A cartridge for locating a desiccant within a vehicle lamp assembly
The cartridge system addresses condensation issues in vehicle lamps by facilitating desiccant replacement and moisture removal through a ventilation passage, enhancing performance and reducing costs.
Patent Information
- Authority / Receiving Office
- GB · GB
- Patent Type
- Applications
- Current Assignee / Owner
- JAGUAR LAND ROVER LTD
- Filing Date
- 2024-10-02
- Publication Date
- 2026-04-22
AI Technical Summary
Condensation occurs within vehicle lamp assemblies due to moisture accumulation, particularly in head and rear lamps, which is exacerbated by heat generation and temperature fluctuations, leading to reduced desiccant performance over time.
A cartridge system with a mounting portion and ventilation passage for desiccant placement within the lamp assembly, allowing gaseous exchange and easy replacement, featuring a storage portion with ventilation openings and optional features like a hinge or snap-fit fasteners for tool-free desiccant replacement.
Effectively removes moisture in a gaseous form, preventing condensation on the lens and enabling desiccant regeneration, while reducing manufacturing costs and space requirements.
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Abstract
Description
TECHNICAL FIELD The present disclosure relates to a cartridge for locating a desiccant within a vehicle lamp assembly. Aspects of the invention relate to the cartridge, the vehicle lamp assembly, and a vehicle. BACKGROUND A common occurrence in vehicle lamp assemblies, such as head lamps and rear lamps, is the appearance of moisture within the assembly, particularly appearing as condensation on the lamp lens. This is caused by heat generated inside, usually by the lamp unit and a fluctuating temperature due to the cooler air outside. It is known to use desiccant bags to adsorb the moisture inside of vehicle lamp assemblies. For example, desiccant bags may be adhered to an interior wall of the housing of a vehicle lamp assembly. However, the performance of the desiccant reduces overtime. It is an aim of the present invention to address one or more of the disadvantages associated with the prior art. SUMMARY OF THE INVENTION Aspects and embodiments of the invention provide a cartridge, a vehicle lamp assembly, and a vehicle as claimed in the appended claims. According to an aspect of the present invention there is provided a cartridge for locating a desiccant within a vehicle lamp assembly. The cartridge comprises a mounting portion configured for mounting and dismounting the cartridge to a housing of the vehicle lamp assembly within an aperture in the housing and comprising a ventilation passage configured to enable gaseous exchange between an interior and an exterior of the vehicle lamp assembly. The cartridge comprises a storage portion extending from the mounting portion and providing a storage space for a desiccant in fluidic communication with the ventilation passage and comprising one or more ventilation openings configured to enable gaseous exchange between the interior of the vehicle lamp assembly and the storage space. The storage portion is openable to enable replacement of a desiccant within the storage space. An advantage of having a cartridge for a desiccant which mounts and dismounts within an aperture in the housing is that the desiccant can be replaced when it saturates to solve a problem of increasing condensation on the lamp lens over the lifetime of the vehicle. An advantage of integrating the desiccant with the lamp vent, via the ventilation passage, is that the desiccant can release the moisture in a gaseous form directly into the vent to exit the lamp assembly when it becomes hot inside the lamp assembly. The desiccant can also remove moisture from ambient air entering the lamp assembly before it is released into the interior proper where it may end up condensing on the lens. An advantage of having an openable storage portion is that the desiccant can be replaced while the cartridge is reused. Optionally the mounting portion comprises a waterproof, breathable membrane configured to prevent liquid ingress into the interior of the vehicle lamp assembly via the ventilation passage. Optionally the storage portion is openable via a hinge and one or more releasable fasteners. An advantage of having a hinged storage portion for the desiccant is that the replacement of the desiccant can be effected easily. Optionally the hinge is a living hinge. An advantage of using a living hinge is that it, and thus the cartridge, can be produced in a single injection moulding operation, reducing manufacturing costs. Optionally the one or more releasable fasteners comprise one or more snap-fit fasteners. An advantage of using snap fit fasteners is that they, and thus the cartridge, can be produced in a single injection moulding operation, reducing manufacturing costs. Optionally the storage portion comprises two shells, a first which is directly connected to and extends from the mounting portion, and a second which is pivotable with respect to the first via the hinge. Optionally the mounting portion comprises mating components configured to mate with corresponding mating components in the aperture in the housing of the vehicle lamp assembly to mount the cartridge in a specific, preset orientation with respect to the housing. Optionally in the specific, preset orientation, the first shell provides a platform on which the desiccant can rest when the vehicle lamp assembly is in situ on a vehicle. Optionally the mating components of the mounting portion are configured to connect and disconnect with the corresponding mating components in the aperture in the housing via rotation and the mounting portion comprises a grippable head for enabling rotation of the cartridge with respect to the aperture in the housing. An advantage of this arrangement is that it facilitates tool-free removal of the cartridge to enable replacement of the desiccant. There is