APERTURE LAMP, APERTURE LAMP HOUSING AND APERTURE LAMP ASSEMBLY
This application claims the benefit of Provisional Application S/N 60/222,378, filed August 1, 2000.
TECHNICAL FIELD The present invention relates to an aperture lamp which includes two sleeves each of which encloses a respective segment of a lamp envelope, each sleeve having a slot through which light may be emitted from the lamp. An aperture lamp assembly which includes such an aperture lamp, and an aperture lamp housing, is also provided. The present invention is particularly useful in automotive applications.
BACKGROUND ART There are many uses for aperture lamps. For example, the use of aperture lamps is known in the automotive industry. One example is illustrated in U.S. patent number 5,931,565, incorporated herein by reference. This patent was granted to Flanagan, Jr. et al . and assigned to Osram Sylvania Inc., the common assignee of the present invention. Without limitation, a particular application of such an aperture lamp is a stop/brake light. One such example is the commonly known center high mount stop light which may, for example, be located in the rear window of a vehicle . Such aperture lamps are typically elongated and include a discharge lamp such as a neon lamp.
There are various types of aperture lamps. For example, it is known to provide a tubular neon lamp coated on its outside surface with a reflecting material, except for a narrow strip or aperture along the length of the tube. Light is generated within the lamp tube and reflected in a conventional manner, except in the region of the aperture. Light is emitted from the lamp only through the aperture .
Aperture lamps fabricated by coating the lamp envelope
with a reflective material have several drawbacks. For example, the coating process is an additional step in the fabrication of the aperture. Not only does this add to the cost of producing the lamp but also adds to quality control considerations, particularly when the lamp is to be used in a vehicle stop/brake light wherein it is desired to achieve uniform illumination over the length of the lamp. In addition, when assembling the aperture lamp, steps must be taken to assure that the light emitting aperture is accurately aligned with the optical . axis of the lamp fixture. The aperture lamp of U.S. patent no. 5,931,565 overcomes these drawbacks.
A further concern of prior art discharge lamps, such as neon lamps of the type described herein, is that the electronics provided to operate such a lamp and the various electrical and mechanical connections to the lamp radiate undesirable electromagnetic interference (EMI) .
Other concerns relate to providing an aperture lamp which may be readily customized for a particular application and may include components which are readily interchangeable . Such needs are particularly desirable in vehicular applications wherein different lamp structures, including those having reduced size and/or electrical connection capabilities are used to perform various functions, and wherein lenses having different shapes and optical characteristics, might be required.
DISCLOSURE OF THE INVENTION It is an object of the present invention to provide an improved aperture lamp .
It is another object of the present invention to obviate the disadvantages of the prior art by providing an improved aperture lamp .
Another object of the present invention is to provide an improved aperture lamp which may be readily customized for a
particular application and includes components which are readily interchangeable .
Yet another object of the present invention is to provide an improved aperture lamp having a reduced size.
It is another object of the present invention to provide an improved aperture lamp which substantially reduces EMI during lamp operation.
A further object of the present invention is to provide an improved vehicular lamp which includes the aperture lamp of the present invention.
Another object of the present invention is to provide an aperture lamp housing for use with the aperture lamp of the present invention.
Yet a further object of the present invention is to provide an aperture lamp assembly which includes the aperture lamp of the present invention.
This invention achieves these and other objects by providing an aperture lamp which includes a lamp, a first sleeve and a second sleeve . The lamp has an axis which extends in a direction and includes an envelope extending in such direction from a first end of the lamp adjacent a first segment of the envelope to an apposite second end of the lamp adjacent a second segment of the envelope. A first electrode connection is provided which extends from the first end and a second electrode connection is provided which extends from the second end. A first sleeve is provided which encloses at least a portion of the first segment. The first sleeve includes a first slot which extends, in the direction and has a width sufficient to emit light therethrough from the lamp. A second sleeve is provided which encloses at least a portion of the second segment . The second sleeve has a second slot which extends in the direction and includes a width sufficient to
emit light therethrough from the lamp. The second slot is aligned with the first slot. An aperture lamp housing and an aperture lamp assembly is also provided.
