Vehicle lamp assembly

Abstract

A vehicle lamp assembly 2 for use in particular for integrated vehicle body lamps and auxiliary vehicle lamps, comprising an internal clipping system. The vehicle lamp assembly 2 further comprising a

Description

FIELD The present subject-matter for which protection is sought relates generally to a vehicle lamp assembly. In particular, but not exclusively, to a lamp assembly for a vehicle comprising an internal lens clipping system. BACKGROUND Vehicle lamp assemblies and their uses are well-known in the art. A conventional lamp assembly 36 is shown in Figure 6. Most conventional vehicle lamp assemblies include a housing portion which defines an enclosed volume; the housing having a front opening that may expose a reflector and a light source. A lens is positioned exterior to the housing to cover the front opening, and the lens may include side walls if the front opening is open-sided. The housing further includes a channel or groove formed around the circumference of the front opening, to receive a liquid adhesive medium. The exterior lens comprises a flange portion formed around the circumference of the exterior lens to provide an arrangement for coupling the exterior lens to the housing. During assembly of the lens and housing the housing groove is filled with adhesive and the flange portion of the exterior lens is mated to the groove and mechanically fixed in place while the adhesive cures. In some vehicle lamp assemblies, the flange portion may further comprise a protruding tab configured to fit within the groove of the housing thereby, providing further structural support for the mated components. Such conventional vehicle lamp assemblies may comprise external clippings, fixtures or fastening mechanisms for maintaining the fixed assembly of the exterior lens and housing while the adhesive sets. If the installation of the vehicle lamp assembly does not involve concealment of the external clippings using additional vehicle elements such as bonnet or wing components, or if the vehicle lamp assembly is an auxiliary lamp designed to be fitted to a vehicle’s exterior, these clippings will be visible to the user. This may be an unwanted and / or aesthetically displeasing feature of such assemblies. Additionally, external fixing mechanisms are vulnerable to damage by elemental forces such as wind or dust particles or by persons of malevolent intent who wish to damage or steal vehicle components. In some conventional vehicle lamp assemblies, the exterior lens and housing may be adhesively coupled as described above but held together without the use of the aforementioned external clipping mechanisms. A vehicle lamp assembly 36 of this sort is structured, as shown in Figure 6, so that the front lens 38 is affixed to the housing 40 and held in place using a glue or fixings composition. The housing may be coupled to a mounting means such as a bracket 42. The front lens 38 is a rigid or linear lens not prone to distortion to facilitate this simple method of assembly. In other vehicle lamp assemblies, the exterior lens and the lamp body are adhesively coupled and instead of external clippings, the coupling is maintained by stapling through a seal groove around the circumference of the lens and housing front opening. However, such lamps require that both the lens and lamp body be composed of a material that permits a stable to pass through it and, for this reason, common lamps comprising aluminium housings or glass lenses cannot be assembled in this way. Aspects and embodiments of the invention have been devised with the foregoing in mind. SUMMARY According to an aspect of the invention, there is provided an improved vehicle lamp assembly. Said vehicle lamp assembly comprises a housing for a light source, providing support for a lens. The housing forming an opening for receiving a lens for the vehicle lamp assembly wherein the housing comprises a first deformable lens engagement formation at a peripheral edge of the opening and a second lens engagement formation. The vehicle lamp assembly further comprises a lens for a vehicle lamp configured to be received at the opening and supported by the housing, wherein the lens comprises a first deformable housing engagement formation complementary to the first lens engagement formation for interengagement therewith at a peripheral edge of the lens, and a second housing engagement at a peripheral edge of the lens. The second housing engagement formation is configured to engage with the second lens engagement formation for pivoting the lens to bring the first housing engagement formation into deformable interengagement with the first lens engagement formation. Optionally, the first housing engagement formation is configured to engage with the first lens engagement formation for pivoting the lens to bring the second housing engagement into deformable interengagement with the second lens formation. Optionally, the first and / or second lens engagement formation and / or the first and / or second housing engagement formation are resiliently deformable and configured to be resiliently biasedly interengaged. Thus, the vehicle lamp assembly is capable of being assembled using either the first or second engagement formations as a pivot point to bring the diametrically opposite formations into interengagement. Optionally, at least one lens engagement formation of the housing, and at least one housing engagement formation of the lens are configured to engage with each other in an interference fit. The friction produced by an interference fit between at least one housing engagement formation and at least one lens engagement formation maintains the clipping system of the vehicle lamp assembly Optionally, the interference between the connecting surfaces of the engagement formations is configured to maintain the interference fit engagement. In particular, the interference between the connecting surfaces of the engagement formations is in the range of 0.1 and 1mm. More particularly, the interference between the connecting surfaces of the engagement formations is in the range of 0.4 and 0.5mm. The amount of interference is configured to be relative to the size of the vehicle lamp assembly and ensure that the interference fit between at least one housing engagement formation and at least one lens engagement formation maintains the clipping system of the vehicle lamp assembly. Optionally, a depth measurement