Two-axis alignment for LED regulation optics

Abstract

A luminaire includes a lens having a front light-emitting surface, three alignment portions extending from the lens, a substrate having a flexible material between the substrate and the three alignment portions, the substrate having three openings aligned with the three alignment portions, and a two-axis adjustment mechanism. The adjustment mechanism includes three elements, each element extending through a respective opening in the substrate and attached to a respective aligned alignment portion.The three elements include a fixed element, a vertical adjustment device fixedly attached to the alignment section and movable with respect to the substrate and configured to adjust a lens with respect to the vertical axis, and a horizontal adjustment device fixedly attached to the alignment section and movable with respect to the substrate, the horizontal adjustment device being configured to adjust the lens with respect to the horizontal axis.

Description

TECHNICAL FIELDThis disclosure relates to the field of regulatory optics used in lights used for lighting or signaling in applications such as vehicle headlights, tail lights, signal lights, etc. The prescription optics may be unitary structures of optical silicone used with LEDs, or may be lenses of plastic, glass or other transparent material to which is attached a silicone or other elastomeric or flexible member, such as a skirt through which two-axis alignment is effected.BACKGROUNDOptical lenses that serve to concentrate and direct the light emitted from light sources are manufactured using basic techniques to adjust the luminous efficiency. Since 1980's, plastic lenses have in most areas detached glass as a transparent outer cover for lighting applications. In the past, plastic lenses have been made from rigid materials such as, but not limited to, polycarbonate (PC), poly(methyl) methacrylate (PMMA), polystyrene (PS), cyclic olefin polymers (COP), and cyclic olefin copolymers (COCP).These materials are substantially rigid and do not substantially deform under pressure or by gravity. Once properly fixed in place, such materials substantially retain their geometric shape. However, the use of plastics for optical lenses has many disadvantages, especially in the automotive sector: they tend to deform or distort under the action of heat, are less abrasion-resistant and therefore prone to scratches and tend to damage by UV radiation (ultraviolet radiation), such as discolorations. In addition, separate components (e.g., when using reflector optics) may result in additional disadvantages and low efficiency. The need for weather-resistant, light lights for electric and autonomous vehicles that meet the different requirements of the different applications and at the same time meet the regulatory requirements is constantly increasing.Another drawback of conventional plastic optical lenses is that an adjustment mechanism is required to align the lamp(s) to compensate for variations in vehicle position relative to the road. A conventional lamp is mounted on a vehicle by, for example, four bosses, and three external adjusting devices are mounted at the respective locations of the lamp. These adjustment devices require space for installation, increase the weight of the luminaire and require time to properly align them. In addition, each luminaire must be its own, separate unit, since the alignment is bound to the luminaire housing.OVERVIEWDisclosed herein are embodiments of uniform optically clear prescription optics or lenses. An example of a unitary prescription optic as disclosed herein has a molded body comprising: a front surface configured to exit light; an integral total internal reflection (TIR) reflector configured to receive and reflect light from an LED light source; and an integral mounting portion configured to mount the molded body within a housing. Herein, uniform means a single uniform molded body.Also disclosed herein are lights, e.g., for vehicles. An example of a luminaire has a uniformly shaped optic or lens comprising: a front surface configured as a light exit; an integral reflector shaped to meet a prescribed light output; and an integral mounting portion. The luminaire also includes an LED light source, the integral reflector receiving and reflecting light from the LED light source, and a housing configured such that the molded body can be fixed in a structure, the integral fixing portion being directly attached to the housing without an additional sealing member.Another example of a single-stage optics luminaire has a unitary, silicone molded body comprising: a front surface configured as a light exit; an integral reflector shaped to meet a prescribed light output; and an integral mounting portion. The luminaire also includes a light source and a housing configured to allow the unitary molded body to be attached to a structure.The unitary silicone regulatory optics disclosed herein provide a single lens optics with integrally molded reflector, the optics being molded from silicone and capable of complex regulations that meet the regulatory requirements for regulated lighting applications. The unitary silicone regulation optics provide a much lighter light fixture that is advantageous for all vehicles, particularly for autonomous vehicles and electric vehicles. Because the optics are made up of a single component, they can achieve an efficiency of 85% +, which is a significant increase over conventional luminaires that lose about 10% to 15% of light power for each optical component through which the light passes, such as a typical exterior luminaire cover lens. The unitary silicone optics are particularly useful for LED applications because optical silicone has a substantially higher temperature resistance than conventional plastic lenses, thereby making it possible to place the optics in close proximity to and even in contact with the LED(s) without distortion or distortion. Since optical silicone is also virtually opaque to UV (ultraviolet) radiation, the close proximity of the optical silicone lens to the LED light source does not involve the risk of material degradation, such as yellowing, which can adversely affect plastic materials. The disclosed prescription optics can be used without coatings or exterior lenses because the silicone is effectively insensitive to UV damage and road dirt impact damage, although silicone coatings that further improve performance durability are also possible. The regulatory optics disclosed herein can be directly incorporated into the vehicle lamp housing without the need for additional sealing means or gaskets, as the silicone can also be configured as an effective gasket. Because the optics are integral, no alignment between the components is required during installation in the application.Also disclosed is a luminaire comprising: a lens having a front light exit surface; three alignment portions extending from at least three edge positions of the lens; a substrate disposed opposite the front light exit surface and positioned parallel to the three alignment portions with a flexible material between the substrate and the three alignment portions, the substrate having three openings aligned with the three alignment portions; and a two-axis adjustment mechanism. The dual axis adjustment mechanism includes: a fixed member fixedly connected to both the substrate and one of the three alignment portions and positioned on both a horizontal axis and a vertical axis of the lens; a vertical adjuster fixedly attached to a second of the three alignment portions and movable with respect to the substrate, the vertical adjuster positioned on the horizontal axis and configured to allow the lens to be adjusted with respect to the vertical axis; and a horizontal adjuster fixedly attached to a third of the three alignment portions and movable with respect to the substrate, the horizontal adjuster positioned along the vertical axis and configured to allow the lens to be adjusted with respect to the horizontal axis. A compliant skirt gapfreely surrounds a front side of the lens at which light exits, the compliant skirt extending to the substrate to enclose the lamp chamber.Also disclosed is a vehicle light comprising: a substrate; a lens forming a lamp chamber between the lens and the substrate to receive a light source, the lens having a horizontal axis and a vertical axis; an alignment member integrally formed with the lens and extending from the lens in at least three portions parallel to the substrate, each of the at least three portions having a