Patent Description:
A vehicle (e.g., automobile, truck, construction equipment, farm equipment, automated factory equipment) may include a number of sensors to provide information about the vehicle and the environment inside and outside the vehicle. For example, a camera may provide information about objects around the vehicle and within a field a view of the camera provided by the lens. Cameras mounted external to the vehicle, e.g., on side mirrors, front grills, etc., can be prone to ice build-up. The ice build-up can impair (or block entirely) the camera field of view and limit availability of the camera. Heater elements can be mounted outside the camera using an external harness assembly using wire management techniques and employing techniques to limit the impact to the styling of the vehicle.

<CIT> (see <FIG>) discloses a lens assembly comprising a lens, a lens barrel and a heater element, the heater element comprising an electrical lead to provide power to the heater element.

The invention is defined by independent claim <NUM>, with preferred embodiments set out in the dependent claims.

For a better understanding, reference may be made to the accompanying drawings, in which:.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which the present disclosure pertains.

The invention comprises, consists of, or consists essentially of the following features, in any combination.

<FIG> schematically depicts a lens assembly <NUM>. The lens assembly <NUM> is similar to that disclosed in <CIT> and titled "Lens Assemblies with Integrated Heater Elements" (published as <CIT>).

The lens assembly <NUM> includes a lens <NUM> having an inner surface (depicted at <NUM> in <FIG>) and an outer surface <NUM>. A lens barrel <NUM> supports the lens <NUM> and has outer and inner lens barrel ends <NUM> and <NUM> (in <FIG>), respectively, separated by a longitudinal axis L. The "longitudinal" direction, as shown herein, is substantially parallel to the longitudinal axis L and is the vertical direction, in the orientation of <FIG>. The lens <NUM> is arranged along the longitudinal axis L to span the outer lens barrel end <NUM> such that the inner surface <NUM> of the lens <NUM> is within the lens barrel <NUM> and the outer surface <NUM> of the lens <NUM> is outside the lens barrel <NUM>.

A heater element (<NUM> in <FIG>) is longitudinally adjacent the inner surface <NUM> of the lens <NUM> and is located within the lens barrel <NUM>. The heater element <NUM> may extend circumferentially about the longitudinal axis L. The term "circumferentially", as used herein, indicates a structure at least partially encircling the longitudinal axis L, in a plane perpendicular thereto, though it should be noted that the "circumferential" structure may be, but is not necessarily, coaxial with the longitudinal axis L. The heater element <NUM> has at least one heater element electrical lead (shown as <NUM> in <FIG>) extending radially and longitudinally therefrom to provide power to the heater element <NUM>. The heater element <NUM> may be helpful, for example, in clearing unwanted moisture, such as precipitation or ice, from the lens <NUM> during use of the lens assembly <NUM> with a motor vehicle.

As shown in the Figures, the lens <NUM> and the lens barrel <NUM> may be provided in a modular assembly arrangement including the heater element <NUM>. The term "modular assembly" is used herein to indicate a situation in which the lens <NUM>, lens barrel <NUM>, and heater element <NUM> are produced as a single-piece subassembly (as shown in <FIG>) by a supplier, and/or at a different time than the lens assembly <NUM> as a whole is completed as shown in <FIG>.

A carrier ring <NUM> extends circumferentially around at least a portion of an outside lens barrel surface <NUM> adjacent the inner lens barrel end <NUM>. The carrier ring <NUM> includes at least one lead station <NUM> radially aligned with the heater element electrical lead <NUM>, when the lens assembly <NUM> is assembled as shown in the Figures. The "radial" direction, as referenced herein, indicates a direction substantially perpendicular to the longitudinal axis L, in a polar coordinate system centered upon the longitudinal axis L. Is contemplated that at least as many lead stations <NUM> are provided to the carrier ring <NUM> as there are heater element electrical leads <NUM> in the lens assembly <NUM>, though one of ordinary skill in the art will readily understand that a larger number of lead stations <NUM> could be provided, to accommodate flexibility in the assembly process. As shown in at least <FIG>, the heater element electrical lead <NUM> may be at least partially interposed between the lens barrel <NUM> and the carrier ring <NUM> for reasons such as, but not limited to, facilitating manufacture of the lens assembly <NUM>.