BRIEF DESCRIPTION OF THE DRAWINGS This invention may be clearly understood by reference to the attached drawings in which like reference numerals designate like parts and in which:
FIG. 1 is a partially sectioned plan view of one embodiment of the aperture lamp assembly of the present invention;
FIG. 2 is a sectional view of FIG. 1 taken along lines 2- 2;
FIG. 3 is a schematic view of an aperture lamp of the present invention diagrammatically illustrating attachment of the aperture lamp to a vehicle window;
FIG. 4 is a partially sectioned plan view of another embodiment of an aperture lamp assembly of the present invention;
FIG. 5 is a partial view of another embodiment of the aperture lamp of the present invention;
FIG. 6 is a partial view of yet another embodiment of the aperture lamp of the present invention; and
FIG. 7 is a sectional view similar to FIG. 2 of another embodiment of the present invention.
MODE FOR CARRYING OUT THE INVENTION
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims taken in conjunction with the
above-described drawings.
The embodiment of this invention which is illustrated in the drawings is particularly suited for achieving the objects of this invention. FIG. 1 illustrates an aperture lamp assembly 2 which comprises an aperture lamp 4 and a ballast housing 6. The aperture lamp 4 comprises an elongated lamp 8 extending in a direction 10 and having an axis 12. In the embodiment illustrated in FIG. 1, axis 12 is a straight line. In other embodiments, the axis may be curved as explained hereinafter. The elongated lamp 8 extends from end 14 to an opposite end 16. In the embodiment illustrated in FIG. 1, elongated lamp 8 comprises an envelope 18. End 14 is adjacent a first segment 20 of the envelope 18, and end 16 is adjacent a second segment 22 of the envelope.
In the embodiment illustrated in FIG. 1, the aperture lamp 4 comprises a first sleeve 24 enclosing at least a portion of the segment 20 of the envelope 18, and a second sleeve 26 enclosing at least a portion of the segment 22 of the envelope.
To this end, sleeves 24 and 26 include respective slots 28 and 30 which enclose respective segments 20 and 22 of envelope 18.
The slot 28 is axially aligned with slot 30. The sleeves 24 and 26, and slots 28 and 30, extend in direction 10. The sleeves 24 and 26 form an aperture lamp housing for the lamp 8, sleeves 24 and 26 being connectable to each other by the envelope 18 being enclosed by the slots 28 and 30.
Slots 28 and 30 each have a width sufficient to emit light therethrough from elongated lamp 8, as described hereinafter. The aperture lamp assembly 2 of FIG. 1 comprises means for electrically connecting the elongated lamp 8 to an electrical power source 32 to energize the elongated lamp as described hereinafter.
FIG. 2 illustrates a cross-section of the sleeve 26, it being understood that sleeve 24 is identical thereto. Without limitation, sleeve 26 may be extruded from metal in a
conventional manner. The embodiment illustrated in FIG. 2 represents an extruded aluminum sleeve 26. As illustrated in FIG. 1, the sleeve 26 has a length measured in direction 10 equal to the length of sleeve 24. The combined length of sleeves 24 and 26, in direction 10, is slightly less than the axial length of the envelope 18 of the elongated lamp 8 thereby providing a space between the sleeves as explained in more detail hereinafter.
In considering the structure of the aperture lamp 4, sleeve 26 includes a front wall 34 and a back wall 36. Front wall 34 provides a lamp retention cavity comprising an inside diameter sufficient to receive and position the elongated lamp 18 relative to the sleeve 26. Such lamp retention cavity is in the form of a recess 38. Without limitation, the recess 38 has a substantially cylindrical inner wall 40 with an inside diameter, and the envelope 18 has a substantially cylindrical outer wall 42 having an outside diameter slightly less than the inside diameter of the recess. In this manner, lamp 8 may be enclosed within sleeve 26. In the embodiment illustrated in FIG. 1, the recess 38 in sleeves 24 and 26 enclose at least a portion of the segments 20 and 22 of the envelope 18.