respective opening aligned with a respective opening in the substrate; and a two-axis adjustment mechanism. The dual axis adjustment mechanism includes three members, each member extending through the respective opening of one of the three portions and the respective opening aligned with the substrate. The three elements include: a fixed element fixedly connected to both the substrate and the alignment element and disposed on both the horizontal axis and the vertical axis; a vertical adjuster fixedly connected to the alignment element and movable with respect to the substrate, the vertical adjuster disposed on the horizontal axis and configured to adjust the lens with respect to the vertical axis; and a horizontal adjuster fixedly connected to the alignment element and movable with respect to the substrate, the horizontal adjuster disposed along the vertical axis and configured to adjust the lens with respect to the horizontal axis. A compliant skirt free of gaps surrounds a front face of the lens at which light exits, the compliant skirt extending to the substrate to enclose the lamp chamber.Also disclosed is a vehicle light comprising: a uniformly shaped optical silicone lens having a vertical axis along a vertical edge and a horizontal axis along a horizontal edge, the uniformly shaped lens comprising: a front surface configured to emit light; an integral reflector adjacent the front surface to meet a prescribed light output; and a reinforcing structure formed into the uniformly shaped lens to provide structural strength to the optical silicone, the reinforcing structure having three alignment portions extending from the reinforcing structure, each of the three alignment portions having an alignment opening. The vehicle lamp further includes: a substrate forming a lamp chamber with the uniformly shaped lens in which a light source is accommodated, the substrate being parallel to the three alignment portions and having three substrate openings, each substrate opening being aligned with a respective alignment opening; and a two-axis adjusting mechanism. The dual axis adjustment mechanism includes three members, each member extending through the substrate opening aligned with the respective alignment opening. The three elements include: a fixed element fixedly connected to both the substrate and one of the three alignment portions and positioned on both the horizontal axis and the vertical axis; a vertical adjuster fixedly attached to a second of the three alignment portions and movable with respect to the substrate, the vertical adjuster positioned on the horizontal axis and configured such that the uniformly shaped lens can be adjusted with respect to the vertical axis; and a horizontal adjuster fixedly attached to a third of the three alignment portions and movable with respect to the substrate, the horizontal adjuster positioned along the vertical axis and configured such that the uniformly shaped lens can be adjusted with respect to the horizontal axis. A compliant skirt surrounds the front of the integrally molded lens and extends to the substrate to form a gap free seal with the integrally molded lens and the substrate, the compliant skirt being configured to maintain the gap free seal during alignment with the dual axis adjustment mechanism.These and other embodiments and aspects are contemplated herein.BRIEF DESCRIPTION OF THE DRAWINGSThe disclosure will be best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, in accordance with general practice, the various features in the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily increased or decreased for clarity. FIG. 1A is a front perspective view of a unitary silicone prescription optic as disclosed herein. FIG. 1B is a rear perspective view of the unitary silicone prescription optic of FIG. 1A. FIG. 1C is a top view of the unitary silicone prescription optic of FIG. 1A. FIG. 1D is a right side view of the unitary silicone prescription optic of FIG. 1A. FIG. 1E is a rear perspective view of a cross-sectional view of the unitary silicone prescription optic of FIG. 1A taken along line E. FIG. 1F is a rear perspective view of a cross-sectional view of the unitary silicone prescription optic of FIG. 1A taken along line F. FIG. 1G is a top view of the unitary silicone prescription optic of FIG. 1E. FIG. 1H is a right side view of the unitary silicone regulation optic in FIG. 1F. FIG. 2 is a front perspective view of another aspect of a unitary silicone prescription optic as disclosed herein. FIG. 3 is a front perspective view of another aspect of a unitary silicone prescription optic disclosed herein with a heater and / or reinforcement embedded in the outer portion of the lens unit. FIG. 4A is a perspective view of a luminaire with a single stage optics as disclosed herein. FIG. 4B is an exploded view of the luminaire of FIG. 4A. FIG. 5A is a front perspective view of a single point adjusted silicone regulatory light as disclosed herein having a transparent skirt. FIG. 5B is a front perspective view of a single point adjusted silicone regulatory light as disclosed herein having an opaque skirt. FIG. 6A is an enlarged portion of a regulatory light showing a front-accessible adjustment mechanism. FIG. 6B is an enlarged portion of a rear perspective view of the regulating light of FIG. 6A showing the adjustment mechanism also accessible from behind. FIG. 7 is a front perspective view of a regulatory light disclosed herein with the skirt removed to better emphasize the components. FIGS. 8A-8C are partial side views of FIG. 7 showing adjustment of the lens using the adjustment mechanism disclosed herein. FIG. 9 is a front perspective view of another regulatory light disclosed herein with the skirt removed to better emphasize the components. FIG. 10A is a front perspective view of a vehicle headlamp as disclosed herein. FIG. 10B is a rear perspective view of the vehicle headlamp of FIG. 10A. FIG. 11A is a front view of a multi-element vehicle headlamp and a vehicle component as disclosed herein. FIG. 11B is a rear view of the multi-element vehicle headlamp and a vehicle component of FIG. 11A. FIG. 12A is a front perspective view of a vehicle headlamp and a vehicle component as disclosed herein. FIG. 12B is a rear perspective view of the vehicle headlamp and a vehicle component of FIG. 12A. FIG. 13 is a diagram of a vehicle with a multi-element vehicle headlamp disclosed herein. FIG. 14 is a front perspective view of a vehicle lamp including a dual-axis adjustment mechanism described herein. FIG. 15 is a front perspective view of another aspect of a vehicle light illustrating the dual-axis adjustment mechanism described herein with a transparently illustrated skirt. FIG. 16 is a rear perspective view of the vehicle lamp of FIG. 14 with the substrate removed. FIG. 17 is a rear view of another embodiment of a vehicle light having a dual-axis adjustment mechanism described herein. FIG. 18 is a rear view of a substrate. FIG. 19 is a front perspective view of FIG. 15 with the skirt and substrate removed. FIG. 20 is a cross-sectional view of FIG. 15 taken along line 20. FIG. 21 is a cross-sectional view of FIG. 14 taken along line 21. FIG. 22 is a vehicle including a vehicle lamp with the two-axle adjusting mechanism described herein. FIGS. 23A and 23B illustrate conventional vehicle lamps with conventional adjusting mechanisms that require a gap.DETAILED DESCRIPTIONConventional automobile lights include a light source that may include a printed circuit board, a primary optical system that may include, for example, a reflector and a separate lens, and secondary optics, wherein the components are housed within a housing that includes an outer lens to provide a generally fluidly isolated system. In certain applications, e.g., fog lamps, additional lenses may also be included in the primary optics, such as a collimating lens. Reflectors are usually produced from various plastics by plastic injection molding, metal casting or stamped metal. The outer lenses of the secondary optics are usually made of glass, but have evolved into plastics such as PC, PMMA, PS, COP and COCP. While glass is both weather- and UV-resistant, plastics are generally not. Therefore, external plastic lenses generally require a UV coating for protection against damage by sunlight and a hard coating for protection against damage by impinging road dirt. In order to additionally protect the luminaire from weathering influences, seals and / or sealing compounds are required in order to properly seal the luminaire at least between the outer lens and the housing.These conventional