With reference now to <FIG>, the lens assembly <NUM> may include a base housing <NUM> having an internal base cavity <NUM>. As shown in, for example, the cross-sectional view of <FIG>, the base housing <NUM> may concurrently circumferentially surround at least a portion of the carrier ring <NUM> and at least a portion of the outside lens barrel surface <NUM>. In some use environments, the carrier ring <NUM> may be entirely located within the internal base cavity <NUM>. When present, the base housing <NUM> may serve to maintain the various components of the lens assembly <NUM> in position as shown, protect portions of the lens assembly <NUM> from ambient conditions, facilitate mounting of the entire lens assembly <NUM> to a substrate or other underlying surface, or could be provided for any other desired reason. The base housing <NUM> may be assembled with one or more other components of the lens assembly <NUM>, such as the lens barrel <NUM>, by a frictional or interference fit, threadable connection with or without a thread locker substance interposed therebetween, adhesive, welding, one or more separately provided fasteners, any other desired attachment or connection scheme, or any combination thereof.

Again as first shown in <FIG>, the inner lens barrel end <NUM> may include an overhang feature <NUM>. Optionally, and as shown in <FIG>, the overhang feature <NUM> may be wedge-shaped or otherwise configured to facilitate passage of the carrier ring <NUM> longitudinally thereover in a direction toward the lens <NUM>, but resist "backing out" of the carrier ring <NUM> from engagement with the lens barrel <NUM> in a direction away from the lens <NUM>. When provided, the overhang feature <NUM> may assist with placing the carrier ring <NUM> in frictional engagement around the outside lens barrel surface <NUM> in a location longitudinally toward the lens <NUM> from the overhang feature <NUM>. The term "frictional engagement" is used herein to represent at least one of an interference fit, caused by overlapping dimensional tolerances, and a "snap fit", caused by the temporary expansion of at least a portion of the carrier ring <NUM> to pass over the overhang feature <NUM> before contracting to a configuration which then resists removal of the carrier ring <NUM> from the lens barrel <NUM>. It is contemplated that the frictional engagement may be temporary (e.g., during assembly as in a "snap fit" context) or at least semi-permanent (maintained long-term via use of the lens assembly <NUM>)--both of these situations will be considered herein to be a "frictional engagement".

In support of the "snap fit" type of frictional engagement, at least a portion of the overhang feature <NUM> may extend outward from the longitudinal axis L past at least a portion of the carrier ring <NUM>. That is, stated differently, at least a portion of the carrier ring <NUM> may be located closer to the longitudinal axis L then at least a portion of the overhang feature <NUM> or another selected portion of the outside lens barrel surface <NUM>.

With reference now to <FIG>, the carrier ring <NUM> may include at least one longitudinally extending carrier tooth <NUM> configured for selective frictional engagement with the overhang feature <NUM>. Each carrier tooth <NUM> can be located as desired upon the carrier ring <NUM> and configured appropriately to selectively "snap" into engagement with the overhang feature <NUM>, or any other desired structure of the lens barrel <NUM>, to prevent removal of the carrier ring <NUM> from the lens barrel <NUM> in a direction away from the lens <NUM>. In the configuration of the lens assembly <NUM> shown in the Figures, the carrier teeth <NUM> are at least partially or slightly located closer to the longitudinal axis L then is at least a portion of the overhang feature <NUM>.

Again as depicted in <FIG>, the carrier ring <NUM> may include at least one carrier locator feature <NUM> configured for selective engagement with a corresponding cavity locator feature (shown at <NUM> in <FIG>) of the internal base cavity <NUM>. When present, the carrier and cavity locator features <NUM> and <NUM> may cooperatively at least partially dictate radial orientation of the carrier ring <NUM> within the base housing <NUM>, when the carrier ring <NUM> is maintained within the base housing <NUM> around the lens barrel <NUM>. The depicted carrier and cavity locator features <NUM> and <NUM> are slots and rails, respectively, as shown herein, such that the carrier ring <NUM> is guided to slide into position respective to the base housing <NUM> during manufacture of lens assembly <NUM>. However, it is contemplated that the slots and rails could be reversed, another interlocking or non-interlocking structure could be provided as a locator feature, or any other mechanical arrangement could be provided to at least partially dictate radial orientation of the carrier ring <NUM> within the base housing <NUM>, or for any other desired purpose.

