductive traces may be positioned on the concave interior surface of the lens, on the convex exterior surface of the lens, or both.

In another aspect, the electrically conductive traces are optionally primarily made of conductive silver ink. In another aspect, the silver ink may be transparent, light transmissive, reflective, or opaque.

In another aspect, the assembly may include a second coating covering the first coating and the one or more electrically conductive traces, wherein the second coating may have a different chemical composition than the first coating, and wherein either the first or second coating (or both coatings) may include an anti-fog compound. In another aspect, the light transmissive lens optionally defines a curved surface area that is at least <NUM> square inches.

In another aspect, the light transmissive lens may be substantially round, and may define a curved cross-section that includes an arc extending outwardly from a center portion of the lens. In another aspect, the light transmissive lens may be about <NUM> to <NUM>½ inches in diameter. In another aspect, the lens may be a headlight lens for a vehicle, that optionally defines an L-shaped cross-section and a corresponding corner region. The electrically conductive traces may extend across the corner region.

In another aspect, the assembly may include at least two electrically conductive terminals on the surface of the light transmissive lens. The at least two electrically conductive terminals are optionally electrically connected to the conductive traces. One of the electrically conductive terminals may be configured to receive power from a vehicle power source. In another aspect, another of the conductive terminals may be configured to receive an electrical connection to a ground circuit. In another aspect, the electrically conductive traces may have a resistance of less than <NUM> ohms.

Further forms, objects, features, aspects, benefits, advantages, and examples of the present invention will become apparent from the detailed description, and drawings provided herewith.

Illustrated at <NUM> is one example of a lamp assembly for a vehicle. As illustrated, a lamp <NUM> may be mounted to a housing <NUM>, for example, with a light-emitting portion <NUM> inside the housing and held in place but if to the housing by a mount <NUM>. The light-emitting portion <NUM> may be arranged and configured to generate and consequently transmit light rays <NUM>, these light rays eventually passing outwardly away from lamp <NUM> and optionally through a light transmissive lens <NUM> mounted to front portion of housing <NUM>. Housing <NUM> may be formed of any suitable material, and therefore may include metallic, nonmetallic, polymeric, or other such suitable materials which may be useful for retaining lamp <NUM> within housing <NUM> behind lens <NUM>. Housing <NUM> may include reflective properties as well on its inside surface <NUM>, and surface <NUM> may be shaped so as to focus or direct light rays <NUM> in any suitable way advantageous for the operation and use of lamp assembly <NUM>.

In another aspect, the lamp assembly <NUM> may be arranged configured in any suitable position, such as on a vehicle, so that light rays <NUM> passing outwardly away from the lamp assembly <NUM> may be useful for providing illumination, warning, and the like. For example, lamp assembly <NUM> may be full as a headlamp for a vehicle such as a truck or a car, or in another aspect, lamp assembly <NUM> may be configured to operate as a turn signal lamp, or in other instances, as a tail lamp, brake lamp, rear illumination lamp, or cargo lamp for illuminating the cargo area of a trailer or truck, to name a few nonlimiting examples.

A power cable <NUM> may be electrically connected to a power source, such as a vehicle power circuit. In another aspect, a ground cable <NUM> may be electrically connected to a circuit ground, such as a frame or other circuit reference point of the vehicle, thus completing a power circuit providing power to lamp <NUM>.

In another aspect, a sealing member <NUM> may be positioned between housing <NUM> and lens <NUM> to partially or fully seal the interior of housing <NUM> to reduce or eliminate the presence of contaminants or foreign object material such as moisture, dust, dirt, and the like. The sealing member <NUM> may comprise any suitable material such as rubber, polymeric material, and the like.

In another aspect, the lens <NUM> may define a curved cross-section with a curvature extending across the lamp <NUM>. The lens <NUM> may also define an inside surface <NUM> which may be the portion of lens <NUM> that is inside housing <NUM> opposite, or across from, lamp <NUM>. The lens <NUM> may also define an outside surface <NUM> which may be a surface outside housing <NUM>. In another aspect, light rays <NUM> emitted by lamp <NUM> pass first through inside surface <NUM> and then through outside surface <NUM> as light leaves lamp assembly <NUM>. Thus inside surface <NUM> may be defined as a first surface of lens <NUM> encountered by light rays <NUM> before the light rays exit lens <NUM> through a second surface such as outside surface <NUM>. In another aspect, lens <NUM> may be formed from any suitable light transmissive material such as glass, or a polymeric material such as a polycarbonate compound. The light transmissive material may be clear or colored to transmit a particular color such as red, amber, and the like, or may include prisms, raised or recessed portions in various shapes or designs, or it may define other irregularities in the lens surface or cross-section which may be introduced to improve the intensity, focus, directionality, or other useful properties of light emitted by lamp assembly <NUM>. In another aspect, lens <NUM> may be formed as a single unitary structure, or may be an aggregate of multiple separate structures retained together such as by an adhesive, ultraviolet or ultrasonic bonding, mechanical fasteners, or by other suitable means.