lamps require multi-stage optics to collect the light appropriately and then bring it into the desired illumination pattern. Since the light passes through multiple components, efficiency is lost. On average, about 10% to 15% efficiency is lost when the light is reflected or passes through each successive medium. The current efficiency of conventional automobile lamps for reflector optical systems is about 40% or less, which means that a large part of the light output of the LEDs is lost.Described herein are embodiments of a single stage optic used with a light source and housing to provide a luminaire that, among other advantages, is light weight, has fewer components, is watertight, and is UV resistant. The unitary silicone prescription optics disclosed herein have a molded silicone body comprising: a front surface configured as a light exit; an integral reflector configured to receive and reflect light from an LED light source; and integral mounting portions configured for mounting in a housing. As used herein, the term "specification" refers to an optics or lens designed to meet certain specifications regarding light or radiation pattern and intensity for a particular use of the optics.The unitary silicone optic disclosed herein is understood by those skilled in the art to find use in a wide variety of applications, including those applications having regulated specifications and those having none. Applications having specifications regulated, for example, by a government or government agency, for which the disclosed optics are particularly suitable include, without limitation, electric and motor vehicles (including automobiles, trucks, aircraft, watercraft, recreational vehicles, off-road vehicles, and the like), aerospace, and other lighting. Vehicle applications include headlights and tail lamps, among others. The headlights and tail lamps described herein include turn signals, low beam, high beam, signal lights, side light lights, auxiliary lights, tail lights, marker lights, position lights, stop lights, stop lights, and fog lights. As used herein, the term "exterior vehicle light" refers generally to those listed as well as other lights known and used in the industry. The uniform silicone specification optics can also be used in other industries and with other invisible lighting features, such as LiDAR transmitters, infrared transmitters, RADAR transmitters and LiFi (information / data transmission using light beams).Optical silicone offers many advantages over the rigid plastic typically used for lenses. Common plastic lenses for headlights, such as PC (polycarbonate), require the additional application of external anti-UV coatings to prevent damage to the plastic, which otherwise quickly becomes opaque, greatly compromising functional performance and negatively impacting the appearance of the product. Such products generally have a limited lifetime, which often leads to a severe optical impairment in the case of prolonged solar radiation (UV), which is clearly negative in the case of products which are frequently or constantly exposed to the sun. Optical silicone is insensitive to damage by UV radiation. Optical silicone tests have given resistance to UV damage of more than 10 years under direct solar radiation. With optical silicone, no anti-UV coating is required.Conventional plastic lenses, especially for vehicle headlights, also require hard coatings to mitigate the rapid surface degradation due to the impact of foreign bodies, such as those occurring during travel. Optical silicone is inherently resistant to the impact of limestone and other road soils. The soft, rubbery properties of the optical silicone are such that the energy does not penetrate and / or damage the surface of the plastic lenses, but is absorbed within the optical silicone without compromising the optical clarity of the material, the debris simply impacting without damaging the optical silicone material.Plastics used to make lenses shrink upon cooling, resulting in a loss of critical optical shape definition since the material varies from the desired optical geometry of the tool. This can be particularly pronounced in the case of large shapes, large optical lens volumes leading to undesired deformations in other critical optical regions. The industry has attempted to solve such problems by multistage forming solutions in which the lenses are made in successive "forming steps", whereby the material accumulates in the subsequent forming operations to control shrinkage and thereby achieve accurate optical performance in the formed state. Such processes are inherently costly because of the design of the molding equipment for multiple steps.Optical silicone can be precisely formed into large-format optics with minimal incidence points or other optical aberrations in a single-step molding process. Silicone optical optics are formed by a chemical reaction process, typically where a base resin is mixed with a catalyst, typically in a 50:50 ratio. Heat is supplied to the process to accelerate the chemical reaction and to accelerate the curing process. Given the minimum, well controllable shrinkage of the material as compared to the substantially greater shrinkage in thermoplastics, a much greater accuracy in optical surface replication is achieved, all in a single molding step. These properties are of decisive importance for the achievement of sharp, knife-edge-shaped optical elements which are otherwise more inaccurate, rounder and less defined when using plastics, as a result of which undesirable optical inaccuracies arise. Optical silicone is inherently rubbery. The flexibility of the optical silicone allows flexible elements to provide substantial "undercuts" which would otherwise prevent plastics from being removed from the mold unless measures are taken on the mold and the ability to deform significantly and yet return to the mold into which it was molded. An essential feature of silicone is its high degree of elasticity and "shape memory", which allows a high degree of deformation, but also allows return to the original, shaped geometry once the external forces are removed. This is in sharp contrast to the rigid nature of plastics and glass optical elements.Although sharp edges can be produced with glass, they are inherently extremely brittle and susceptible to damage due to handling, impacts or vibrations. Any such damage immediately results in very negative optical effects, so that the use of glass materials for sharp-edged configurations is impractical. In contrast, with optical silicone materials, very sharp, highly defined optical surfaces can be obtained which are practically insensitive to handling, vibration and even light exposure. Light effects are in turn easily absorbed, wherein the material's own memory ensures the return to the original geometry, whereby the optical function is retained even in the case of adverse, even extreme, functional requirements.A further advantage of using optical silicone is its substantially higher temperature resistance than other common plastics for optical purposes, which makes optical silicone of particular interest for LED applications in which a direct proximity between the optical element and the LED source is functionally advantageous. Such a proximity between LEDs and conventional plastic lenses is often not possible because, for example, plastic optics are thermally damaged by high temperatures. Conventional clear plastics are temperature resistant only up to about 100°C. PC, for example, deforms from 120° C. and PMMA is temperature-resistant only up to approximately 90° C. Silicones are generally temperature-resistant up to temperatures in the range of 200° C., which is almost twice as high as in conventional optical plastics. High-power LEDs as developed for automotive headlights generally have an external surface temperature of about 135° C., which is far above the softening temperature of optical PC materials. Therefore, care must be taken that the plastic optical components are sufficiently far from the LED light sources to preclude deformation or even melting. Silicone optics can therefore be placed near or directly over high temperature LED light sources, which significantly improves optical performance and at the same time precludes damage over time - a key functional advantage. Of course, the uniform silicone specification optics can also be used with incandescent lamps, halogen lamps, high pressure landing / xenon lamps and projection units.Another advantage of optical silicone refers to the aforementioned tendency of PC to degrade under