Patent Description:
Many vehicles have lighting systems that include some form of a head lamps, tail lamps, and side marking lamps. Lighting systems that use incandescent or HID bulbs, for example, generate sufficient waste heat so that snow and/or ice does not form or stick on lenses of the lighting system when the ambient temperature is below the freezing temperature of water. Snow or ice on the lens of the lighting system may reduce luminous transmittance of the lens, thereby degrading the performance of the lighting system. Some lighting systems, such as those using light emitting diode (LED) bulbs, do not generate sufficient waste to heat melt ice or snow on the lighting system lens due to their energy efficiency.

<CIT> discloses a connector connected to a mating connector, which is fixed in a case of a motor, wherein the connector comprises: an outer housing attached to the case; a first inner housing accommodating a first terminal engaging to the mating connector, being accommodated in the outer housing movably in the engaging direction of the first terminal and in the intersectional direction of the engaging direction; a first inner connector engaging to the mating connector; a second inner housing accommodating a second terminal electrically connected to an electric circuit in the case and being fixed in the outer housing and a braided wire, and further including a connection portion connecting the first terminal and the second terminal and a packing attached to the first inner housing. Publication <CIT> discloses a vehicular lighting fixture having a lamp body, a luminous source installed in this lamp body, and a front lens assembled in a front opening part of the lamp body. A resistance heating element is installed in at least one side of the inner and outer surfaces of the front lens.

Therefore, what is needed are improved systems and methods to sufficiently heat a lighting system lens to melt snow and ice to avoid reducing luminous transmittance of the lighting system lens.

According to one embodiment of the invention, a lighting assembly is provided. The lighting assembly includes a lens covering a light source, a resistive circuit disposed on a surface of the lens, a post terminal connected to the resistive circuit, and a receptacle terminal having a connection portion defining an aperture configured to receive a corresponding plug terminal along a longitudinal axis and an attachment portion configured to attach the receptacle terminal to a wire. The lighting assembly also includes a terminal housing defining a first oval-shaped opening and an oval-shaped cavity in which the connection portion is disposed. The connection portion is sized, shaped, and arranged within the cavity to be movable along a lateral axis perpendicular to the longitudinal axis. The lighting assembly further includes a terminal housing cover defining a second oval-shaped opening aligned with the first oval-shaped opening, wherein the terminal housing and the terminal housing cover are integrally formed, wherein a hinge is disposed between the terminal housing and the terminal housing cover, wherein the terminal housing cover is attached to the terminal housing by a flexible latch feature located opposite the hinge on the terminal housing cover which engages a ridge on the terminal housing, and wherein the terminal housing cover is configured to enclose the cavity and secure the connection portion within the cavity.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, a slot is formed between the terminal housing and the terminal housing cover through which the attachment portion extends.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the connection portion is characterized as having a circular ring shape.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the attachment portion is angularly offset relative to the connection portion.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the attachment portion is arranged at a <NUM>-degree angle relative to the connection portion.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the connection portion defines a contact spring configured to exert a contact force on the post terminal.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the light source comprises a light emitting diode.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the post terminal has a cylindrical body and a rounded tip.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the connection portion defines a plurality of contact springs arranged about the aperture configured to exert a contact force on the post terminal.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the post terminal is soldered to the resistive circuit.

In an example embodiment having one or more features of the lighting assembly of the previous paragraph, the lighting assembly further includes a pair of the receptacle terminals, a pair of the terminal housings, a pair of the terminal housing covers, and a pair of the post terminals, wherein the pair of the terminal housing covers are attached to the terminal housings by living hinges.