The lamp assembly <NUM> may include one or more conductive traces like conductive traces <NUM>-<NUM>. These one or more electrically conductive traces may be positioned on any surface of the lens <NUM>, such as on inside surface <NUM>, and/or on outside surface <NUM>. In another aspect, <FIG> illustrates an example of a light transmissive lens that defines a curved cross-section with a curvature extending across a length and/or width of the lens. In another aspect, lamp assembly <NUM> may be curved with the light transmissive lens defining a concave interior surface and/or a convex exterior surface, and the electrically conductive traces may optionally be positioned on the concave interior surface of the lens. The conductive traces <NUM>-<NUM> may be mounted adjacent the interior surface of the lens as illustrated to reduce or eliminate environmental effects on the traces, or, the conductive traces may optionally be mounted on the exterior outer surface of the lamp where such a mounting is advantageous (such as with trace <NUM>). In another aspect, traces <NUM>-<NUM> may be mounted to or mounted adjacent lens <NUM>.

In another aspect, the electrically conductive traces disclosed herein (such as traces <NUM>-<NUM> and others like them) may be primarily made of conductive silver ink. In another aspect, the disclosed electrically conductive traces, may extend outwardly away from the surface of the lens and have a thickness greater than <NUM>, greater than <NUM>, greater than <NUM>, or more. In another aspect, the electrically conductive traces disclosed herein may individually, or collectively as an overall circuit, may have a resistance of greater than <NUM> ohms, greater than hundred ohms, greater than <NUM> ohms, or greater than a thousand ohms or more. For example, the conductive traces <NUM>-<NUM> may be made primarily of conductive silver ink, have a resistance of less than <NUM> ohms, and may extend outwardly away from the surface of the lens at a thickness of at least <NUM>. Any suitable combination of thickness, resistance, and conductive material may be useful depending on various factors including the size of the light transmissive lens, the number of traces, and how the lamp is intended to be used, to name a few nonlimiting examples.

In another aspect, the electrically conductive traces disclosed herein may define any suitable cross-sectional shape such as in the case of traces <NUM>-<NUM> which define a rectangular cross-sectional shape. Other shapes may be useful such as squares, partial oval's, half circles, and the like. For example, traces <NUM>-<NUM> may be positioned on the light transmissive lens with a short edge of the rectangle closest to inside surface <NUM> of the light transmissive lens <NUM>. By positioning the long axis of a rectangular electrically conductive trace generally parallel to light rays <NUM>, the electrically conductive traces may thus advantageously minimize the light that is blocked by the presence of the conductive traces.

<FIG> illustrates other aspects of the lamp assembly <NUM> shown in <FIG>. In one aspect, one or more electrically conductive traces <NUM>-<NUM> are positioned on a surface of the lens, the electrically conductive traces extending across and curving with the curvature of the lens. For example, the lens <NUM>, curves across lamp assembly <NUM> in front of housing <NUM> with a concave shape defined by the length and/or width of lens <NUM>. In another aspect, the lens may be planar across the length and/or the width of the lens.

In another aspect, conductive traces <NUM>-<NUM> may be electrically connected to one or more terminals <NUM> and <NUM>. In this example, terminals <NUM> and <NUM> are electrically connected at opposite ends of the conductive circuit that includes traces <NUM>-<NUM>. In another aspect, conductive traces mounted to the lens of lamp <NUM> may be thought of as separate traces <NUM>-<NUM>, or as a single elongated trace rapping back and forth across lens <NUM>. In either case, terminals <NUM> and <NUM> may be coupled electrically to power, and/or ground connections respectively thus creating a complete circuit through which electricity may flow from one terminal to the other so that electrically conductive traces <NUM>-<NUM> generate heat from the electric current. In this way, conductive traces mounted to lens <NUM> may be configured to generate heat adjacent one <NUM> to remove moisture such as fog, ice, and the like.