the influence of UV radiation, which is even poorly emitted by most LEDs. Over time, such UV radiations can adversely affect the color and transmission of PC and other optically clear plastics, leading to additional design problems that affect optical performance both in the short and long term. Optical silicone transmits UV radiation, as a result of which the molecular composition and / or the properties of the material are not influenced over time.The ability to unite the outer lens, some or all of the additional optical elements and the reflector into a unitary housing, thus enabling complete optical management, also offers many advantages. The silicone optics do not require additional lenses for protection or further refraction and can be exposed directly to the atmosphere.FIG. 1A is a front perspective view of an embodiment of a single stage optic or lens for a luminaire or unitary silicone prescription optic 100, and FIG. 1B is a rear perspective view of FIG. 1A. The front surface 102 is an exit surface through which light exits the optics. The front surface 102 may be smooth, it may have vertical or horizontal grooves, such as the horizontal grooves 210 shown in the unitary silicone prescription optics of FIG. 2. The front surface 102 may include pads or other contours required to achieve the required light distribution pattern and / or light intensity. The grooves, depressions, or other optical features are formed into the front surface 102 during the forming of the prescription optic 100. The front surface 102 is designed to conform to the specification and specifications for which it is to be used. The front surface 102 is generally free of coatings unless coatings are applied which still increase the already high functionality of the optical silicone by a further improvement in chemical resistance, surface strength and the like. A coating for protection against UV radiation or damage is generally not required, since the silicone material is UV-resistant and generally resistant to damage by impinging dirt.As seen in FIG. 1B, the reflector 104 is integrally formed with the front surface 102. The reflector 104 is configured to receive and reflect light from a dashed LED light source 112. The reflector 104 has one or more light receiving surfaces 106 which are surfaces formed about vertical and horizontal axes. The reflector 104 also has a plurality of reflective surfaces 108. FIG. 1D is a side view of the unitary silicone prescription optic 100. FIG. 1E is a perspective view of a cross section of FIG. 1B taken along the line E, and FIG. 1F is a perspective view of another cross section of FIG. 1B taken along the line F. FIG. 1G is a plan view of FIG. 1E, and FIG. 1H is a right side view of FIG. 1F when viewed from the front. Figures 1G and 1H together show the multi-light reflecting surfaces 108. The multiple light reflecting surfaces 108, which constitute TIR (Total Internal Reflection) surfaces, concentrate the light and allow an efficiency of over 85%. The reflector 104 cooperating with the light exit surface, front 102, is shaped according to specifications, application and specifications. The reflector depicted here is illustrative and is not to be understood as limiting.The unitary silicone prescription optic 100 also has integral mounting portions 110 that will retain the unitary silicone prescription optic 100 in a housing or support member. Due to the rubber-like, flexible nature of the optical silicone, the unitary silicone regulatory optics 100 may be their own seal to seal with the housing. Conventional rigid plastics require the use of a seal and / or sealant between the lens and the housing to seal the interior from moisture, such as rain, snow and moisture, which may result in moisture accumulation inside the luminaire or otherwise form condensation on the inside of the lens. Such a seal or other additional sealing element is not required, since the contact between the housing and the suitably configured unitary silicone regulation optics 100 is designed to seal against weather conditions without the need for a seal or other additional sealing element. To establish the watertight contact between the silicone optics and the housing, a simple mechanical support can be used to establish a uniform, tight contact.The rubbery flexibility of optical silicone makes thin lenses or thin regions of lenses susceptible to deformation by external forces such as gravity, external mechanical pressure, aerodynamic pressure, vibrations, etc. Although the integral combination of the lens and the reflector in the disclosed uniform prescription optics generally results in a structure that is sufficiently thick and therefore not affected by the rubbery flexibility with respect to deformation, some portions of the disclosed uniform prescription optics may be thin enough to be affected. Accordingly, internal mechanical reinforcement in the thin portions may be desirable.FIG. 3 shows a further aspect of a uniform silicone regulation optical system 300. As shown, the unitary optic 300 is thicker where the lens or front surface 302 and reflector 304 are formed and thinner at the mounting portions 310. To provide structural mechanical strength to the attachment portions 310, a reinforcing structure 320, such as a reinforcing mesh, is molded into the silicone material of the attachment portions 310. The unitary prescription optic 300 is internally reinforced at the mounting portions 310 by the suitable mechanically strong reinforcing structure 320 as well as by the thickness of the remaining optic. The reinforcement structures 320 may be configured to provide sufficient structural reinforcement for the optics, and may be selected for aesthetic or other reasons. The reinforcing structure 320 may be made of a variety of known materials, such as thin wires, molded plastics, cast or molded metals, metal stampings, and the like. The reinforcing structure 320 is not limited to the fixing portions 310. The lens itself may be so thin that it mechanically deforms under normal use conditions, e.g. by vibration, mechanical pressure, aerodynamic loads or even by gravity, as optical silicone is very flexible due to its rubbery properties. An internal mechanical reinforcement may be cast into the lens to mechanically stabilize the lens. This boost device may also perform the function of a heating mechanism by configuring these boosts to perform a heating function, e.g., by applying electrical current to the entire boost grid or portions of the boost grid. The gain structures may be configured so as not to interfere with the light pattern generated by the lens and / or the reflector.Furthermore, luminaires having a single-stage lens system, for example for vehicle applications, are described here. An example of a light fixture for a vehicle having a single stage optics is shown in FIGS. 4A and 4B, where FIG. 4B is an exploded view of FIG. 4A. The luminaire 400 has a unitary molded body 402 formed of silicone. The unitary molded body 402 has a round cross-section and is different from the bodies illustrated in the other drawings to give an example of another shape and regulation. It should be noted that the unitary molded body may have any cross-sectional shape required for the construction of the luminaire to engage the housing. The uniform front surface and the reflector can be designed differently depending on the specification. In FIG. 4, the unitary molded body includes a front surface 404 configured as a light exit, an integrally molded reflector 406 that satisfies a prescribed light output in cooperation with the front surface 404, and an integral mounting portion 408. As shown, the attachment portion 408 includes a first attachment member 410 and a second attachment member 412. The attachment portion 408 may have any configuration that enables the required attachment to the housing and provides a watertight seal without the need for an additional sealing element, such as a seal, although this does not preclude the use of adhesives or other attachment means, if desired. The attachment portion 408 in FIG. 4 includes the first attachment member 410 that fits within a housing 420 and the second attachment member 412 that contacts the housing in a flange-like feature. Either or both of the first fastener 410 and the second fastener 412 may have a reinforcing structure as described above.The luminaire 400 also includes an LED light source 430, wherein the integrated reflector receives and reflects the light from the LED light source 430. The LED light source is not limited and may be one or more LEDs and