typically little space around the housing of the vehicle lamp assembly to accommodate the use of tools. Optionally the first shell is a solid shell; the second shell is a vented shell comprising the one or more ventilation openings. An advantage of this arrangement is that, if the solid shell is oriented below the desiccant, it will prevent water extracted from the air within the lamp assembly by the desiccant, from dripping out of the cartridge onto any electrical components positioned below the cartridge (where a PCB may be typically located). Optionally one of the first and second shells comprises, at an end distal from the mounting portion, a cantilever snap-fit fastener and the other of the first and second shells comprises, at an end distal from the mounting portion, a corresponding mating component, and the two ends, when fastened, form a closed end to the storage portion. Optionally one of the releasable fasteners is a snap-fit fastener comprising an edge of the second shell proximal to the mounting portion and a protrusion from the mounting portion which overhangs a part of the storage space, wherein the overhung part of the storage space provides a snap-in area for the edge of the second shell. Optionally the second shell comprises a cantilever snap-fit fastener and a connecting portion of the cartridge between the mounting portion and the first shell comprises a corresponding mating component. Optionally the ventilation passage has two branches, one connecting to the storage space and one bypassing the storage space and configured to enable gaseous exchange directly between an interior and an exterior of the vehicle lamp assembly. An advantage of this arrangement is that, if the desiccant becomes saturated, the ventilation openings can become blocked and then the provision of a bypass enables the necessary air flow between the interior and exterior of the vehicle lamp assembly in this eventuality. This additional airflow may also facilitate drying of the desiccant to reduce saturation. Optionally an inlet for the branch bypassing the storage space is located in a connecting portion of the cartridge between the mounting portion and the storage portion, and the branch bypassing the storage portion extends perpendicularly to the branch connecting to the storage space and a common portion of the ventilation passage. An advantage of this arrangement is that air within the vehicle lamp assembly will flow in a vertical direction with respect to the cartridge because it will be positioned, extending horizontally, above the source of heat and, therefore, the perpendicular arrangement of the bypass will have improved airflow into the ventilation passage. Additionally, the inlet being located in the connecting portion means that it will be adjacent the housing surface which will tend to guid air flow into the bypass, again leading to improved air flow into the ventilation passage. Optionally the storage portion comprises a metal plate within the storage space. An advantage of this arrangement is that the high thermal conductivity of the metal plate will result in the concentrated transfer of heat, generated within the vehicle lamp assembly, to the desiccant also within the storage space, leading to drying (and thus regenerating) of the desiccant. Optionally the vehicle lamp wiring harness is routed through the mounting portion and the mounting portion comprises an electrical connector configured to enable other electrical systems of a vehicle to connect to the vehicle lamp wiring harness. An advantage of this arrangement is that by combining the cartridge for the desiccant with the cartridge for the wiring harness, the amount of available space required within the vehicle lamp assembly is reduced. According to another aspect of the invention, there is provided a system comprising: a housing defining a cavity having a first portion configured to receive at least a lamp unit and providing mounting points to which 3 the lamp unit is mountable and a second portion configured to enable circulation of air heated by the lamp unit; and the cartridge for locating a desiccant within the vehicle lamp assembly. The cartridge is mounted in an aperture in the housing and extends into the second portion of the cavity defined by the housing. According to another aspect of the invention, there is provided a vehicle lamp assembly comprising: a lamp unit, comprising one or more light sources; a housing defining a cavity configured to receive at least the lamp unit and providing mounting points to which the lamp unit is mounted; a lens closing the cavity defined by the housing; and the cartridge for locating a desiccant within the vehicle lamp assembly. The cartridge is mounted in an aperture in the housing and extends into a portion of the cavity defined by the housing which is unoccupied by the lamp unit. Optionally the housing defines a cavity having a portion which, when the vehicle lamp assembly is in situ on a vehicle, is above the lamp unit and the aperture in which the cartridge is mounted opens into this portion. An advantage of this arrangement is that, since hot air rises, air heated by the lamp unit will rise into this portion of the cavity. Arranging the cartridge to extend into this portion places the desiccant into the hot, fast moving air where it will be most effective. Optionally the light sources comprise at least one light emitting diode. Optionally an end of the storage portion distal from the mounting portion is unsupported within the vehicle lamp assembly. Optionally the cartridge bridges the cavity between the housing and the lens and an end of the storage portion distal from the mounting portion engages a socket on the inner side of the lens. According to another aspect of the invention, there is provided a vehicle comprising one or more of the vehicle lamp assembly. According to a further aspect of the present invention there is provided a cartridge for locating a desiccant within a vehicle lamp assembly. The cartridge comprises a mounting portion configured for mounting and dismounting the cartridge to a housing of the vehicle lamp assembly. The cartridge comprises a storage portion extending from the mounting portion and providing a storage space for a desiccant and comprising one or more ventilation openings configured to enable gaseous exchange between the interior of the vehicle lamp assembly and the storage space. The storage portion is openable to enable replacement of a desiccant within the storage space. Within the scope of this application, it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination that falls within the scope of the appended claims. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination that falls within the scope of the appended claims, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner. BRIEF DESCRIPTION OF THE DRAWINGS One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG 1 illustrates an example of a vehicle as described herein; FIG 2 schematically illustrates an example of a vehicle lamp housing as described herein; FIGs 3A-D schematically illustrate an example of a mounting portion of a cartridge as described herein; FIG 4 schematically illustrates an example of a cartridge as described herein; FIGs 5A-D illustrate detail views of an example of a cartridge as described herein; FIG 6 illustrates a detail view an example of a connecting portion of a cartridge as described herein; FIG 7 schematically illustrates an example of a cartridge as described herein; FIG 8 illustrates a detail view of an example of a cartridge as described herein; FIG 9 schematically illustrates an example of a cartridge as described herein; FIG 10 schematically illustrates an example of a cartridge as described herein; FIG 11 illustrates a detail view of an example of a cartridge as described herein; FIG 12 schematically illustrates an example of a cartridge as described herein; FIG 13 schematically illustrates an example of a cartridge as described herein; FIG 14 illustrates a detail view of an example of a cartridge as described herein; FIG 15 illustrates a detail view of an example of a cartridge as described herein; and FIG 16 schematically illustrates an example of a cartridge as described herein. DETAILED DESCRIPTION A vehicle 1 in accordance with an embodiment of the present invention is described herein with reference to the accompanying FIG. 1. In some, but not necessarily all examples, the vehicle 1 is a passenger vehicle, also referred to as a passenger car or as an automobile. In other examples, embodiments of the invention can be implemented for other applications, such as commercial vehicles. The vehicle 1 comprising one or more of vehicle lamp assemblies 10 of a type illustrated in FIG 2. The vehicle lamp assemblies 10 can be configured forthe exterior of the vehicle 1, and may be configured to for illuminating the way ahead or other areas of way or environments or for signalling. The vehicle lamp assemblies 10 can include, without limitation, head lamps, fog lamps, rear lamps, brake lamps, reversing lamps or direction indicator lamps. FIG 2 schematically illustrates an example cross-sectional view of a vehicle lamp assembly 10. The vehicle lamp assembly 10 comprises a housing 20. The housing 20 defines a cavity 22 which is closed by a lens 30 (sometimes called a cover). The cavity 22 defined by the housing 20 is configured to receive at least a lamp unit 40. The housing 20 provides mounting points 24 to which the lamp unit 40 is mounted. The lamp unit 40 comprises one or more light sources 42 and control circuitry, for example embodied in a printed circuit board (PCB) 44. The light source(s) 42 is the entity that generates light for the lamp unit. In some examples the light source(s) 42 comprises at least one light emitting diode (LED). The problem of condensation within the vehicle lamp assembly 10, particularly on the lens 30, may be more prevalent with LEDs than with, for example, incandescent light sources such as filament bulbs since filament bulbs themselves generate heat and thus provide a source of heat near to the lens 30, whereas a main source of heat when using LEDs is the control circuitry 44 which may be positioned further from the lens, as illustrated in this example. The cavity 22 defined by the housing 20 is larger than the lamp unit 40 and thus, there is a first portion 22A of the cavity 22 which is occupied by the lamp unit 40, when mounted to the housing 20 and a second portion 22B of the cavity 22 which is unoccupied by the lamp unit 40. This second portion 22B may be configured to enable the circulation of air heated by the lamp unit 40. An aperture 26 is provided in the housing 20 and opens into the second portion 22B. A cartridge 100 for locating a desiccant 50 within the vehicle lamp assembly 10 is mounted in the aperture 26 in the housing 20 and extends into the second portion 22B of the cavity 22 defined by the housing 20. In some examples, the second portion 22B is located above the lamp unit 40 when the vehicle lamp assembly 10 is in situ on a vehicle 1 (with each of its wheels in contact with a horizontal surface). Air heated by the lamp unit 40 will rise into this second portion 22B of the cavity 20. Arranging the cartridge 100 to extend into this second portion 22B places the desiccant 50 into the hot, fast-moving air where it will be most effective. The cartridge 100 comprises a mounting portion 200. The mounting portion 200 is configured for mounting and dismounting the cartridge 100 to the housing 20 of the vehicle lamp assembly 10 within the aperture 26 in the housing 20. The mounting portion 200 comprises a ventilation passage 202, which is configured to enable gaseous exchange between an interior 12 and an exterior 14 of the vehicle lamp assembly 10. A detailed example of the mounting portion 200 will subsequently be described with respect to FIGs 3A-D. By providing for the desiccant 50 a cartridge 100 which mounts and dismounts within