The front wall 34 also provides the slot 28 in sleeve 24 and the slot 30 in sleeve 26, the width 44 of each slot 28, 30 being sufficient to emit light therethrough from elongated lamp 8. Front wall 34 also provides an aperture 46 within the sleeve 26 through which light may be projected from the lamp 8. Aperture 46 is positioned between the recess 38 and the exterior of the aperture lamp 4. In the embodiment illustrated in FIGS. 1 and 2, aperture 46 is a slot which extends axially in direction 10 from one end of the sleeve 26 to the other end. The slot includes walls 48 and 50.
The front wall 34 also provides a reflector cavity 52 having a reflective portion which provides a reflector 54. In the embodiment illustrated in FIG. 1, the reflective portion is in the form of a circular concave reflective surface which
forms reflector 54. Reflector 54 reflects light, passing from the recess 38 and through slot 28 in sleeve 24, and slot 30 in sleeve 26, in a forward direction through the aperture 46 and away from the lamp 8. Although the surface forming reflector 54 is circular in cross-section as illustrated in FIG. 2, some other configuration may be provided depending upon the orientation of the reflection desired. For example, rather than being circular, the surface forming reflector 54 may have a parabolic cross section.
In the embodiment illustrated in FIG. 2, the walls 48 and 50 extend at a respective angle 56, 58 relative to the center of the circular surface forming reflector 54. Angles 56, 58 are each about sixty degrees, although a narrower or broader aperture may be used. The front wall 34 may have a specular surface to maximize the amount of light projected forward if desired.
The metal sleeve of the present invention also includes structure for attaching a lens thereto. For example, in the embodiment illustrated in FIGS. 1 and 2, a lens 60 has a slide coupling structure which mates with the front wall 34 of the metal sleeves 24 and 26. To this end, front wall 34 includes grooves 62 and 64 which extend in direction 10 from one end of the metal sleeve 26 to the opposite end. Lens 60 includes tongues 66 and 68 which extend in direction 10. Tongues 66 and 68 mate with and slide along respective grooves 62 and 64 to removably attach the lens 60 to the sleeves 24 and 26 and thereby connect the sleeves together. Alternatively, the lens may be provided with grooves and the metal sleeve may be provided with respective mating tongues . Any other known manner of attaching a lens to a lamp assembly may be provided if adaptable to the present invention. Each reflector 54 is positioned between the lens 60 and a respective slot 28, 30 so that light emitted through slots 28 and 30 will be reflected by the reflector and through the lens .
One of the advantages of the form of lens attachment
illustrated in FIGS. 1 and 2 is that standardized metal sleeves may be provided with which various interchangeable lenses having various functional characteristics may be used. In the embodiment illustrated in FIGS. 1 and 2, lens 60 is a plastic resin body having an axial extension in direction 10 having a length equal to about the combined length of the sleeves 24 and 26 plus the width of the space therebetween. An example of a plastic resin is a polycarbonate material. Lens 60 may have no optical effect on the light projected from the lamp 8 and reflective surface 54, and thereby act merely as a protection for the enclosed lamp. Alternatively, the lens 60 may include a curved, faceted or other optically effective surface or surfaces to influence the projected light as in known in the art. For example, the forward face 70 of the lens 60 may include vertical curvature to provide vertical spread of the projected light and be curved in the axial direction to provide horizontal spread to the projected light.
If desired, the forward face 70 of a lens 60 ' may be shaped to conform with the curvature of the inside surface 72 of a vehicle window, such as the rear window 74 of a passenger vehicle as illustrated schematically in FIG. 3. In such a embodiment, the sleeves 24 and 26 may also be curved to conform to the lens in which case the axis 12 ' may be a curved line substantially parallel to the surface 72. Further, if desired the ballast housing 6' may be attached to the aperture lamp, as described hereinafter, and then the headliner of the vehicle may be installed to cover and thereby conceal the working part of the aperture lamp assembly. In one embodiment, the lens surface 70 will be adhesively bonded to the inside surface 72 of window 74, in a manner similar to a rearview mirror attachment, after the aperture lamp and lens have been assembled. Alternatively, the lens surface 70 may first be adhesively bonded to the inside surface 72 of window 74, and the aperture lamp may then be clipped or otherwise attached to the lens. In the embodiment illustrated in FIGS. 1 and 2, the aperture 46 and reflector cavity 52 provide a space between the lens 60 and the lamp 8. Alternatively, the lens 60 may have an
input portion that extends through aperture 46 and reflector cavity 52, and conforms with the forward facing surface 76 of the lamp 8. In such embodiment, the lens 60 receives light directly from the lamp surface 76.