According to another embodiment of the invention, a receptacle connector assembly for a lighting assembly is provided. The receptacle connector assembly includes a receptacle terminal having a ring-shaped connection portion defining a central aperture configured to receive a corresponding plug terminal along a longitudinal axis and an attachment portion configured to attach the receptacle terminal to a wire. The receptacle connector assembly also includes a terminal housing defining a first oval-shaped opening and an oval-shaped cavity in which the connection portion is disposed. The connection portion is sized, shaped, and arranged within the cavity to be movable along a lateral axis perpendicular to the longitudinal axis. The receptacle connector assembly further includes a terminal housing cover separate from the terminal housing and defining a second oval-shaped opening. The terminal housing cover is attached to the terminal housing by two flexible latch features that are located on opposite ends of the terminal housing cover, thereby enclosing and securing the connection portion within the cavity. The first oval-shaped opening is aligned with the second oval-shaped opening.

In an example embodiment having one or more features of the receptacle connector assembly of the previous paragraph, a slot is formed between the terminal housing and the terminal housing cover through which the attachment portion extends.

In an example embodiment having one or more features of the receptacle connector assembly of the previous paragraph, the attachment portion is angularly offset relative to the connection portion.

In an example embodiment having one or more features of the receptacle connector assembly of the previous paragraph, the attachment portion is arranged at a <NUM>-degree angle relative to the connection portion.

In an example embodiment having one or more features of the receptacle connector assembly of the previous paragraph, the connection portion defines a plurality of contact springs surrounding the central aperture configured to exert a contact force on the corresponding plug terminal.

In the preceding drawings and in the following description, similar elements share the last two reference numbers.

In the following detailed description, numerous specific details are set forth to provide a thorough understanding of the various described embodiments.

<FIG> illustrate a non-limiting example of lighting assembly <NUM>, e.g. a motor vehicle headlight. The lighting assembly <NUM> includes a light source or lamp <NUM>, in this example a light emitting diode (LED) array. The LED lamp <NUM> is disposed within a lamp housing <NUM>. As best shown in <FIG>, a lens <NUM> encloses the lamp <NUM> within the lamp housing <NUM>. As best shown in <FIG>, the lens <NUM> has a resistive heating circuit <NUM> disposed on a surface of the lens <NUM> that is heated by an electric current flowing through the heating circuit <NUM> to heat the lens <NUM> to remove ice and/or snow from the lens <NUM>. In the illustrated example of a headlight, the lens <NUM> has a luminous transmittance greater than or equal to <NUM>. The lighting assembly <NUM> also includes an electrical connector assembly <NUM> to provide an electrical current to the heating circuit <NUM> on the lens <NUM>. The connector assembly <NUM> includes a pair of male post terminals <NUM> attached to the lens <NUM> and a pair of female receptacle terminal assemblies <NUM> configured to mate with the male post terminals <NUM>. The lighting assembly <NUM> also includes several retaining rings to secure the lens <NUM> to the lamp housing <NUM> and the receptacle terminal assemblies <NUM> within the lamp housing <NUM>.

<FIG> show the lens <NUM>. The heating circuit <NUM> is arranged on the inner surface of the lens <NUM> and contains several radial elements and concentric elements. The heating circuit <NUM> may be formed on the lens <NUM> by a screen-printing process, a pad printing process or by depositing the circuit material on the lens <NUM> using a robotically controlled dispenser. The lens <NUM> may be formed of a glass or polymeric material. The post terminals <NUM> are attached to connection pads in the heating circuit <NUM>. The post terminals <NUM> may be attached to the heating circuit <NUM> using a low temperature solder. Alternatively, the post terminals <NUM> may be attached to the heating circuit <NUM> using an electrically conducive adhesive, spin welding, or other materials and processes suitable for connecting a metal terminal to a circuit material disposed on glass or polymer. In the example lighting assembly <NUM> illustrated in <FIG>, the lens <NUM> is characterized as having a round shape and a first post terminal <NUM> is arranged at a two o'clock position which is radially opposite a second post terminal <NUM> arranged at an eight o'clock position.

<FIG> illustrate the connector assembly <NUM> as it is installed within the lighting assembly <NUM>. The male post terminal <NUM> on the lens <NUM> is received within a female receptacle terminal <NUM> of the receptacle terminal assembly <NUM>, thereby providing an electrical connection to the heating circuit <NUM> on the lens <NUM>.