an aperture 26 in the housing 20 of the vehicle lamp assembly 10, the desiccant 50 can be replaced when it saturates to solve a problem of increasing condensation on the lamp lens 30 over the lifetime of the vehicle 1. The cartridge 100 may be mounted to the housing 10 in a cantilevered manner, wherein an end 306 distal to the mounting portion 200 is unsupported, as is illustrated in FIG 2. Alternatively, the cartridge 100 may be mounted to the housing 10 in a bridging manner as will be illustrated in FIG 16. The cartridge 100 comprises a storage portion 300. The storage portion 300 extends from the mounting portion 200. The storage portion 300 provides a storage space 302 for the desiccant 50. The storage portion 300 comprises one or more ventilation openings 304, which are configured to enable gaseous exchange between the interior 12 of the vehicle lamp assembly 10 and the storage space 302. The storage space 302 is in fluidic communication with the ventilation passage 202. This enables the desiccant 50 to release the moisture in a gaseous form directly into the ventilation passage 202, and thus forthe moisture to exit the lamp assembly 10, when it becomes hot inside the lamp assembly 10. The desiccant 50 can also remove moisture from ambient air entering the lamp assembly 10 before it is released into the interior proper 12 where it may end up condensing on the lens 30. The storage portion 300 is openable to enable replacement of a desiccant 50 within the storage space 302. This enables the desiccant 50 to be replaced while the cartridge 100 is reused. Any suitable means for opening and closing the storage portion 300 may be used. For example, the storage portion 300 may be formed as a tube which is closed at an end 306 distal to the mounting portion 200. A threaded connection between the mounting portion 200 and the storage portion 300 may be provided to facilitate detachment of the storage portion 300 from the mounting portion 200 and access to the storage space 302 via the end 308 detached from the mounting portion 200, which, when detached, is an open end. Alternatively, the end 306 of the storage portion 300 which is distal to the mounting portion 200 may be closed by a cap which can be removed to permit access to the storage space 302 via the distal end 306. Alternatively, the threaded connection may be replaced by a clipping arrangement which enables a proximal end 308 of the storage portion 300 to clip to and unclip from the mounting portion 200. In at least some other examples, the storage portion 300 is openable via a hinge 310. The storage portion 300 may be held closed by one or more releasable fasteners. The storage portion 300 thus comprises two shells, a first 314 which is directly connected to and extends from the mounting portion 200, and a second 316 which is pivotable with respect to the first 314 via the hinge 310. The hinge 310 may extend longitudinally between or substantially between an end 308 of the storage portion 300 proximal to the mounting portion 200 and an end 306 of the storage portion 300 distal to the mounting portion 200. Alternatively, the hinge 310 may extend laterally across the distal end 306 of the storage portion 300. Detailed examples of the storage portion 300 will subsequently be described with respect to FIGs 4-16. Examples using a hinge 310, in particular a longitudinal hinge 310, are shown in FIGs 5A-D, 8, 11, 14, 15. FIG 3A schematically illustrates an example of the aperture 26 in the housing 20 of the vehicle lamp assembly 10 in which the cartridge 100 is mounted. FIG 3B schematically illustrates an example of the cartridge’s mounting portion 200, which is configured to cooperate with the aperture 26 of FIG 3A for mounting and dismounting of the cartridge 100. FIG 3C schematically illustrates a cutaway view of the aperture 26 along the line C-C in FIG 3A and FIG 3D schematically illustrates a cross-section of the mounting portion 200 along the line D-D in FIG 3B. The mounting portion 200 comprises one or more mating components 204 configured to mate with corresponding (oppositely gendered) mating components 27 in the aperture 26 in the housing 20 of the vehicle lamp assembly 10 to mount the cartridge 100 in a specific, preset orientation with respect to the housing 20. In some of the examples where the storage portion 300 is comprised of two shells 314, 316 joined by a hinge 310 (these features are not shown in FIGs 3A-D), the specific, preset orientation is such that the first shell 314, being the one which is directly connected to the mounting portion 200, provides a platform on which the desiccant 50 can rest when the vehicle lamp assembly 10 is in situ on the vehicle 1. This avoids the weight of the desiccant 50 exerting a force on the storage portion 300 in a direction for opening the storage portion 300. In the illustrated example, the one or more mating components 204 of the mounting portion 200 are configured to connect and disconnect with the corresponding mating components 27 in the aperture 26 in the housing 20 via rotation. For example, they may utilise the bayonet connection principle. The one or more mating components 204 are radial protrusions or pins from the main body of the mounting portion 200. The aperture 26 has a corresponding number of L-shaped slots 27 forthe radial protrusions 204. The one or more L-shaped slots 27 are provided by one or more gaps in an internal flange 28 provided within the aperture 26 and by one or more stops 29 extending from the flange 29. The one or more stops 29 limit an extent of rotation of the radial protrusions 204 once they have been inserted through the gaps in the flange 28. The one or more L-shaped slots 27 may or may not themselves limit an extent to which the mounting portion 200 may be inserted through the aperture 26. In the illustrated example, the extent to which the mounting portion 200 may be inserted through the aperture 26 is in fact limited by an external flange 206 provided on the mounting