As with the lead stations <NUM> and heater element electrical leads <NUM>, the carrier and cavity locator features <NUM> and <NUM> could be provided in differing numbers, orientations, locations on their respective components, or have any other variable design. It is contemplated, for both of these functions, that a carefully selected pattern of suitable structures could be placed upon the components of lens assembly <NUM> in such a way that different ones are brought into mutual engagement for differently configured heater elements <NUM>, base housings <NUM>, or other structures of the lens assembly <NUM>. For example, one of ordinary skill in the art could design a carrier ring <NUM> and cooperative structures of the lens assembly <NUM> to either facilitate or prevent the use of one specific type of carrier ring <NUM> or base housing <NUM> sequentially with a variety of different other components of the lens assembly <NUM>. It is contemplated that, in this manner, a single selected design of carrier ring <NUM>, for example, could be used with a plurality of different designs of a base housing <NUM> for various use environments of lens assembly <NUM>, and thus reduce the number of parts that a manufacturer would need to hold in inventory.

One of ordinary skill in the art, with reference to at least <FIG>, will understand how the carrier ring <NUM> and the various features thereof facilitates the manufacturer of the lens assembly <NUM>, potentially in an at least semi-automated manner. As opposed to prior art lens assemblies, for which the heater element electrical leads need to be carefully threaded through portions of the various other components by hand, a manufacturer of a lens assembly <NUM> utilizing the carrier ring <NUM> can, for example, guide the carrier ring <NUM> into desired radial orientation with respect to the base housing <NUM>. The manufacturer can then "snap" or otherwise frictionally fit the radially aligned carrier ring <NUM> about the lens barrel <NUM>, such as through use of the overhang feature <NUM> and carrier teeth <NUM>. It then becomes relatively simple for the manufacturer to have confidence that each heater element electrical lead <NUM> is positioned within a lead station <NUM> once the carrier ring <NUM> is seated into place as desired. This partially-assembled arrangement is shown in <FIG>.

Turning now to <FIG>, at least one terminal blade <NUM> may be provided for placing an associated heater element electrical lead <NUM> into electrical contact with a source of power and/or signal, to facilitate desired operation of the heater element <NUM> when the lens assembly <NUM> is in use. The lead stations <NUM> may each include a terminal slot <NUM> for selectively maintaining a terminal blade <NUM> in a longitudinally extending position with respect to the carrier ring <NUM>. This could be facilitated, for example, by longitudinal insertion of the blade ears <NUM> of the terminal blades <NUM> into the terminal slot <NUM>.

Once the terminal blade <NUM> is inserted into the terminal slot <NUM>, a predetermined amount of longitudinal force (downward, in the orientation of <FIG>) is exerted upon the terminal blade <NUM>, such that the lead slot <NUM> of each terminal blade <NUM> "bites" into the insulation around the heater element electrical lead <NUM> to electrically connect the terminal blade <NUM> to the heater element electrical lead <NUM> in a known manner. (It is contemplated that, for most use environments, the longitudinal force and/or physical characteristics of the carrier ring <NUM> will be calibrated to prevent the terminal blade <NUM> from severing the heater element electrical lead <NUM>).

Once more, the structure of the carrier ring <NUM> can be helpful in initiating and maintaining this connection. That is, the lead station <NUM> of the carrier ring <NUM> supports the heater element electrical lead <NUM> in electrical contact with the terminal blade <NUM>, when present. It is contemplated that at least a portion of the terminal blade <NUM> (e,g. , the blade ears <NUM>) may be driven into the material of the terminal slot <NUM> to maintain the terminal blade <NUM> in position. It is also contemplated that the terminal blade <NUM> may be soldered and/or welded to the heater element electrical lead <NUM>, in addition to or instead of the described force-driven "biting" engagement. Again, the presence and design of the carrier ring <NUM> can be helpful in facilitating predictable and repeatable positioning of the terminal blade <NUM> and the heater element electrical lead <NUM>, which may assist with automating the manufacture process for the lens assembly <NUM>.