may include a printed circuit board and / or other means for powering and controlling the LED(s). A housing 420 is configured to sealingly enclose the unitary molded body 402 and to secure the unitary molded body 402 in the exterior of a vehicle, wherein the integral attachment portion 408 is directly attached to the housing 420 without an additional sealing member. The housing 420 includes a single-stage lens mount 422 configured to be attached to the unitary molded body 402, fasteners 424 to attach the light 400 to a vehicle or other lighting application, and optionally a heat sink 426. The heat sink 426 may also or alternatively be provided on the LED light source.The unitary silicone regulatory optics disclosed herein provide a single stage, integrally molded reflector optics, the optics being molded from silicone and capable of complex regulations that meet the regulatory requirements for regulated lighting applications, either individually or in cooperation with one or more additional light units configured to achieve the desired overall optical radiation pattern results. The unitary silicone regulatory optics provide a much lighter light fixture that is advantageous for all vehicles, particularly for autonomous vehicles and electric vehicles. Because the optics are made up of a single component, it can achieve an efficiency in excess of 85%, which is a significant increase over conventional luminaires that lose about 10-15% of efficiency for each optical component through which the light passes or is reflected. The uniform silicone prescription optics can be used with high power LEDs because the silicone has a higher temperature resistance than conventional plastic lenses. The disclosed prescription optics are used without coatings or exterior lenses because the silicone is effectively insensitive to UV damage and most damage from road dirt impingement, although additional coatings may be used to achieve even higher robustness and chemical resistance requirements. The regulatory optics disclosed herein can be installed directly into the vehicle's lamp housing without the need for an additional element such as a seal because the silicone acts as a seal and protects the optics from weather problems such as ingress of liquids, dust, or other contaminants. An adhesive or mechanical fuse may be used to achieve a smooth, tight fit between the housing and the optic. Because the optics are integral, no alignment between the components is required during installation in the application.The use of silicone enables a single point setting of the specification optics. The single point adjustment mechanism can be used with either the prescription optics disclosed herein or with conventional plastic or glass lenses, as long as the conventional plastic lenses have a portion of the lens coated or overmolded with a compliant material such as rubber or silicone, which portion is the portion through which the adjustment mechanism extends.FIG. 5A is a perspective view of a regulation luminaire 500 having a single point adjustment mechanism 550. FIG. 5A is illustrated with a substrate 502 and a transparent skirt 506 in contact with the substrate 502. FIG. 5B is a perspective view of the prescription light 500' with an opaque skirt 506' mounted on the carrier 502. In FIGS. 5A and 5B, the single point adjustment mechanism 550 is accessible only from one side of the substrate 502. FIGS. 6A and 6B are enlarged views of a prescription light 600 having a single point adjustment mechanism 650 accessible from both the front 604, the skirt 606, and the heat sink side 602.Referring now to Figures 7 and 8A-8C, the single point adjustment mechanism 650 will be described. FIG. 7 shows the regulating light 600 with the flexible skirt 606 removed. The prescription light 600 has a prescription optics 610 as disclosed herein. The prescription optic 610 is a unitary molded body molded from silicone and includes a front surface 612 configured as a light output, an integral reflector 614 shaped to meet a prescribed light output, an integral mounting portion 616, and a reinforcing structure 618 molded with the unitary molded body, the reinforcing structure 618 providing structural strength to the mounting portion 616. An LED light source is included (not shown), and integral reflector 614 receives and reflects light from the LED light source. The LED light source may be made of one or more types of LEDs and may include one or more LED circuit boards. A substrate 622 supports the LED light source. The substrate 622 may be a supporting structure on which the LED light source and the regulating optics 610 are mountable, or additionally a heat sink for the LED light source. A pivot mechanism 624 extends from the substrate 622 and has opposing pivot points 626, with the reinforcing structure 618 hingedly attached to the opposing pivot points 626. The mounting portion 616 includes an alignment portion 620 that integrally extends from the mounting portion 616 parallel to the substrate 622. The adjustment mechanism 650 extends through an opening 652 in the alignment portion 610 of the reinforcement structure 618 at a location where the reinforcement structure 618 is covered with the compliant skirt 606. The compliant skirt 606 is a cover that fits around the front surface 612 of the optics 610 and is attached to the substrate 622 to cover and protect the attachment and alignment structures of the light 600. The front surface 612 is exposed to the atmosphere because the silicone lens does not require additional lenses or covers to protect it from the atmosphere as previously described.The single point adjustment mechanism 650 may be a rotatable mechanism accessible from the front of the luminaire 600, outside the skirt 606, or from the back of the luminaire 600, outside the substrate 622, or from both the front and back of the luminaire 600. As a non-limiting example, the adjustment mechanism 650 may be a screw that is threaded to the single point 652 of the reinforcing structure 618. To be accessible from both the front and back surfaces of the luminaire 600, the screw would extend outside the skirt 606 as shown in FIG. 6A and through the substrate 622 as shown in FIG. 6B. The end of the adjustment mechanism 650 accessible from the substrate 622 may be flush with the substrate 622, as shown in FIGS. 8A-8C. The adjustment mechanism 650 can only be screwed at its interface with the opening 652 in the reinforcing structure 618 in order to move the reinforcing structure 618 and thus the regulation optics 610 relative to the pivot points 626. As a non-limiting alternative, the adjustment mechanism 650 may be fixedly attached to the reinforcing structure 618 at the opening 652 by adhesive or flanges on both sides of the reinforcing structure 618 and then screwed to the substrate 622 through the substrate opening 630. Any configuration is acceptable as long as the adjustment mechanism 650 is configured to move and fix the reinforcing structure 618, and thus the prescription optic 610, relative to the pivot points 626.FIG. 8A shows a neutral position of the prescription optics 610 without a degree of tilt with respect to the substrate 622. When the adjustment mechanism 650 is rotated in one direction, the reinforcing structure 618 moves in a first direction with respect to the pivot points 626, thereby moving the entire silicone optic 610 formed with the reinforcing structure 618 about the pivot mechanism 624 or the focus in the first direction, as shown in FIG. 8B. Conversely, by rotating the adjustment mechanism 650 in the other direction, the entire reinforcing structure 618 with the integral silicone regulation optics 610 is moved about the pivot mechanism 654 in a second, opposite direction, as shown in FIG. 8C. The movement required for alignment of the luminaire is small, usually about 4° in each direction.The single point adjustment mechanism 550, 650 functions with the reinforced silicone optics because the silicone is flexible. The silicone compresses or expands when the reinforced structure is tightened or loosened against the heat sink via the adjustment mechanism, thereby moving the silicone optic about the focal point or axis of the pivot points, because the reinforcing structure extends over the entire mounting portion of the unitary molded body and is mounted at the opposing pivot points. In a plastic lens or optics, there is no flexibility that the adjustment mechanism can act upon, thereby precluding this type of adjustability. It is conceivable that a lens made of plastic, glass or another transparent material can be used