portion 200. This external flange 206 has a diameter larger than the aperture 26. An O-ring 60 may be provided between the flange 206 and the housing 20 encircling the aperture 26 and is configured to provide a fluid-tight seal. The O-ring is configured to act as spring between the flange 206 and the housing 20 encircling the aperture 26 so that the one or more radial protrusions 204 are pressed against the flange 28 once inserted through the gaps and rotated into contact with the stops 29. In some examples, to aid rotation of the cartridge 100 with respect to the aperture 26 in the housing 20, the mounting portion 200 is provided with a grippable head. The grippable head could comprises raised features 208 on the flange 206. There is typically little space around the housing 20 of the vehicle lamp assembly 10 to accommodate the use of tools so the grippable head can facilitate tool-free removal of the cartridge 100 to enable replacement of the desiccant 50. In some examples, the mounting portion 200 comprises a waterproof, breathable membrane 210 configured to prevent liquid ingress into the interior 12 of the vehicle lamp assembly 10 via the ventilation passage 202. FIG 4 schematically illustrates an example of the cartridge 100. The mounting portion 200 can be as described in relation to FIGs 3A-D. In this example, the ventilation passage 202 has two branches 212, 214. What has hereinbefore been referred to as the ventilation passage 202 comprises a common portion 216, which in use opens to an exterior 14 of the vehicle lamp assembly 10 and a first branch 212 connecting to the storage space 302. In this example, a 8 second branch 214 bypasses the storage space 302 and is configured to enable gaseous exchange directly between an interior 12 and an exterior 14 of the vehicle lamp assembly 10. This has the advantage that if the desiccant 50 becomes saturated such that the one or more ventilation openings 304 become blocked, the necessary airflow between the interior 12 and exterior 14 of the vehicle lamp assembly 10 can occur directly via the second branch 214. Furthermore, the additional air flow through the second branch 214 can facilitate drying of the desiccant 50 to reduce saturation. In some examples, an inlet 215 for the second branch 214 is located in a connecting portion 400 of the cartridge 100 between the mounting portion 200 and the storage portion 300. The second branch 214 extends perpendicularly to the first branch 212. This is advantageous particularly where the cartridge 100 is positioned, extending horizontally, above the source of heat in the vehicle lamp assembly 10, which is typically the lamp unit 40. Air within the vehicle lamp assembly 10 will therefore flow in a vertical direction with respect to the cartridge 100. The perpendicular arrangement of the second branch 214, will provide improved air flow into the ventilation passage 202. Additionally, the inlet 215 being located in the connecting portion 400 means that it will be adjacent the surface of the housing 20, which will tend to guide air flow into the second branch 214, again leading to improved airflow into the ventilation passage 202. Several detail views of a cartridge 100 according to the example of FIG 4 are shown in FIGs 5A-D. In the examples of FIGs 5A-D, the storage portion 300 is configured to open and close via a hinge 310 and one or more releasable fasteners. In these examples, the hinge 310 is a living hinge and the one or more releasable fasteners comprise two snap-fit fasteners 318, 320. The storage portion 300 comprises two shells, a first 314 which is directly connected to and extends from the mounting portion 200 by means of the connecting portion 400, and a second 316 which is pivotable with respect to the first 314 via the hinge 310. The first and second shells 314, 316 are vented shell, each comprising a plurality of ventilation openings 304. FIG 5A depicts this example of the cartridge 100 with its storage portion 300 in a closed configuration. FIG 5B depicts a cross-section along the line B-B in FIG 5A. FIG 5C depicts a cross-section along the line C-C in FIG 5A. FIG 5D depicts this example of the cartridge 100 with its storage portion 300 in an open configuration. As can be seen in FIG 5B, one of the first and second shells 314, 316 (in the illustrated example it is the first shell 314) comprises, at an end 322 distal from the mounting portion 200, a first (distal) cantilever snap-fit fastener (hook) 318 and the other of the first and second shells 314, 316 (in the illustrated example it is the second shell 316) comprises, at an end 324 distal from the mounting portion 200, a corresponding mating component (catch) 326, and the two ends 322, 324, when fastened, form a closed (or substantially closed) end 306 to the storage portion 300. The catch 326 may have a chamfer 328 on the entry side for easier clipping. As can be seen in FIG 5C, the second shell 316 comprises a second (proximal) cantilever snap-fit fastener (hook) 320 and the connecting portion 400 of the cartridge 100 between the mounting portion 200 and the first 9 shell 314 comprises a corresponding mating component (catch) 402. The catch 402 may be preceded on the entry side by one or more sloping ribs 404 for easier clipping. The orientation of the hook 320 and catch 402 may both be changed by 90 degrees, compared to what is illustrated, for reduced stress on the second shell 316. An example of such a re-orientation can be seen in FIG 8. Though in this example there is one cantilever snap-fit fastener 318, 320 on each shell 314, 316, it will be appreciated that the second shell 316 could comprise both of the cantilever snap-fit fasteners 318, 320 or both of the corresponding mating components 326, 402. FIG 6 illustrates an example of a connecting portion 400 of the cartridge 100 between the mounting portion 200 and the storage portion 300. In this example, the connecting portion comprises a short beam section to resist loads arising from mounting the