As used herein, the singular forms "a," "an" and "the" can include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," as used herein, can specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

As used herein, the term "and/or" can include any and all combinations of one or more of the associated listed items.

As used herein, the phrase "at least one of X and Y" can be interpreted to include X, Y, or a combination of X and Y. For example, if an element is described as having at least one of X and Y, the element may, at a particular time, include X, Y, or a combination of X and Y, the selection of which could vary from time to time. In contrast, the phrase "at least one of X" can be interpreted to include one or more Xs.

It will be understood that when an element is referred to as being "on", "attached" to, "connected" to, "coupled" with, "contacting", "adjacent", etc., another element, it can be directly on, attached to, connected to, coupled with, contacting, or adjacent the other element, or intervening elements may also be present. In contrast, when an element is referred to as being, for example, "directly on", "directly attached" to, "directly connected" to, "directly coupled" with, "directly contacting", or "directly adjacent" another element, there are no intervening elements present. It will also be appreciated by those of ordinary skill in the art that references to a structure or feature that is disposed "directly adjacent" another feature may have portions that overlap or underlie the adjacent feature, whereas a structure or feature that is disposed "adjacent" another feature might not have portions that overlap or underlie the adjacent feature.

Spatially relative terms, such as "under", "below", "lower", "over", "upper", "proximal", "distal", and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms can encompass different orientations of a device in use or operation, in addition to the orientation depicted in the figures.

While aspects of this disclosure have been particularly shown and described with reference to the example aspects above, it will be understood by those of ordinary skill in the art that various additional aspects may be contemplated. For example, the specific methods described above for using the apparatus are merely illustrative; one of ordinary skill in the art could readily determine any number of tools, sequences of steps, or other means/options for placing the above-described apparatus, or components thereof, into positions substantively similar to those shown and described herein. A "predetermined" status may be determined at any time before the structures being manipulated actually reach that status, the "predetermination" being made as late as immediately before the structure achieves the predetermined status. The term "substantially" is used herein to indicate a quality that is largely, but not necessarily wholly, that which is specified--a "substantial" quality admits of the potential for some relatively minor inclusion of a non-quality item. Though certain components described herein are shown as having specific geometric shapes, all structures of this disclosure may have any suitable shapes, sizes, configurations, relative relationships, cross-sectional areas, or any other physical characteristics as desirable for a particular application. Any structures or features described with reference to one aspect or configuration could be provided, singly or in combination with other structures or features, to any other aspect or configuration, as it would be impractical to describe each of the aspects and configurations discussed herein as having all of the options discussed with respect to all of the other aspects and configurations. A device or method incorporating any of these features should be understood to fall under the scope of this disclosure as determined based upon the claims below and any equivalents thereof.

Claim 1:
A lens assembly (<NUM>), comprising:
a lens (<NUM>) having an inner surface (<NUM>) and an outer surface (<NUM>);
a lens barrel (<NUM>) supporting the lens (<NUM>) and having outer and inner lens barrel ends (<NUM>, <NUM>) separated by a longitudinal axis, the lens (<NUM>) arranged along the longitudinal axis (L) to span the outer lens barrel end (<NUM>) such that the inner surface (<NUM>) of the lens (<NUM>) is within the lens barrel (<NUM>) and the outer surface (<NUM>) of the lens (<NUM>) is outside the lens barrel (<NUM>);
a heater element (<NUM>) longitudinally adjacent to the inner surface (<NUM>) of the lens (<NUM>) and located within the lens barrel (<NUM>), wherein the heater element (<NUM>) has a heater element electrical lead (<NUM>) extending radially and longitudinally therefrom to provide power to the heater element (<NUM>); and
a carrier ring (<NUM>) extending circumferentially around at least a portion of an outside lens barrel surface (<NUM>) adjacent to the inner lens barrel end (<NUM>), the carrier ring (<NUM>) including at least one lead station (<NUM>) radially aligned with the heater element electrical lead (<NUM>), the heater element electrical lead (<NUM>) extending into the lead station (<NUM>) of the carrier ring (<NUM>) so as to be engaged by and electrically connected to an electrical component (<NUM>) subsequently inserted into the lead station (<NUM>).