of the lens is more than a depth measurement of the housing. Optionally, the lens is compressed along an axis such that a depth measurement of the lens is less than a depth measurement of the housing, to bring the lens into interengagement with the housing. The relative depth measurements of the lens and housing provide the advantage of ensuring that the vehicle lamp assembly is maintained under compression. Optionally, the housing is operably coupled to the lens to form a cavity configured to enclose at least a light source, and / or optical reflection means, and / or electrical connecting circuitry. Optionally, the housing comprises a plurality of thermally conductive fins extending from the housing body configured to dissipate heat generated by the vehicle lamp. Optionally, the housing is composed of extruded aluminium, thus providing the advantage of thermally conductive surface and a heatsink feature. Optionally, the lens is composed of injection-moulded polycarbonate, thus providing the advantage of a sufficiently durable, impact-resistant, and flexible lens. BRIEF DESCRIPTION OF THE DRAWINGS One or more specific embodiments of the present invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: Fig. 1 illustrates a cross-sectional view of a vehicle lamp assembly according to an embodiment of the present invention; Fig. 2 illustrates a side perspective view of a vehicle lamp assembly according to an embodiment of the present invention; Fig. 3 illustrates an enlarged sectional view of a first portion of the vehicle lamp assembly according to one or more embodiments of the present invention; Fig. 4 illustrates an enlarged sectional view of a second portion of the vehicle lamp assembly according to one or more embodiments of the present invention; Fig. 5 illustrates a side perspective view of the housing element of the vehicle lamp assembly according to one or more embodiments of the present invention; and Fig. 6 illustrates a side perspective view of a conventional vehicle lamp assembly. DETAILED DESCRIPTION Figure 1 is a simplified diagrammatic illustration of a vehicle lamp assembly 2 when viewed from a cross-sectional perspective in accordance with an embodiment of the invention. The vehicle lamp assembly 2 comprises a housing 4 for a light source, the housing comprising adjoining wall members 6 &8 connecting at a 90-degree angle configured to support a lens. The housing itself defines a heat sink in which wall members 6 &8 comprise a plurality of thermally conducting fins 10 that create a path of low thermal resistance for heat to dissipate through. In the described embodiment the housing 4 is composed of a thermally conductive material, for example extruded aluminium. In the described embodiment, an inwardly extending groove 12 is formed in the interior face of the wall member 6. An extension of the curvature of groove 12 forms a first lens engagement formation. The first lens engagement formation takes the form of a hooking lip 14. The portion of the interior face of wall member 6 running from the outermost edge to the origin of the inward groove 12 is defined as an underside face 16. Wall member 8 comprises a portion protruding from it, in which is formed a groove 18 running in parallel to analogous inward groove 12. The grooves 12 and 18 define receptacles for receiving a fixing material, such as an epoxy glue or some other plastics fixing composition. Wall member 8 further comprises an indentation adjacent to the groove 18 which defines a second lens engagement formation. The second lens engagement formation takes the form of a rear ledge 20. The vehicle lamp assembly 2 further comprises an outer lens 22 supported by the housing 4 and having at least a 1.1 mm deep recess 24 formed along the top edge of the lens 22 forming a first housing engagement formation. The first housing engagement formation takes the form of a locking tab 30. Additionally, a second housing engagement formation is formed along the bottom rear edge of the lens. The second housing engagement formation takes the form of a rear tab 26 extending from the edge of the lens 22. In the described embodiment, the rear tab 26 and the rear ledge 20 are configured to engage with an interference fit. The interference between the connecting surfaces of the rear tab 20 &rear ledge 26 is configured to maintain said interference fit. Particularly the interference between the connecting surfaces of the rear tab 20 &rear ledge 26 is in the range of 0.1 and 1mm. More particularly, the interference between the connecting surfaces of the rear tab 20 &rear ledge 26 is in the range of 0.4 and 0.5mm. The depth of the lens 22 across an axis 28 measures more than the depth of the housing 4 across an axis 28. Figure 2 is a simplified diagrammatic illustration of a vehicle lamp assembly 2 when viewed from a side perspective and adjusted orientation, in accordance with an embodiment of the invention. The rear tab 26 of the lens 22 is configured to be deformably interengaged with the rear ledge 20 of the housing 4. Coupling of the rear tab 26 and the rear ledge 20 thereby provides an anchored pivot point about which the lens 22 may be rotated. The lens 22 may be rotated to bring the hooking lip 14 into proximity with the locking tab 30, such that the recess 24 is aligned with the underside face 16 of the housing 4 and the two features abut each other. The lens 22 is resiliently deformable and is manually compressed along an axis 28 such that a depth measurement of the lens 22 across the axis 28 is less than the depth of the housing 4 and / or until the lens 22 is positioned so that the locking tab 30 is affixed to the hooking lip 14. In the described embodiment, the rear tab 26 and the rear ledge 20 engage with an interference fit of 0.5mm, within manufacturing tolerances. In one or more embodiments, the housing 4 and the lens 22 are operably coupled such that a cavity 34 is formed between the housing and the lens. This cavity 34 is configured to enclose a light source for providing illumination. Typically, the light source is a lightbulb, which in the described embodiment is one or more light emitting diodes (LEDs). Additionally enclosed therein may be one or more reflectors and / or circuitry may be disposed within the chamber providing electrical connection to the light source. Figure 3 shows an enlarged view of the front clipping features of an embodiment. The recess 24 formed along the