In the embodiment illustrated in FIGS . 1 and 2 , the elongated lamp 8 is a discharge lamp. For example, elongated lamp 8 may be a low or moderate pressure discharge lamp. For example, in one embodiment, a low pressure neon discharge lamp may be used which comprises a cylindrical envelope having an outer diameter of about 5.0 millimeters. In such an embodiment, the inner diameter of the cylindrical inner wall 40 will be slightly greater than about 5.0 millimeters. Each end of such discharge lamp will have a conventional press seal through which will extend respective electrode connections connected to respective electrodes, contained within the envelope 18, in a conventional manner. For example, such electrode connections may be in the form of conventional lead wires 78 and 80 illustrated in FIG. 1. A simple 12 volt ballast can be fitted inside the ballast housing 6 and connected to the neon lamp to drive the lamp. Other types and sizes of lamps may be used, if desired. For example, a similarly sized rare • gas lamp or a subminiature fluorescent lamp may be used.
Various means may be provided for electrically connecting the lamp to the power source. For example, in the embodiment illustrated schematically in FIG. 4, the aperture lamp housing for lamp 8 is formed from two sleeves 24' and 26', each of which is fitted over and encloses a respective segment 20 and 22 of the lamp envelope 18 as described above regarding the embodiment of FIGS. 1 and 2. In the embodiment of FIG. 4, the lamp 8 is electrically connected to a power source 32 through ballast circuit 82 located within a housing 82'. In this embodiment the sleeves 24' and 26' may be extruded from metal or a plastic material, the electrical connections provided by lead wires 78 and 80 being electrically and mechanically connected to the ballast circuit 82 through conductors 84 and
86, respectively. Ballast circuit 82 is electrically and mechanically connected to the electrical power source 32 through conductors 88 and 90 in a conventional manner. It will be obvious to those skilled in the art that if a ballast circuit is not required, the conductors 84 and 86 will be directly connected to the power source 32.
In an embodiment of the type illustrated in FIG. 1, the metal sleeves 24 and 26 may provide the electrical conductive path between the lamp 8 and (a) a ballast circuit 6' contained in ballast housing 6 or (b) directly to the power source 32, as required. For example, in the embodiment illustrated in FIG. 1, the ballast circuit 6' enclosed within ballast housing 6 is coupled to the power source 32 by conductors 92 and 94. The neon lamp 8 is also coupled to the ballast circuit 6' . To accomplish this feature, sleeves 24 and 26 comprise respective conductive metal tabs 96 and 98 which are electrically and mechanically attached to respective lamp lead wires 78 and 80. To this end, tabs 96 and 98 may be drilled, notched or similarly formed to provide a coupling for a respective lead wire 78 and 80. As a practical matter, lead wires 78 and 80 may be electrically and mechanically connected to respective tabs 96 and 98 in any conventional manner. To complete the required circuit, the metal sleeves 24 and 26 comprise respective electrical connectors 100 and 102. Electrical connectors 100 and 102 are in the form of respective male prongs which mate with respective contacts 104 and 106, which are electrically coupled to the ballast circuit 6 ' within the ballast housing 6, to electrically and mechanically connect the metal sleeves 24 and 26 with such ballast circuitry. The electrical connectors 100 and 102 are electrically coupled to the power source 32 through the ballast circuit 6' within ballast housing 6. In this manner, each sleeve 24, 26 receives electrical input from the ballast circuit 6 ' and conducts such supplied power to a respective tab 96, 98 and respective lead wire 78,80. If the ballast circuit 6' is not used, the connectors 100 and 102 may be directly connected to power source 32 by conductors 92 and 94, respectively.
With reference to FIG. 1, the electrical connectors 100 and 102 are in the form of prong-like tabs which extend from the back side 36 of respective sleeves 24 and 26 and mate with the female contacts 104 and 106, respectively. The ballast housing 6 may be attachable to and held in place relative to the sleeves 24 and 26 by engagement between the connectors 100 and 102 and respective contacts 104 and 106. In an alternative embodiment, a variation of the embodiments illustrated in FIG. 1 and 4 may be provided wherein one of the electrical connectors, such as connector 100 may be connected to a mating contact, such as contact 104, and the other contact 106 may be directly connected to lead wire 80 by a conductor (not shown) .