with the single point adjustment mechanism if a covering or overmould made of silicone, rubber or another flexible material is present at least at the adjustment point and at least between the lens and the substrate or cooling body. This would allow the lens of plastic, glass or other suitable material to move about the pivot point when the adjustment mechanism is rotated, either compressing the cover or allowing the cover to expand. As shown in luminaire 600' in Figure 9, since the optic 610' is made of a material other than silicone without the need for a reinforcing structure, the aperture 652' through which single point adjustment mechanism 650' extends is located in an alignment portion 620' of mounting portion 616' of silicone-free optic 610', both of which are also made of the suitable silicone-free material. The attachment portion 616' is also directly connected to the pivot mechanism 624'. To allow the low degree of alignment required, the alignment portion 620' of the glass or plastic prescription optic 610' between the alignment portion 620' and the substrate 622' is coated with a flexible material 630' such as silicone or rubber. The provision of the flexible material 630' between the rigid alignment portion 620' of glass, plastic, or other suitable material and the substrate 622' allows for the low amount of movement required for alignment of the prescription optic 610'.FIGS. 10A and 10B show a regulating light 700 with a housing 702. In FIG. 10A, the housing 702 fits against the skirt 704 of the silicone optic 710. FIG. 10B shows the substrate 706 as a heat sink, in this case with ribs to increase the surface area in order to improve cooling. Four fastening elements 708 are shown for fastening the optical module to the housing 702. The single point adjustment mechanism 750 is accessible from the heat sink side of the luminaire. The housing 702 may be secured to the substrate 706 by any acceptable means such as adhesive, clamps, etc.It is also noted that the single point adjustment mechanism may be used with a structural headlamp as disclosed in U.S. Pat. No. 8,845,128, entitled "Structural Headlamp Assemblies for Vehicular Applications" (structural headlamp assemblies for vehicle applications), which is incorporated herein by reference. The internally adjustable module shown in Figures 5 to 8 can be mounted by means of the structural element. The structural element becomes the housing of the luminaire. As shown in FIGS. 11A and 11B, a vehicle headlamp and component assembly 800 may include one or more lenses, this example showing three lamps 802, a vehicle structural member 804 as a lamp housing that cooperates with the lamp 802 to at least partially define a lamp chamber that is generally fluidly isolated from an ambient atmosphere outside the lamp chamber, at least one light source provided in the lamp chamber, a substrate 806 shown here as a heat sink with fins to increase surface area and improve cooling, the substrate 806 supporting the light source and the lens being pivotally attached to the substrate 806 as previously described. The vehicle structural member 804 is configured to support structural loads applied by a vehicle component. A single point adjustment mechanism 850 is disposed through an adjustment portion of the lens. The substrate 806 supporting the skirt, the regulation optics, the light source and the adjustment mechanism is fastened to the structural member 804 of the vehicle by fastening elements 810 to give a non-limiting example. It is noted that each light 802 is individually adjusted with its respective adjustment mechanism 850. The light 802 may have an integral silicone prescription optic with a reinforcing structure and skirt as disclosed herein, or may be made of plastic, glass, or other suitable material, as long as the lens is covered with silicone or rubber or the like between the alignment portion and the substrate at the setpoint, with the lens attached via the pivot point. FIGS. 12A and 12B show a vehicle headlamp and component assembly 900 as described in FIGS. 11A and 11B, but with five individual lights and a non-linear formation configured to provide increased lateral illumination, such as the function of a bending light or other similarly configured function. The vehicle headlamp and component assembly 900 also includes a vehicle structural member 904.The vehicle structural member 804, 904 may be an exterior structure of a vehicle, such as an exterior panel, fender, bumper, reinforcement, shield, etc. The vehicle structural member, such as the light housing, is configured to carry a load from a vehicle component, which may be, as non-limiting examples, an interior wing bracket, a radiator bracket / module, a vehicle structural member, a battery box, an electronic control module, a snow plough beam structure, and a reinforcement structure. FIG. 13 is an illustrative example of a vehicle headlamp and component assembly 800, 900 as described in FIGS. 11A and 11B and FIGS. 12A and 12B, wherein the vehicle structural member 804, 904 is a front fender or bumper 950 of the vehicle 960.FIGS. 14-19 show embodiments of a light fixture having a dual axis adjustment mechanism that allows the lens to adapt to requirements during and after vehicle assembly without requiring a gap around the lens to allow lens movement. In Figures 14, 16 and 19, the dual axis adjustment mechanism is accessible only from the back side of the substrate. In Figures 15, 17 and 18, the dual axis adjustment is accessible from both the back side of the substrate and the front side of the compliant skirt. Apart from accessibility, the embodiments are implemented in the same manner.FIG. 14 is a front perspective view of a vehicle light 1000 including a lens 1002 having a front light exit surface 1004. A compliant skirt 1006 surrounds the front light exit surface 1004 and extends to a substrate 1008, as best shown in FIGS. 16, 18 and 19, to seal the vehicle light without gaps. Referring now to FIG. 15, a vehicle light 1000 is illustrated in which the resilient skirt 1006 is transparent so that the internal components may be described. FIG. 17 corresponds to FIG. 15 with the compliant skirt 1006 and the substrate 1008 removed. The vehicle lamp 1000 also has at least three alignment portions 1010, the at least three alignment portions 1010 extending from three edge positions 1016 of the lens 1002, the alignment portions 1010 extending parallel to the substrate 1008. As shown in the figures, there are four alignment portions 1010, one extending from each edge position 1016 of the lens 1002. Although the two-axis adjusting mechanism uses only three alignment portions 1010, the vehicle lamps 1000 are typically manufactured with four, with one remaining unused. Thereby, the vehicle lamp 1000 having the two-axle adjusting mechanism on the right or left side of the vehicle can be used, and the three alignment portions 1010 are selected depending on the side for use in the two-axle adjusting mechanism. Of course, it is also possible that a vehicle lamp is specifically manufactured for a right or left side and therefore has only three alignment portions all used for the two-axis adjusting mechanism.When the lens 1002 is made of conventional plastic or glass, the alignment portions 1010 may also be made of plastic or glass and may be integrally formed with and extend from the lens 1002. Due to the rigid nature of the plastic or glass, a flexible material is arranged between the substrate 1008 and the at least three alignment portions 1010. The flexible material supports the small changes (+ / - 4°) in orientation required in the two axis adjustment mechanism. As disclosed with respect to the single point alignment embodiments, if the lens 1002 is a unitary molded optical silicone lens having a front light exit surface 1004 and an integral reflector 1012 adjacent the front light exit surface 1004, an alignment member 1014 of a rigid material may be used, where the optical silicone is molded over the alignment member 1014. The alignment portions 1010 extend from the alignment member 1014 and are also insert molded into the optical silicone. The alignment element 1014 may extend along vertical sides or edges 1017 of the lens 1002, as shown. The alignment element 1014, when used with the optical silicone, is a reinforcing structure that is cast into the uniformly shaped lens 1002 to provide structural strength to the optical silicone. The alignment element 1014, when used as a reinforcement structure, may also include additional support structures 1018, for example along the lower or