lens 22 is coupled to the underside face 16 of the wall member 6, such that the locking tab 30 of the lens 22 and the hooking lip 14 of the housing 4 are deformably interengaged. In the described embodiment, the locking tab 30 and the hooking lip 14 are resiliently deformably interengaged. Figure 4 shows an enlarged view of the rear clipping features of an embodiment. The rear tab 26 extending from the rear edge of the lens 22 is coupled to the rear ledge 20 of the wall member 8 in a deformable interengagement and configured such that the interference between the connecting surfaces is 0.5mm. In the described embodiment, interengagement of the rear tab 26 and the rear ledge 20 defines a pivot point for pivoting of the lens to bring the diametrically opposite engagement formations into interengagement. Figure 5 shows the housing 4 of an embodiment viewed from a side perspective. The angle 32 between a continuation of the line drawn through the hooking lip 14 and the line drawn from the hooking lip 14 to the rear ledge 20 measures between 55-85 degrees. More particularly, this angle measures between 70-80 degrees, and suitably 75 degrees. The vehicle lamp assembly described above has many advantages over existing vehicle lamp assemblies where the lens requires external clipping or fastening or alternatively requires stapling together of the male and female parts. By integrating clipping features into the design of the components of the vehicle lamp assembly, maintenance of the coupling of the lamp lens and housing is achieved without the need for additional fixative elements. This internal clipping system may be desirable for the production of vehicle lamps where visible external features are unwanted. In addition to the above, one or more embodiments of the present invention provides an advantage over existing vehicle lamp assemblies wherein glue or adhesive alone is used to retain the coupling of the vehicle lamp lens and housing. Such embodiments may require the lens to hold its shape under pressure which would necessitate longer injection moulding cycle times to achieve tight tolerance production. In one or more embodiments of the present invention, the lens comprises injection-moulded polycarbonate which results in lower tolerance production. This may provide cost-savings as well as providing ease of production, through shorter injection moulding cycle times. In the description of the present invention, it should be understood that the terms “front”, “rear”, “top”, “bottom”, “left”, “right”, and the like indicate an orientation or relative position based on that shown in Figure 1 and are used only for convenience of describing the disclosed subjectmatter. The use of such terms should not indicate that one or more embodiments of the present invention to be referred must have a specific orientation. As used herein any reference to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment. Moreover, one or more features of different embodiments may be combined to create further embodiments not specifically described herein, and any one or more features may be combined consistent with their technical and operational compatibility. To the extent that one or more features from respective embodiments may not be combined without being inconsistent with the technical and / or operational compatibility, such features from respective embodiments may be selected for combination which do not have such technical and / or operational compatibility. All such embodiments are contemplated within the scope of this disclosure. As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. In view of the foregoing description, it will be evident to a person skilled in the art that various modifications may be made within the scope of the described embodiments. For example, although embodiments have been described in which the lens engagement formations of the housing take the form of a hooking lip 14 and a rear ledge 20 and the housing engagement formations of the lens take the form of a locking tab 30 and a rear tab 26, persons skilled in the art will recognize that the lens engagement formations of the housing may instead take the form of a locking tab and a rear tab, and the housing engagement formations of the lens may instead take the form of a hooking lip and a rear ledge. Additionally, the engagement formations of the lens and the housing may take any alternative form suitable to achieve the interengagement of the relevant formations. One or more embodiments have been described wherein the second housing engagement formation and the second lens engagement formation are configured to engage, for pivoting the lens 22 to bring the first housing engagement formation into deformable interengagement with the first lens engagement formation. Optionally, the first housing engagement formation and the first lens engagement formation may be engaged such that the interengagement of the locking tab 30 and the hooking lip 14 provides a pivot point about which the lens 22 may be rotated. The lens 22 may be rotated / pivoted to bring the rear tab 26 and the rear ledge 20 into proximity and thus bring the second housing engagement formation into deformable interengagement with the second lens engagement formation. Persons skilled in the art will recognise that either the first engagement formations or the second engagement formations may provide a pivot point, about which the lens 22 may be rotated to facilitate the fixture of the diametrically opposite formations. Additionally, although embodiments have been described wherein the first lens engagement formation and the first housing engagement formation are resiliently deformable and configured to be resiliently biasedly interengaged. The first and / or second lens engagement formation and / or the complementary first and / or second housing engagement formation may 5 be resiliently deformable and configured to be resiliently biasedly interengaged. The vehicle lamp assembly described herein will be understood by those skilled in the art to have utility in numerous applications that include, without limitation, integrated vehicle body lamps and auxiliary lamps. Applications outside of vehicles may be envisaged. The disclosed lamp assembly will have utility in any luminaire comprising interengaging lens and housing 10 components. For example, road or street lighting luminaires, floodlighting luminaires, and household device luminaires.