In the embodiment illustrated in FIG. 1, metal sleeves 24 and 26 include insulation therebetween so that conduction of electricity between the metal sleeves during operation of the lamp is prevented. To this end, metal sleeve 24 comprises an end portion 108 positioned at an end thereof away from the lead wire 78, and metal sleeve 26 comprises an end portion 110 positioned at an end thereof away from the lead wire 80. The contour of end portions 108 and 110 may be complementary with each other. End portions 108 and 110 may have an air gap 112 therebetween which provides insulation between sleeves 24 and 26, the insulation being effected by offsetting end portion 108 from end portion 110 a distance sufficient to prevent conduction of electricity between the sleeves. Alternatively, insulation may be effected by providing a solid insulator 114 positioned in the gap between end portions 108 and 110, as illustrated in FIG. 1.
In the embodiment illustrated in FIG. 1, the end portions 108 and 110 are coplanar with a respective plane, each respective plane being perpendicular to axis 12. In this manner, an air gap 112 may be provided which is perpendicular to axis 12. It is believed that in such a construction, there is a tendency for some of the light emitted from lamp 8 to escape through the gap 112, the light tending not to be
concentrated to the same degree as it is along the rest of the lamp. It is believed that such disturbance in the beam pattern of light caused by the perpendicular gap 112 may be improved by forming end portions which are complementary yet are not perpendicular to axis 12. For example, FIG. 5 schematically illustrates an embodiment identical to that of FIG. 1 wherein the end portions 108 and 110 are replaced by end portions 108' and 110'. End portions 108' and 110' are not coplanar with a plane perpendicular to axis 12 but rather includes interdigitating complementary fingers. Such fingers are oriented in a square wave configuration. Saw toothed or other non-perpendicular configurations could replace fingers 108' and 110'. In FIG. 6, another embodiment is illustrated which is identical to that of FIG. 1 with the exception that the end portions 108 and 110 are replaced by end portions 108" and 110". End portions 108" and 110" are parallel to each other and to an angle to axis 12 other than ninety degrees . It is believed that the configurations illustrated in FIGS. 5 and 6, and other configurations wherein the end portions 108 and 110 do not lie in planes perpendicular to axis 12, provide embodiments which allow the gap in the beam pattern to be partially filled while being spread over a greater portion of the axis 12. The visual impression of the beam gap is then diffused.
In the embodiment illustrated in FIG. 1, the ballast housing 6 is a metal ballast housing. Since the metal sleeves 24 and 26 provide an electrical conductive path during operation of the aperture lamp 4, insulation must be provided between the metal ballast housing, on the one hand, and at least one of the sleeves 24 and 26, on the other, to prevent conduction of electricity between the ballast housing and each of the sleeves, and therefore between the sleeves. In the embodiment illustrated in FIG. 1, such insulation is in the form of an air gap 116 between both of the sleeves 24 and 26, and the ballast housing 6. The insulation provided by air gap 116 is effected by offsetting the ballast housing 6 from the sleeves 24 and 26 a distance sufficient to prevent conduction
of electricity from the ballast housing to one or both of the sleeves during operation of the lamp. In another embodiment , such insulation may be in the form of an insulator positioned between one or both of the sleeves 24 and 26, and the ballast housing 6.
In the embodiment illustrated in FIG. 1, the ballast housing 6 is .an elongated metal box attached to the back side of the aperture lamp 4. The housing 6 has sufficient volume to retain the ballast circuitry 6 ' . Conductors 92 and 94 are electrically and mechanically connected to the ballast circuit 6' so that the ballast circuit receives, power from the power source 32. Connectors 104 and 106 are also electrically and mechanically connected to the ballast circuit 6 ' . The metal housing 6 provides a substantial barrier to EMI radiation from the electronic components and related connections to the lamp.