Illustrated in <FIG>, is a lens <NUM> illustrating aspects of an automotive headlamp lens that may also be included in any of the disclosed examples. A light transmissive lens <NUM> may be positioned in front of a lamp <NUM> such that the lamp <NUM> may project light rays outwardly toward an inside surface <NUM>, the light rays passing through an outside surface <NUM> before leaving light transmissive lens <NUM> altogether. In this respect, inside surface <NUM> may be thought of as the surface of light transmissive lens <NUM> closest to lamp <NUM> and/or the first surface encountered by light rays from lamp <NUM>.

In another aspect, conductive traces <NUM>, <NUM>, <NUM>, and <NUM> may be positioned adjacent the inside surface <NUM> (or alternatively, outside surface <NUM>) of the light transmissive lens. The conductive traces may, for example, be in direct contact with the surface of the lens, although direct contact is not required for heat to transfer from the conductive traces <NUM>-<NUM> to light transmissive lens <NUM>.

In another aspect, one or more coatings may be applied to partially or fully cover the conductive traces mounted on the lens. These coatings may be transparent, semi-transparent, tinted, or may include other advantageous properties. For example, the one or more coatings covering the conductive traces may include a chemical compound useful for reducing or eliminating the formation of fog or other moisture buildup on the lens.

For example, a first coating <NUM> may partially or completely cover a first conductive trace such as conductive trace <NUM>, and a coating <NUM> may partially or completely cover a second conductive trace such as conductive trace <NUM>. The coating <NUM> may also cover a portion of light transmissive lens <NUM>, leaving and uncoated region <NUM> between coating <NUM> and coating <NUM>. Similarly, a coating <NUM> may partially or fully cover a conductive trace <NUM>, and a coating <NUM> may coat a conductive trace <NUM> leaving and uncoated region <NUM> on the inside surface <NUM>. In another aspect, portions of inside surface <NUM> of light transmissive lens <NUM> may be coated with a coating such as an anti-fog coating, while other portions may not be coated. Thus a first coating may cover the one or more electrically conductive traces, and the first coating may cover a portion of the lens surface leaving a separate second portion uncovered.

In another aspect, lens <NUM> may be curved with the light transmissive lens defining a concave interior surface and a convex exterior surface, and the electrically conductive traces may optionally be positioned on the concave interior surface of the lens, on the convex exterior surface, or both. The disclosed coatings <NUM>-<NUM> may therefore be positioned on the exterior surface of the lens, on the interior surface of the lens, or both.

<FIG> illustrates other aspects of conductive traces mounted to a light transmissive lens that may be useful in any of the disclosed examples of a vehicle lamp. Examples of conductive traces <NUM> are shown mounted adjacent, or directly to, a light transmissive lens <NUM> like other such light transmissive lenses disclosed herein elsewhere. In one example, a conductive trace <NUM> may be arranged and configured adjacent to light transmissive lens <NUM> with a cross-section that is wider than it is tall, that is, rectangular, and having the long side of the rectangle adjacent light transmissive lens <NUM>. In this example, conductive trace <NUM> may be optically reflective reflecting light rays <NUM> coming towards conductive trace <NUM>, such as from a lamp mounted behind light transmissive lens <NUM>. In this example, light rays <NUM> may be reflected directly back towards the lamp in a direction opposite, or nearly opposite, to the original path traveled toward conductive trace <NUM>. In another aspect, light rays <NUM>-<NUM> passthrough light transmissive lens <NUM> unobstructed by any of the disclosed conductive traces.

In another aspect, the disclosed conductive traces may include a rectangular cross-section such as conductive trace <NUM> where the short side of the rectangle is adjacent light transmissive lens <NUM> thus forming a trace that is taller than it is wide. In this example, trace conductive trace <NUM> may stand taller away from light transmissive lens <NUM> and project towards the light source which may allow for a conductive trace that has a similar volume as trace like trace <NUM> volume and is thus able to generate a similar amount of heat when powered, while obstructing fewer light rays <NUM> then would be obstructed by a trace like trace <NUM>, or <NUM>. Thus it may be advantageous to have traces on a light transmissive lens that are taller than they are wide thus standing further away from the lens surface but with a narrower cross-section. In another aspect, conductive traces as disclosed herein may be opaque or light absorbing like conductive trace <NUM> rather than light reflecting like trace <NUM>. This property may be advantageous for capturing any available energy (however small) that is transmitted by light rays <NUM> to aid in the heating process.