upper edges 1020 of the lens 1002, as long as the reinforcement structure does not interfere with the front light exit surface 1004. If the lens 1002 is round or oval, the alignment element may reinforce the lens by extending around the entire perimeter of the lens 1002, or only extend along arcs on either side of the lens 1002. The compliant skirt would also be round or oval and would allow for a continuous seal with the lens and substrate.In the vehicle lamp 1000, the substrate 1008 is also disposed at the rear of the lamp opposite to the front light exit surface 1004 to enclose the vehicle lamp 1000 with the compliant skirt 1006 and the front light exit surface 1004. The substrate 1008 and the lens 1002 define a lamp chamber 1022 between the lens 1002 and the substrate 1008 to receive a light source 1024, such as an LED. The light source 1024 may be disposed directly on the substrate 1008 or on an optionally placed circuit board 1026. The substrate 1008 may be a heat sink exposed to the ambient atmosphere outside the lamp chamber 1022 such that the heat from the light source 1024 is transferred to the ambient atmosphere.Lens 1002 has a vertical axis V parallel to a vertical edge 1017 and a horizontal axis H parallel to a lower or upper edge 1020 of the lens, as shown in Figure 16, with the substrate removed to show the fixtures. The vertical axis V may extend along each vertical edge of the lens 1002 and may be at a distance D from the actual vertical edge 1017 of the lens 1002, as shown in FIG. 16. The vertical axis V may also extend directly along the vertical edge 1017 of the lens 1002, as shown in FIG. 17. The horizontal axis H may be aligned with or spaced from a lower or upper edge 1020 of the lens 1002. The same applies when the lens is round or oval, the vertical edge being the center of the perimeter that is rightmost or leftward, the lower or upper edge being the center of the perimeter that is at the upper or lower edge of the perimeter.The three alignment portions 1010 extend from the plastic / glass lens or from the alignment element 1014 so as to be parallel to the substrate 1008 but equidistant from the substrate 1008. The flexible material with the glass / plastic lens is disposed between the three alignment portions 1010 and the substrate 1008 and may extend entirely between the substrate 1008 and the three alignment portions 1010. In the optical silicone overmolded alignment portions 1010, the optical silicone is also located between the alignment portions 1010 and the substrate 1008.The substrate 1008, shown from behind in FIG. 18, may include three openings 1028 aligned with the three alignment portions 1010. As previously mentioned, the lamps may be fabricated for both sides and have four openings in the substrate aligned with the four alignment portions, while only three of the four are used for adjustment. A dual axis adjustment mechanism 1030 extends through the openings 1028 in the substrate 1008 and is attached to the respective alignment portion 1010 as seen in FIGS. 15, 20 and 21. The dual axis adjustment mechanism 1030 includes three members, each member extending through a respective opening 1028 in the substrate 1008 and attached to a correspondingly aligned alignment portion 1010. The three elements include: a fixed element 1032 fixedly connected to the substrate 1008 and one of the three alignment portions 1010 and disposed on both the horizontal axis H and the vertical axis V of the lens 1002. A vertical adjuster 1034 is fixedly attached to the second of the three alignment portions 1010 and movable with respect to the substrate 1008, the vertical adjuster 1034 positioned on the horizontal axis H and configured to adjust the lens 1002 with respect to the vertical axis V. A horizontal adjuster 1036 is fixedly attached to the third of the three alignment portions 1010 and movable with respect to the substrate 1008, wherein the horizontal adjuster 1036 is positioned along the vertical axis V and is configured to adjust the lens 1002 with respect to the horizontal axis H.As mentioned above, the three members 1032, 1034, 1036 of the dual axis adjustment mechanism 1030 may protrude through the compliant skirt to be accessible from the front of the light 1000, as shown in FIG. 20. The three elements 1032, 1034, 1036 may be fixedly coupled to a corresponding alignment portion 1010. Alternatively, as shown in FIG. 21, the alignment portions 1010 may have a corresponding opening 1038 through which the three members 1032, 1034, 1036 extend. The three elements are fixedly attached to the alignment portions through the openings 1038. The vertical adjuster 1034 and the horizontal adjuster 1036 are movable relative to the substrate 1008. They may be frictionally fitted through the apertures 1028 so that they do not move freely but may be rotated by a human or tool. The vertical adjuster 1034 and the horizontal adjuster 1036 may be threaded with the openings 1028 in the substrate 1008 as shown in FIG. 19. Other means may also be used to achieve movement of the alignment portions 1010 by moving the vertical adjuster 1034 and the horizontal adjuster 1036 relative to the substrate 1008.The vehicle light 1000 as disclosed herein may be any type of headlamp or tail lamp. The vehicle light 1000 may be mounted to a vehicle structural member configured to support a load from a vehicle component, wherein the vehicle structural member and the compliant skirt form a seamless seal. The vehicle structural member may either cover the compliant skirt 1006 such that only the front light exit surface 1004 of the lens 1002 is visible or expose the compliant skirt 1006. The vehicle structural member may be an exterior trim, fender, bumper, or other vehicle exterior component. FIG. 22 is an illustrative example of a vehicle light 1000 as described with respect to FIGS. 14-21, wherein the vehicle structural member 804, 904 is a front fender or bumper 950 of the vehicle 2000. In Figure 22, the compliant skirt 1006 is exposed to the atmosphere along with the front light exit surface 1004 of the lens 1002.The lamps are positioned during vehicle assembly. That is, while the lights are normally preset in the supplier, final adjustment is required due to vehicle design variations at the end of the assembly line. Only the lamps identified as such may be adjusted in situ to enable fine adjustment of the headlamp for final alignment in the vehicle.A conventional headlamp 10 is shown in FIGS. 23A and 23B. The alignment mounting portions 12 of the conventional lamp 10 extend from outside the lamp chamber. The adjustment mechanisms 14 are secured to a surrounding rigid environment 16 that is spaced from the front surface 18 of the lens by a gap 20 surrounding the entire front surface 18. This is necessary in order that the luminaire can freely adjust and pivot. This gap is unsightly and provides a path for dust and dirt. The gap also provides a path for wind penetration which can contribute noise and negative aerodynamic properties. The luminaire and the surrounding rigid environment are usually accommodated in a housing, so that the gap is not visible when looking at the vehicle. This housing is then mounted on the vehicle, typically with a type of bezel, to improve the aesthetic nature of the housing.The flexible flexible skirt 1006 of the vehicle lights 1000 surrounds the front light exit surface 1004 of the lens 1002, wherein the flexible skirt 1006 extends as far as the substrate 1008 and encloses the lamp chamber 1022 without any gaps. The compliant skirt 1006 may be formed of a transparent or opaque material. In one aspect, the compliant skirt 1006 is made of silicone that provides a gap-free seal with the lens 1002 and is configured to maintain the gap-free seal during adjustment with the dual axis adjustment mechanism 1030. Due to this sealing, the lamps 1000 disclosed herein do not require a housing covering the compliant skirt 1006 and the lens 1002. Instead, the compliant skirt 1006 and the lens 1002 may be exposed directly to the atmosphere outside the vehicle. If the lens 1002 is formed of silicone, the lens 1002 does not require further coating because the silicone is UV resistant and resistant to dent and dirt. This is illustrated in Fig. 22. Due to the tight, gap-free seal between the compliant skirt 1006, the lens 1002, and the substrate 1008, there are no gaps so that dust and dirt cannot enter. The gap-free seal also prevents wind from entering, which can contribute to noise generation and negative aerodynamic properties.The lamps 1000 disclosed herein may be used with advanced front lighting systems (AFS). At AFS, the lens moves from left to right as the steering wheel rotates. As shown in FIG. 20, a stepper motor 1050 may be connected to the vertical adjuster 1034 to dynamically laterally manipulate the lens 1002 about the vertical axis. Stepper motor 1050 or other stepper motor may additionally or alternatively be connected to horizontal adjuster 1036 and used to dynamically up and down lens 1002 about the horizontal axis.Although the disclosure has been described in connection with particular embodiments, it is to be understood that the disclosure is not limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be construed as broadly as possible to cover all legally-permitted modifications and equivalent structures.References included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedU.S. Pat. No. 8,845,128