The aperture lamp of the present invention may include one or more end covers which close any or all of the ballast housing 6, the recess 38, the reflector cavity 52, the aperture 46 and lens 60, if desired. For example, in the embodiment illustrated in FIG. 1, end .covers 118 are provided for enclosing the ends of respective sleeves 24 and 26. Each end cover 118 includes a recess 120 which mates, and provides a snap-fit, with the back wall 36 of the sleeves 24 and 26 at each respective end. Each recess 120 is sufficiently deep to enclose the respective lead wires 78 and 80 and tabs 96 and 98. If desired, end covers may be provided for one or both ends of the ballast housing illustrated in FIG. 1. If both ends are enclosed, it will be necessary to provide a manner in which the conductors 92, 94 can extend to the power source and to any grounding external of the ballast housing, if required. One manner of accomplishing this is to provide apertures through one or more of the housing end covers through which the appropriate conductors can be extended. In such embodiment, all of the end covers, can be configured to provide a tight fit with the sleeves and the housing, as the case may be, to provide a water tight seal for the aperture lamp assembly. In
the embodiment illustrated in FIG. 1, only one end 122 of the ballast housing 6 is provided with an end cover 124 to enclose end 122. End cover 124 includes a protuberance 126 which mates, and provides a snap-fit, with the inner surface 128 of the housing 6 at end 122. The opposite end 130 of the housing 6 is open, and the conductors 92 and 94 extend through such open end to the power source 32. End covers 118 and 124 may be fabricated from a resin material in a conventional manner such as, for example, by injection molding.
Although sleeves 24 and 26 are extruded from metal, the present invention is not so limited. For example, applicant has found that the efficiency of a lamp made in accordance with the present invention may be improved by fabricating sleeves 24 and 26 from resin, as, for example, by a conventional extrusion process. In particular, applicant believes that to the extent that there is reduced efficiency of light output from a lamp which includes metal sleeves to conduct the electricity to the lamp lead wires, such reduction is due to the capacitive coupling of the fields in the tube with those in the metal rather than the resistance of the metal. Such capacitive coupling is not as evident when the sleeves which provide the lamp housing are moved away from the lamp envelope surface or otherwise do not surround the envelope. FIG. 7 illustrates a cross section of a sleeve 132 which is formed from a resin material. In this embodiment, the interior surface 134 of the reflector cavity 136 and the recess 138 of each of the two sleeves which encloses the elongated lamp 8 in the manner illustrated in FIG. 1 regarding sleeves 24 and 26, may be metallized or otherwise treated as partially shown at 140 to provide the desired reflectivity. The exterior surface 142 may also be metallized as at 144 to ground the lamp for EMI protection. In the embodiment of FIG. 7, a fine or very small wire (or wires) 146 may extend along the length of each sleeve 132 which forms the housing for the lamp 8 to supply power to the lamp lead wires from a power source (not shown) . Such wire(s) 146 may extend in an elongated recess 148 in the sleeve 132. Elongated covers 150 may be provided which cover each
recess 148 and slide into place to enclose the conductor 146 and thereby contribute to the reduction in EMI. In this embodiment, the wire(s) 146 do not tend to cause significant tube dimming, there being very little capacitive effect between the relatively small wire and the lamp. In the embodiment illustrated in FIG. 7, the thickness of the plastic wall 152 should be great enough to prevent high voltage breakdown between the power leads of the lamp and the ground plane of the lamp due to the greater electrical resistance of the plastic resin housing material. This potential for electrical breakdown of the plastic resin wall is particularly true when power is supplied, and the lamp housing has a relatively higher electrical resistance. It will be apparent to those skilled in the art that the mechanical and construction cost convenience of using a metal lamp housing which provides the conductive path to the lamp will need to be balanced against the need for a more efficient lamp which can be obtained using the plastic resin lamp housing embodiment. In considering the embodiment illustrated in FIG. 7, a lens 154 may extend between, and attach together two sleeves 132 in the same manner in which the lens 60 is attached to sleeves 24 and 26.
The embodiments which have been described herein are but some of several which utilize this invention and are set forth here by way of illustration but not of limitation. It is apparent that many other embodiments which will be readily apparent to those skilled in the art may be made without departing materially from the spirit and scope of this invention.