cartridge 100 to the housing 20 in a cantilevered manner. The beam section has a functionally l-shaped profile, though it is warped to accommodate a central positioning of the common portion 216 of the ventilation passage 202. The beam section comprises two flanges 406, 408 and a web comprised of straight section 410 on one side of the first flange 406, warped section 412 between the two flanges 406, 408, and a section, which doubles as the catch 402 for the second (proximal) cantilever snap-fit fastener (hook) 320, on the other side of the second flange 408. The warped section 412 skirts the common portion 214 of the ventilation passage 202. The warped section 412 comprises an aperture 414 therein which joins the second branch 214 of the ventilation passage 202 to the common portion 216. It will be appreciated that FIG 6 illustrates only one possible example for providing structural stability to the cartridge 100. In examples where the cartridge 100 is downsized, the shells 314, 316 may sufficiently bear load that a beam section is not required. Furthermore, alternative structural elements could be used such as a rib 334 along underside (exterior) of first shell (314) which lends structural stability as shown in FIG 11. FIG 7 schematically illustrates another example of the cartridge 100. This example differs from the one illustrated in FIG 4 in that the first shell 314 is a solid shell. Only the second shell 316 is a vented shell and comprises a plurality of ventilation openings 304. If the solid shell 314 is oriented below the desiccant 50, for example providing a platform on which the desiccant may rest, it will prevent water, extracted from the air within the lamp assembly 10 by the desiccant 50, from dripping out of the cartridge 100 onto any electrical components positioned below the cartridge 100, which is typically where the PCB 44 embodying the control circuitry for the lamp unit 40 would be located. The one or more mating components 204 of the mounting portion 200 may therefore be configured to mate with corresponding mating components 27 in the aperture 26 in the housing 20 of the vehicle lamp assembly 10 to mount the cartridge 100 in an orientation with respect to the housing such that the first shell 314 provides a platform on which the desiccant 50 can rest when the vehicle lamp assembly 10 is in situ on a vehicle 1. Reference to first and second shells 314, 316 in this example should not be understood to imply that the shells 314, 316 can move with respect to each other. Any suitable means for opening the storage portion 300 may be used and the example of FIG 7 is not limited to use of a hinge 310. A detail view of a cartridge 100 according to the example of FIG 7 is shown in FIG 8. FIG 8 depicts this example of the cartridge 100 with its storage portion 300 in an open configuration. In the specific example of FIG 8, the storage portion 300 is configured to open and close via a hinge 310 and one or more releasable fasteners. The hinge 310 and the one or more releasable fasteners can be as described in relation to FIGs 5A-D. The difference between the example of FIG 8 and the example of FIGs 5A-D is that the first shell 314 is a solid shell. FIG 9 schematically illustrates another example of the cartridge 100. This example differs from the one illustrated in FIG 7 in that the storage portion 300 comprises a heat sink, for example in the form of a metal plate 500, within the storage space 302. The high thermal conductivity of the metal plate 500 will result in the concentrated transfer of heat, generated within the vehicle lamp assembly 10, to the desiccant 50 also within the storage space 302, leading to drying (and thus regenerating) of the desiccant 50. A main source of heat within the vehicle lamp assembly 10 may be the PCB 44, which may be below the cartridge 100, as has been described. In some examples, the metal plate 500 is located within the storage area 302 at the location which is closest to the PCB 44 when the cartridge 100 is mounted. Therefore, in such examples, the metal plate 500 may be provided on an inner surface of the first shell 314, covering at least a portion of this inner surface. In some examples, the metal plate 500 may be formed as an elongate strip set into a depression in the inner surface of the first shell 314. Though illustrated with the first shell 314 being a solid shell as in the example of FIG 7, it will be appreciated that the metal plate 500 may also be provided within the storage space 302 of the example illustrated in FIG 4, that is in conjunction with the first shell 314 being a vented shell. FIG 10 schematically illustrates another example of the cartridge 100. This example differs from the one illustrated in FIG 9 in that the ventilation passage 202 is not branched. In particular, it comprises no branch 214 configured to bypasses the storage space 302 to enable gaseous exchange directly between an interior 12 and an exterior 14 of the vehicle lamp assembly 10. This facilitates downsizing of the cartridge 100 and thus may be appropriate for smaller vehicle lamp assemblies 10. Implementing this example with a solid first shell 214 is optional. Implementing this example with a metal plate 500 within the storage area 302 is optional. To assist with downsizing of the cartridge 100, the second (proximal) cantilever snap-fit fastener 320 may be replaced with an alternative releasable fastener, which may be more compact. For example, as illustrated in the detail view of FIG 11, there may be provided a snap-fit fastener 218 comprising an edge 332 of the second shell 316 proximal to the mounting portion 200 and a protrusion 220 from the mounting portion 200 which overhangs a part of the storage space 302, wherein the overhung part of the storage space provides a snap-in area for the edge 332 of the second shell 316. The protrusion 220 may also function as one of the radial protrusions 204 of the mounting portion 200 used for mounting the cartridge 100 in a