In another aspect, conductive traces as disclosed herein may include a square cross-section with a height and width that is approximately equal like what is shown at conductive trace <NUM>. In another aspect, conductive traces as discussed herein may be like conductive trace <NUM> with a partially or fully transparent property so that light rays such as light rays <NUM> may pass through the conductive trace with little to no obstruction, reflection, or absorption.

In another example, the conductive traces discussed herein may be of other shapes such as an oval, semi-oval, half circle, and the like, similar to conductive trace <NUM>. Light rays <NUM> may be reflected in multiple directions from conductive trace <NUM> effectively scattering the reflected light, or in another example, light may be absorbed rather than scattered.

In another aspect, the lens in <FIG> may be concave with a concave inner surface and a convex outer surface, or planer with substantially parallel inner and outer surfaces. As disclosed herein elsewhere, the conductive traces may be advantageously positioned on either the inner or outer surface of the lens, or on both surfaces.

Another example of a light transmissive lens with properties that may be included in any of the illustrated examples disclosed herein is shown at <NUM>. In one aspect, conductive traces <NUM>-<NUM> may be mounted adjacent to a light transmissive lens <NUM>. In another aspect, the disclosed conductive traces may be covered with multiple coatings with different properties. For example, conductive trace <NUM> may be partially or completely covered with first coating <NUM> optionally covering a portion of light transmissive lens <NUM>. In another aspect, first coating <NUM> may optionally leave uncoated portions between coating <NUM> and <NUM>, where the first coating over traces <NUM>, and <NUM> optionally does not extend completely across the inside surface of lens <NUM>. In another aspect, a second coating <NUM> may cover conductive trace <NUM>, conductive trace <NUM>, and possibly other conductive traces as well. Either the first or second coating, or both, may include chemical properties reducing or eliminating buildup of fog, droplets, or other obstructions on an inside surface of the lens. In another aspect, the first or the second coating may also be applied to adhere or otherwise retain conductive traces adjacent, or directly, to the light transmissive lens. This may also advantageously increase the heat transfer properties of the conductive traces to further reduce reduce or eliminate fog, droplets, or ice buildup on either the inside or outside of the lens.

In another aspect, the lens at lens <NUM> may be concave with a concave inner surface and a convex outer surface. The conductive traces in the disclosed first and second coatings may be advantageously positioned on the concave interior surface of the lens, or optionally, on the outside convex surface of the lens, or both.

Another example of a lens <NUM> is illustrated in <FIG>. In this example, lens <NUM> is generally circular in shape having a radius <NUM> and a diameter <NUM>. Multiple conductive traces <NUM>-<NUM> may be included in mounted adjacent to lens <NUM> either on an inside surface or outside surface of the lens. As in the other examples disclosed herein, conductive traces <NUM>-<NUM> may also be thought of as a single conductive trace that winds its way around lens <NUM> in any suitable manner, only one of which is illustrated, such arrangement being illustrative rather than restrictive. A terminal <NUM> and terminal <NUM> may be included for connecting to power and ground connections which may apply electrical current through the conductive trace(s). Such conductive current may cause heating in the traces thus raising the temperature of lens <NUM> to reduce or eliminate fluid buildup either on the interior or exterior surface of the lens.

As illustrated in <FIG>, lens <NUM> may have a curved cross-section such that the lens defines an arc <NUM> with an outside surface <NUM>. With an arcuate cross-section, lens <NUM> may also define a depth <NUM> giving the lens a depth as well as an approximately equal length and width according to the generally circular shape of the lens. In another aspect, the lens diameter <NUM> (which here corresponds to with <NUM>) may be less than or equal to <NUM> inches, greater than <NUM> inches, greater than <NUM> inches, greater than <NUM> inches, or more. In another aspect, lenses disclosed herein which may be round, rectangular, L-shaped, or any other suitable shape, may define surface area that is less than or equal to <NUM> square inches, greater than <NUM> square inches, greater than <NUM> square inches, greater than <NUM> square inches, or more. For example, lens <NUM> may be about <NUM> to <NUM>½ inches in diameter with a surface area of <NUM> square inches, or more.