[0041]

Claims

A vehicle light comprising: a substrate; a lens forming a lamp chamber in the lens and the substrate to receive a light source, the lens having a horizontal axis and a vertical axis; an alignment member extending from the lens in at least three portions parallel to the substrate, each of the three portions each having an opening aligned with a respective opening in the substrate; a dual axis adjustment mechanism comprising: three members, each member extending through the respective opening of one of the at least three portions and the respective opening aligned with the substrate, the three members comprising: a stationary member fixedly connected to both the substrate and the alignment member and disposed on both the horizontal axis and the vertical axis; a vertical adjuster fixedly attached to the alignment member and movable with respect to the substrate, the vertical adjuster being disposed on the horizontal axis and configured to allow the lens to be adjusted with respect to the vertical axis; and a horizontal adjuster fixedly attached to the alignment member and movable with respect to the substrate, the horizontal adjuster being disposed along the vertical axis and configured to allow the lens to be adjusted with respect to the horizontal axis; and a compliant skirt which non-gap surrounds a front surface of the lens from which light exits, the compliant skirt extending toward the substrate to enclose the lamp chamber.The vehicle lamp of claim 1, wherein: the alignment member extends along vertical sides of the lens; the lens is formed of silicone; and the silicone covers the alignment member including the at least three portions.The vehicle light of claim 1, wherein the lens is made of a material other than silicone and the at least three portions of the alignment member includes a flexible material between each of the at least three portions and the substrate.The vehicle lamp according to claim 1, wherein the substrate is a heat sink exposed to the ambient atmosphere outside the lamp chamber so that heat is transferred from the light source to the ambient atmosphere.The vehicle light of claim 1, wherein the resilient skirt is made of silicone.The vehicle light of claim 1, wherein the resilient skirt is one of a transparent or opaque material.The vehicle light of claim 1, wherein the compliant skirt is silicone and is configured to maintain a gap free seal during adjustment by the two-axle adjustment mechanism.The vehicle lamp of claim 1, wherein the three members of the two-axis adjusting mechanism extend through a surface of the resilient skirt, thereby permitting adjustment from a front side of the vehicle lamp.The vehicle light of claim 1, further comprising a bracket, wherein the bracket is a structural member of the vehicle configured to support a load from a vehicle component, wherein the bracket and the resilient skirt form a gap-free seal.The vehicle light of claim 9, wherein the structural member of the vehicle is an outer panel, a fender, a bumper, or another exterior component of the vehicle.The vehicle lamp according to claim 1, wherein the vehicle lamp is a headlamp or a tail lamp.The vehicle light of claim 1, wherein the vertical axis is aligned with a vertical edge of the lens.The vehicle light of claim 1, wherein the horizontal axis is aligned with a horizontal edge of the lens.A vehicle lamp comprising: a uniformly shaped optical silicone lens having a vertical axis along a vertical edge and a horizontal axis along a horizontal edge, the uniformly shaped lens comprising: a front surface formed as a light exit; an integral reflector adjacent the front surface to meet a prescribed light output; and a reinforcing structure disposed in the uniformly shaped lens to provide structural strength to the optical silicone, the reinforcing structure having three alignment portions, each of the three alignment portions having an alignment opening; a substrate forming a lamp chamber with the uniformly shaped lens in which a light source is accommodated, the substrate being parallel to the three alignment portions and having three substrate openings, each substrate opening being aligned with a respective alignment opening; a dual axis adjustment mechanism comprising: three members, each member extending through the substrate opening aligned with the respective alignment opening, the three members comprising: a fixed member fixedly connected to both the substrate and one of the three alignment portions and positioned on both the horizontal axis and the vertical axis; a vertical adjuster fixedly attached to a second of the three alignment portions and movable with respect to the substrate, the vertical adjuster positioned on the horizontal axis and configured such that the integrally molded lens can be adjusted with respect to the vertical axis; and a horizontal adjuster fixedly attached to a third of the three alignment portions and movable with respect to the substrate, the horizontal adjuster positioned along the vertical axis and configured to allow the integrally molded lens to be adjusted with respect to the horizontal axis; and a compliant skirt framing the front surface of the integrally molded lens and extending to the substrate, the compliant skirt configured to maintain a gap-free seal during alignment with the dual axis adjuster mechanism.The vehicle light of claim 14, wherein the compliant skirt is opaque and encloses the dual-axis adjustment mechanism on a front side of the substrate, the dual-axis adjustment mechanism accessible from a back side of the substrate.The vehicle light of claim 14, wherein the two-axis adjustment mechanism is also accessible from a surface of the compliant skirt.A luminaire comprising: a lens having a front light exit surface; at least three alignment portions extending from the lens; a substrate disposed opposite the front light exit surface and positioned parallel to the at least three alignment portions, with a flexible material between the substrate and the three alignment portions, the substrate having three openings aligned with the three alignment portions; a two-axis adjustment mechanism comprising: three members, each member extending through a respective opening in the substrate and attached to a respective aligned alignment portion, the three members comprising: a fixed member fixedly connected to both the substrate and one of the three alignment portions and positioned on both a horizontal axis and a vertical axis of the lens; a vertical adjuster fixedly attached to a second of the three alignment portions and movable with respect to the substrate, the vertical adjuster positioned on a horizontal axis and configured to allow a lens to be adjusted with respect to the vertical axis; and a horizontal adjuster fixedly attached to a third of the three alignment portions and movable with respect to the substrate, the horizontal adjuster positioned along the vertical axis and configured to allow the lens to be adjusted with respect to the horizontal axis; and a compliant skirt that frames the front light exit surface of the lens without a gap, the compliant skirt extending toward the substrate.The luminaire of claim 17, wherein: the lens is formed of silicone; the three alignment portions extend from a reinforcement member formed in the silicone on opposite sides; and the flexible material is silicone in which the three alignment portions are embedded.The luminaire of claim 17, wherein the horizontal axis is a horizontal edge of the lens and the vertical axis is a vertical edge of the lens.The luminaire of claim 17, wherein the vertical adjuster is bolted to the substrate and the horizontal adjuster is bolted to the substrate.

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