specific, preset orientation with respect to the housing 20 as described in relation to FIGs 3A-D. In some examples, a section of the edge 332 of the second shell 316 may be thinned to enable increased flexing for snap-fitting into the snap-in area. It will be appreciated that while the snap-fit fastener 218 may be more compact than the cantilever snap-fit fastener 320 and may thus assist with downsizing the cartridge 100, the snap-fit fastener 218 may be used regardless of the size of the cartridge 100. FIGs 12 and 13 schematically illustrate another two examples of the cartridge 100. These examples differ from the one illustrated in FIG 10 in that the vehicle lamp wiring harness 600 is routed through the mounting portion 200 and the mounting portion 200 comprises an electrical connector 502 configured to enable other electrical systems of a vehicle 1 to connect to the vehicle lamp wiring harness 600. The examples of FIGs 12 and 13 differ from one another in that FIG 12 illustrates a plug-type electrical connector 602 while FIG 13 illustrates wire-type electrical connectors 602. By combining into one the cartridge 100 for the desiccant 50 and a bracket for vehicle lamp wiring harness 600, the amount of available space required within the vehicle lamp assembly 10 is reduced. In some examples, to accommodate the routing of the vehicle lamp wiring harness 600, the first shell 314 is made flat. This differs from the foregoing examples in which the first shell 314 has comprised a concave inner surface. For a correspondingly sized cartridge 100, the storage area 302 for the desiccant is approximately halved by making the first shell 314 flat. This provides space below the first shell 314 for the vehicle lamp wiring harness 600. From the underside (exterior) of the first shell 314, one or more cable guides 604 may extend. The first shell 314 is a solid shell to prevent water, extracted from the air within the lamp assembly 10 by the desiccant 50, from dripping out of the cartridge 100 onto the vehicle lamp wiring harness 600. FIGs 14 and 15 show detail views ofcartridges 100 according, respectively, to the examples of FIGs 12 and 13. FIG 16 schematically illustrates an example in which the cartridge 100 is mounted in a bridging manner, bridging between the housing 20 and the lamp lens 30. The inner side 32 of the lens 30 is provided with socket 34 configured to receive and support the distal end 306 of the storage portion 300. The socket 34 may be provided by a ring which attaches to or is formed integrally with the inner side 32 of the lens 30 and projects into the interior 12 of the vehicle lamp assembly 10. In this example, the cartridge 100 differs from the examples hereinbefore described in that it comprises a stopper rib 336 along underside (exterior) of first shell (314) which helps to locate the cartridge 300 with respect to the socket 34 and lends structural stability across the bridging section. The cartridge 100 may, in accordance with any of the foregoing examples, be formed from any appropriate material. For example, it may be formed from plastic materials such as Polycarbonate / Acrylonitrile Butadiene Styrene (PC-ABS), Polypropolyne (PP), polyamide Nylon (PA), or Polybutylene terephthalate (PBT). In some examples the cartridge 100 is formed from the same material as forms the housing 10 or a material having similar expansion and contraction rates. The cartridge 100 may be fabricated by injection moulding. The cartridge 100 may be fabricated as a single piece, except for the optional waterproof, breathable membrane 210 and optional metal plate 500. The mounting portion 200, storage portion 300, and any connecting portion 400 may be formed integrally. Examples as shown in the detailed views of FIGs 5A-D, 6, 8,11,14 and 15 comprise no undercuts except for the ventilation passage 202, which can be produced using only a single slider, making fabrication of the cartridge 100 cheap. The optional waterproof, breathable membrane 210 may, in accordance with any of the foregoing examples, be formed from any appropriate material. For example, it may be formed from a polyester non-woven fabric or expanded polytetrafluoroethylene (ePTFE). The optional metal plate 500 may, in accordance with any of the foregoing examples, be formed from any appropriate material. For example, it may be formed from any material suitable for use in, for example, a heat sink. Examples include aluminium, steel, copper, and brass. In accordance with any of the foregoing examples, the metal plate 500 may be replaced with a non-metal plate having suitable thermal conductivity. In some examples, the cartridge 100 may be a thermally conductive, injection-mouldable plastic, such as may, for example, be formed from blending graphite with a polymer. In such examples the cartridge 100 as a whole can act as a heat sink for the vehicle lamp assembly 10, transferring of heat, which is generated within the vehicle lamp assembly 10, to the desiccant 50 within the storage space 302, leading to drying (and thus regenerating) of the desiccant 50. In such examples, a further metal plate 500 may be unnecessary. It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application. In the foregoing examples, the storage portion 300 has been shown to be substantially cylindrical or semi cylindrical, but it will be appreciated that the storage portion 300 could be take the shape of any prism or frustrum or the like. In the foregoing examples, the storage portion 300 has been shown to be elongate, having a length extending from away from the mounting portion 200 which is greater than its diameter. The purpose of this is to locate the desiccant 50 within as much of the airflow within the vehicle lamp assembly 10 as possible. However, it will be appreciated that the relative dimensions of the storage portion 300 will be informed by the available space within the vehicle lamp assembly 10 and thus the storage portion 300 may not be elongate. By means of example only, the