<FIG> illustrate the receptacle terminal assembly <NUM> which includes the receptacle terminal <NUM> that is formed from sheet metal, e.g. plated brass sheet stock. The receptacle terminal <NUM> has a ring-shaped connection portion <NUM> that defines a central aperture <NUM> in which the post terminal <NUM> is received along a longitudinal axis. The connection portion <NUM> defines a plurality of arcuate contact spring <NUM> surrounding the central aperture <NUM> that is configured to exert a contact force on the corresponding post terminal <NUM>. The receptacle terminal <NUM> also includes an attachment portion <NUM> that is configured to attach the receptacle terminal <NUM> to an electrical wire <NUM>. The attachment portion <NUM> is angularly offset relative to the connection portion <NUM>. In the illustrated example, the attachment portion <NUM> is arranged at a <NUM>-degree angle relative to the connection portion <NUM>. The angled arrangement of the connection portion <NUM> allows a tighter fit between the lens and the housing, lessening the likelihood of gaps between the lens <NUM> and lamp housing <NUM> that could allow light leaks from the lighting assembly <NUM>.

The illustrated attachment portion <NUM> include a pair of crimp wings <NUM> that are crimped to the wire <NUM>. Alternative embodiments of the attachment portion <NUM> may be envisioned that have a tubular section configured to be soldered to the wire <NUM> or a flat section to which the wire <NUM> may be sonically welded. The receptacle terminal assembly <NUM> also includes a terminal housing <NUM> that defines a first oval-shaped opening <NUM> and an oval-shaped cavity <NUM> in which the connection portion <NUM> is disposed. The connection portion <NUM> is sized, shaped, and arranged within the cavity <NUM> to be movable along a lateral axis Y that is perpendicular to the longitudinal axis Z. The oval-shaped cavity <NUM> provides lateral positional tolerance between the receptacle terminal <NUM> and the post terminal <NUM>. The terminal housing <NUM> also defines a pair of slits <NUM> in the side walls <NUM> of the cavity <NUM> that allow the connection portion to also move along a transverse axis X that is perpendicular to both the lateral axis Y and the longitudinal axis Z. These slits <NUM> provide two degrees of freedom of movement for the connection portion <NUM>, thereby providing additional positional tolerance between the receptacle terminal <NUM> and the post terminal <NUM>. The receptacle terminal assembly <NUM> further includes a terminal housing cover <NUM> defining a second oval-shaped opening <NUM> attached to the terminal housing <NUM>, thereby enclosing the connection portion <NUM> within the terminal housing <NUM>. The first oval-shaped opening <NUM> is aligned with the second oval-shaped opening <NUM>. A slot <NUM> is formed between the terminal housing <NUM> and the terminal housing cover <NUM> through which the attachment portion <NUM> extends. In example illustrated in <FIG>, the terminal housing <NUM> and the terminal housing cover <NUM> are integrally formed having a living hinge <NUM> is disposed between the terminal housing <NUM> and the terminal housing cover <NUM> formed of a thin section of material between the terminal housing <NUM> and the terminal housing cover <NUM>. <FIG> illustrate a process of assembling the receptacle terminal assembly <NUM>. The receptacle terminal <NUM> is placed within the cavity <NUM> and then the hinge <NUM> is folded to attach the terminal housing cover <NUM> to the terminal housing <NUM>. The terminal housing cover <NUM> is secured to the terminal housing <NUM> by a flexible latch feature <NUM> located opposite the hinge <NUM> on the terminal housing cover <NUM> which engages a ridge or ledge <NUM> on the terminal housing <NUM>.