Another example of a lamp assembly <NUM> is illustrated in <FIG>, <FIG>. A lamp assembly <NUM> optionally includes a lens assembly <NUM>, a sealing member <NUM>, and a lamp mounting assembly <NUM>, all of which may be configured to couple together by any suitable means. The lens assembly <NUM> may include a light transmissive lens <NUM> according to any of the examples illustrated herein and described elsewhere. A terminal <NUM> and terminal <NUM> may also be included and configured to electrically connect to power cable <NUM> and ground cable <NUM> respectively in order to complete electric circuit with conductive traces such as <NUM>-<NUM>. lens assembly <NUM> optionally includes a turn signal lamp mount <NUM> that may include a turn signal bulb or other such lamps.

In another aspect, lens assembly <NUM> may also be curved, such as in a general L-shape, thus defining a corner region <NUM> where the lamp bends around at nearly right angles to accommodate the corner shape of the vehicle. Such an L-shape is optional, as some headlamp assemblies like the one disclosed may not include this configuration corner configuration.

In another aspect illustrated in <FIG>, lamp assembly <NUM> may include an optional lamp mounting assembly <NUM> having an optional lamp mount <NUM> that may include one or more reflectors <NUM> and <NUM>. In another aspect, lamps <NUM> and <NUM> like those disclosed herein elsewhere, may be mounted at the rear portion of the reflector <NUM> and reflector <NUM> individually. Lamps <NUM> and <NUM> may be electrically connect to power via power and ground cables <NUM>, <NUM>, <NUM>, and <NUM>. The reflector <NUM> and reflector <NUM> may be advantageously shaped and configured to direct light rays from lamps mounted at the rear portion of the reflector to focus and direct light passing through lens assembly <NUM> and light transmissive lens <NUM> in particular.

Aspect, lamp assembly <NUM> may include a power terminal <NUM> configured to receive power from power cable <NUM> and two electrically connect with terminal <NUM> of the lens <NUM> thus providing power to traces mounted to light transmissive lens <NUM>. In another aspect illustrated in <FIG>, traces <NUM>-<NUM> may extend across a length <NUM> of the lens <NUM>, and across its depth <NUM> as the traces wrap around the corner region <NUM> and onto the corner portion of the L-shaped lens. In another aspect, traces <NUM>-<NUM> may extend across a width <NUM> of the lens.

While examples of the invention are illustrated in the drawings and described herein, this disclosure is to be considered as illustrative and not restrictive in character. The detailed description is included herein to discuss aspects of the examples illustrated in the drawings for the purpose of promoting an understanding of the principles of the inventions. No limitation of the scope of the inventions is thereby intended. Any alterations and further modifications in the described examples, and any further applications of the principles described herein are contemplated as would normally occur to one skilled in the art to which the inventions relate. Some examples are disclosed in detail, however some features that may not be relevant may have been left out for the sake of clarity.

Singular forms "a", "an", "the", and the like include plural referents unless expressly discussed otherwise. As an illustration, references to "a device" or "the device" include one or more of such devices and equivalents thereof.

Directional terms, such as "up", "down", "top" "bottom", "fore", "aft", "lateral", "longitudinal", "radial", "circumferential", etc., are used herein solely for the convenience of the reader in order to aid in the reader's understanding of the illustrated examples. The use of these directional terms does not in any manner limit the described, illustrated, and/or claimed features to a specific direction and/or orientation.

Multiple related items illustrated in the drawings with the same part number which are differentiated by a letter for separate individual instances, may be referred to generally by a distinguishable portion of the full name, and/or by the number alone. For example, if multiple "laterally extending elements" 90A, 90B, 90C, and 90D are illustrated in the drawings, the description may refer to these as "laterally extending elements 90A-90D," or as "laterally extending elements <NUM>," or by a distinguishable portion of the full name such as "elements <NUM>".

Claim 1:
A lamp assembly for a vehicle, comprising
a lamp positioned in a housing;
a light transmissive lens coupled to the housing in front of the lamp, the light transmissive lens defining a curved cross-section with a curvature extending across the lens;
one or more electrically conductive traces positioned on a surface of the lens, the electrically conductive traces extending across and curving with the curvature of the light transmissive lens; and
a first coating covering the one or more electrically conductive traces, wherein the first coating covers a portion of the lens surface leaving a separate second portion uncovered;
wherein the electrically conductive traces extend outwardly away from the surface of the lens and have a thickness of at least <NUM>,
characterized in that the electrically conductive traces have a cross-section that is taller than it is wide.