diameter may be between 10 and 38 mm and the length may be between 20 and 70 mm. At such dimensions, the storage portion 300 may be capable of storing between 5 and 30 g of desiccant in the form of silica gel, though other forms of desiccant may also be used. It will be appreciated that though examples have been provided which use a hinge 310 as the means for opening the storage portion 300, those features which are not inextricably linked to the use of the hinge 310 may all be implemented in a storage portion 300 which uses another means of opening. Whether the storage portion 300 is openable by means of a hinge 310 or else by other suitable means is optional. Whether the first shell 314 is solid or vented is optional. Whether the ventilation passage 202 is branched or not is optional. Whetherthe connecting portion 400 comprises a short beam portion, as described 5 in relation to FIG 6, or not is optional. Whether a metal plate 500 is provided within the storage area 302 or not is optional. Whetherthe vehicle lamp wiring harness 600 is routed through the mounting portion 200 or not is optional. Features described in the preceding description may be used in combinations other than the combinations 10 explicitly described. Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not. Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not. 15
Claims
1. A cartridge for locating a desiccant within a vehicle lamp assembly, the cartridge comprising:a mounting portion configured for mounting and dismounting the cartridge to a housing of the vehicle lamp assembly within an aperture in the housing and comprising a ventilation passage configured to enable gaseous exchange between an interior and an exterior of the vehicle lamp assembly; anda storage portion extending from the mounting portion and providing a storage space for a desiccant in fluidic communication with the ventilation passage and comprising one or more ventilation openings configured to enable gaseous exchange between the interior of the vehicle lamp assembly and the storage space,wherein the storage portion is openable to enable replacement of a desiccant within the storage space.
2. The cartridge of claim 1 wherein the mounting portion comprises a waterproof, breathable membrane configured to prevent liquid ingress into the interior of the vehicle lamp assembly via the ventilation passage.
3. The cartridge of claim 1 or claim 2 wherein the storage portion is configured to open and close via a hinge and one or more releasable fasteners.
4. The cartridge of claim 3 wherein the storage portion comprises two shells, a first which is directly connected to and extends from the mounting portion, and a second which is pivotable with respect to the first via the hinge.
5. The cartridge of claim 4 wherein the first shell is a solid shell and the second shell is a vented shell comprising the one or more ventilation openings.
6. The cartridge of claim 4 or 5 wherein one of the first and second shells comprises, at an end distal from the mounting portion, a cantilever snap-fit fastener and the other of the first and second shells comprises, at an end distal from the mounting portion, a corresponding mating component, and the two ends, when fastened, form a closed end to the storage portion.
7. The cartridge of any preceding claim wherein the mounting portion comprises mating components configured to mate with corresponding mating components in the aperture in the housing of the vehicle lamp assembly to mount the cartridge in a specific, preset orientation with respect to the housing.
8. The cartridge of claim 7 wherein the mating components of the mounting portion are configured to connect and disconnect with the corresponding mating components in the aperture in the housing via rotation and the mounting portion comprises a grippable head for enabling rotation of the cartridge with respect to the aperture in the housing.
9. The cartridge of any preceding claim wherein the ventilation passage has two branches, one connecting to the storage space and one bypassing the storage space and configured to enable gaseous exchange directly between an interior and an exterior of the vehicle lamp assembly.
10. The cartridge of claim 9 wherein an inlet for the branch bypassing the storage space is located in a connecting portion of the cartridge between the mounting portion and the storage portion, and the branch bypassing the storage portion extends perpendicularly to the branch connecting to the storage space and a common portion of the ventilation passage.
11. A vehicle lamp assembly comprising:a lamp unit, comprising one or more light sources;a housing defining a cavity configured to receive at least the lamp unit and providing mounting points to which the lamp unit is mounted;a lens closing the cavity defined by the housing; andthe cartridge for locating a desiccant within the vehicle lamp assembly, as claimed in any preceding claim,wherein the cartridge is mounted in an aperture in the housing and extends into a portion of the cavity defined by the housing which is unoccupied by the lamp unit.
12. The vehicle lamp assembly of claim 11 wherein the housing defines a cavity having a portion which, when the vehicle lamp assembly is in situ on a vehicle, is above the lamp unit and the aperture in which the cartridge is mounted opens into this portion.
13. The vehicle lamp assembly of claim 11 wherein the one or more light sources comprise at least one light emitting diode.
14. The vehicle lamp assembly of claim 11 wherein an end of the storage portion distal from the mounting portion is unsupported within the vehicle lamp assembly, or wherein the cartridge bridges the cavity between the housing and the lens and an end of the storage portion distal from the mounting portion engages a socket on the inner side of the lens.
15. A vehicle comprising one or more of the vehicle lamp assembly of any of claims 11 to 14.s
Citation Information
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