Claims

1. A vehicle lamp assembly comprising:i) a housing for a light source of a vehicle lamp, providing a lens support the housing forming an opening for receiving a lens for the vehicle lamp assembly and comprising:a first deformable lens engagement formation at a peripheral edge of the opening, anda second lens engagement formation;ii) a lens for a vehicle lamp configured to be received at the opening and supported by the housing, the lens comprising:a first deformable housing engagement formation complementary to the first lens engagement formation for interengagement therewith at a peripheral edge of the lens, anda second housing engagement formation at the peripheral edge of the lens;wherein the second housing engagement formation is configured to engage with the second lens engagement formation for pivoting the lens to bring the first housing engagement formation into deformable interengagement with the first lens engagement formation.

2. A vehicle lamp assembly according to claim 1, wherein the first housing engagement formation is configured to engage with the first lens engagement formation for pivoting the lens to bring the second housing engagement formation into deformable interengagement with the second lens engagement formation3. A vehicle lamp assembly according to claim 1 or claim 2, wherein the first and / or second lens engagement formation and / or the first and / or second housing engagement formation are resiliently deformable and configured to be resiliently biasedly interengaged.

4. A vehicle lamp assembly according to any preceding claim, wherein at least one lens engagement formation of the housing and at least one housing engagement formation of the lens are configured to engage with each other in an interference fit5. A vehicle lamp assembly according to claim 4, wherein the interference between the connecting surfaces of the engagement formations is configured to maintain the interference fit engagement.

6. A vehicle lamp assembly according to claim 5, wherein the interference between the connecting surfaces of the engagement formations is in the range of 0.1 and 1mm.

7. A vehicle lamp assembly according to claim 6, wherein the interference between the connecting surfaces of the engagement formations is in the range of 0.4 and 0.5mm.

8. A vehicle lamp assembly according to any preceding claim, wherein a depth measurement of the lens is more than a depth measurement of the housing.

9. A vehicle lamp assembly according to claim 7, wherein the lens is compressed along an axis such that a depth measurement of the lens is less than a depth measurement of the housing to bring the lens into interengagement with the housing.

10. A vehicle lamp assembly according to any preceding claim, wherein the housing is operably coupled to the lens to form a cavity configured to enclose at least a light source, and / or optical reflection means, and / or electrical connecting circuitry.

11. A vehicle lamp assembly according to any preceding claim, wherein the housing further comprises a plurality of thermally conductive fins extending from the housing body configured to dissipate heat generated by the vehicle lamp.

12. A vehicle lamp assembly according to any preceding claim, wherein the housing is composed of extruded aluminium.

13. A vehicle lamp assembly of any preceding claim, wherein the lens is composed of injection-moulded polycarbonate.

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