<FIG> illustrate an example of the post terminal <NUM>. The post terminal <NUM> is formed of an electrically conducive material, e.g. a copper-based material. The post terminal <NUM> is generally cylindrical with a rounded tip and a flat base, thereby giving the post terminal <NUM> a bullet shape. The post terminal <NUM> may be a solid piece formed by machining a billet or rod to the desired shape or casting a molten material to the desired shape. Alternatively, the post terminal <NUM> may be hollow and formed by rolling and stamping sheet metal.

<FIG> shows the connector assembly <NUM> in a partially assembled position. The rounded end of the post terminal <NUM> contacts and spreads the contact springs <NUM> of the receptacle terminal <NUM> so that the contact springs <NUM> exert a contact force on the post terminal <NUM> to ensure a reliable and low resistance electrical connection between the post terminal <NUM> and the receptacle terminal <NUM>.

<FIG> illustrate an alternative design of the receptacle terminal assembly <NUM>. In this design, the terminal housing <NUM> and the terminal housing cover <NUM> are two separate pieces and the terminal housing cover <NUM> is attached to the terminal housing <NUM> by two flexible latch features <NUM> that are located on opposite ends of the terminal housing cover <NUM>.

While the illustrated example is a motor vehicle headlight, other embodiments of the invention may be applied to motor vehicle taillights, side marker lights, and center high mounted stop lights. Other embodiments of the invention may be applied to non-automotive applications, such as building security lighting systems. Yet other embodiments for the invention may be applied to non-lighting applications, such as covers for a camera, a radio detection and ranging (RADAR) system, or a light imaging detection and ranging (LIDAR) system.

Accordingly, a lighting assembly <NUM> including an electrical connector assembly <NUM> for a heating circuit <NUM> on the lens <NUM> and a receptacle terminal assembly <NUM> for such a lighting assembly <NUM> is provided. The connector assembly <NUM> provide a simple push in electrical connection that may be made when coincidentally with installing the lens <NUM> to the lamp housing <NUM>. The receptacle terminal <NUM> has two axes on movement within the receptacle terminal assembly <NUM> providing dimensional tolerance for the electrical connection.

While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments and are by no means limiting and are merely prototypical embodiments.

As used herein, 'one or more' includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.

The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and/or" as used herein refers to and encompasses all possible combinations of one or more of the associated listed items. It will be further understood that the terms "includes," "including," "comprises," and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Claim 1:
A lighting assembly (<NUM>), comprising:
a lens (<NUM>) covering a light source (<NUM>);
a resistive circuit disposed on a surface of the lens (<NUM>);
a post terminal (<NUM>) connected to the resistive circuit;
a receptacle terminal (<NUM>) having a connection portion (<NUM>) defining an aperture configured to receive the post terminal (<NUM>) along a longitudinal axis (X) and an attachment portion (<NUM>) configured to attach the receptacle terminal (<NUM>) to a wire (<NUM>);
characterized by
a terminal housing (<NUM>) defining a first oval-shaped opening (<NUM>) and an oval-shaped cavity (<NUM>) in which the connection portion (<NUM>) is disposed, wherein the connection portion (<NUM>) is sized, shaped, and arranged within the cavity (<NUM>) to be movable along a lateral axis (Y) perpendicular to the longitudinal axis (X);
a terminal housing cover (<NUM>) defining a second oval-shaped opening (<NUM>) aligned with the first oval-shaped opening (<NUM>), wherein the terminal housing (<NUM>) and the terminal housing cover (<NUM>) are integrally formed, wherein a hinge (<NUM>) is disposed between the terminal housing (<NUM>) and the terminal housing cover (<NUM>), wherein the terminal housing cover (<NUM>) is attached to the terminal housing (<NUM>) by a flexible latch feature (<NUM>) located opposite the hinge (<NUM>) on the terminal housing cover (<NUM>) which engages a ridge (<NUM>) on the terminal housing (<NUM>), and wherein the terminal housing cover (<NUM>) is configured to enclose the cavity (<NUM>) and secure the connection portion (<NUM>) within the cavity (<NUM>).