LKQ CORPORATION EX. 1020
`LKQ CORPORATION v. CLEARLAMP, LLC
`Trial IPR2013-00020
`
`001
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`US. Patent
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`Mar. 20, 2012
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`Sheet 1 of 8
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`US 8,136,971 B2
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`Mar. 20, 2012
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`Sheet 3 of8
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`Mar. 20, 2012
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`US. Patent
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`Mar. 20, 2012
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`Sheet 7 of 8
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`US 8,136,971 BZ
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`1
`VEHICULAR LIGHT ASSEMBLY AND
`ASSOCIATED METHOD FOR REPAIRING
`THE SAME
`
`CROSS RI'iI-"IERIZNCES '10 R12] .A'I‘l-Elj)
`
`APPI..ICATI()N(S)
`
`This application claims the benefit of US. Provisional
`Application Ser. No. 601859.573. filed Nov. 16. 2006. entitled
`“VEHICULAR LIGHT ASSEMBLY AND ASSOCIATED
`METHOD FOR REPAIRING THE SAME" and US. Provi-
`
`sional Application Ser. No. 60878.480 filed Jan. 3. 2007.
`entitled “VEHICULAR LIGHT ASSEMBLY AND ASSO—
`(TlA‘l‘lEl) Milli IUD l-‘OR REPAIRING ’I‘I Ill SAME.“ which
`are hereby incorporated herein by reference in their entirety.
`including all references cited therein.
`
`BACKGROUND OF "fl-IE INVENTION
`
`] . Field of the Invention
`
`The present invention relates in getteral to a vehicular light
`assembly. and more particularly. to a vehicular light assem-
`bly. suclt as a headlight auditor taillight assembly. which
`includes at least one previously damaged sub-component
`which has been repaired utilizing a mold from a vehicular
`ligltt assembly void of damage relative to the repaired sub-
`component.
`2. Background Art
`Vehicular light assemblies have been known in the art for
`several years. In particular. headlight andi’or taillight assem-
`blies have been utilized on automobiles auditor trucks for well
`
`over a century. While vehicular light assemblies have been
`known in the art. issues associated with longevity remain
`largely problematic. For example. securcmentlalignment
`sub—components (e.g. tabs. slots. etcetera) frequently become
`damaged alter exposure to extreme climate variations andfor
`minor collisions. I-leretofore. once a vehicular light assembly
`was damaged. the only known option. to the best ol'Appli-
`cant’s knowledge. was to replace tlte same with a new vehicu-
`lar light assembly. which can be extremely expensive—espe-
`cially considering the fragile nature of the same.
`It
`is
`therefore. an object of the present invention. to provide a
`vehicle owner at least one option (Le. repair) other than pur-
`chasing a completely new light assembly should the same
`become damaged.
`
`SUMMARY OF THE INVENTION
`
`The present invention is directed to one or more vehicular
`light assemblies as provided herein having at least one ofthe
`disclosed structural. functional. andr‘or ornamental character-
`isttcs.
`
`The present invention is also directed to a vehicular light
`assembly. comprising: (a) a housing; and (b) a lens cover.
`wherein the housing andfor lens cover includes one or more
`previously damaged sttb—component(s) which have been
`repaired utilizing a mold from a vehicular light assembly
`andfor assembly sub-component void of damage relative to
`the repaired snb-componentts}.
`In a preferred embodiment of tlte present invention. the
`vehicular light assembly includes a reflector auditor a bulb.
`In another preferred embodiment of the present invention.
`the repaired sttb—component includes a secttrement member.
`and;tor an alignment member. In this embodiment the member
`may include. for example. a tab. a slot. a prong. a detent.
`andlor combinations thereof.
`
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`Preferably the lens cover is at least partially coated with a
`protectant. such as cured UVl-lC-SDOD.
`In another aspect of the invention. the lens cover is at least
`partially coated with a [JV-cured protectant having been ther-
`mally flashed between approximately 150 and approximately
`175 degrees Fahrenheit prior to exposure to a [JV-curing
`source.
`
`The present invention is also directed to a method for
`repairing a vehicular ligltt assembly. comprising the steps of:
`(a) providing a vehicular ligltt assembly having at least one
`damaged sub-component: (b) providing a mold from at least
`one ol‘a vehicular light assembly and vehicular light assent-
`bly sub-component void ofdamage relative to the at least one
`damaged sub-component; and (c) generating a new sub-com-
`ponent frotn the mold to.
`in turn. repair the at
`least one
`damaged sub-component.
`In a preferred embodiment of the present invention. the
`method includes one or more of the following steps: (a) the
`step of cleaning the vehicular light assembly; (b) the step of
`sanding a lens cover of the vehicular light assembly; (c) the
`step of balling a lens cover of the vehicular light assembly:
`auditor (d) the step ofannealing the vehicular light assembly.
`In yet another aspect of the present invention a step of
`curing the lens cover of the vehicular light assembly is pro-
`vided which may include the step ofcuring the cover ol'a fully
`fabricated vehicular light assembly having a housing. a
`reflector, a bulb. author a lens cover.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`The invention will now be described with reference to the
`
`drawings wherein:
`FIG. 1 is a perspective representation ofa damaged vehicu-
`lar light assembly iii accordance with the present invention;
`FIG. 2 is a perspective representation ofa damaged vehicu-
`lar light assembly in accordance with the present invention;
`FIG. 3 is a perspective representation ofa damaged vehicu-
`lar light assembly in accordance with the present invention:
`FIG. 4 is a perspective representation of a two piece mold
`in accordance with the present invention;
`FIG. 5 is a perspective representation ofa two piece mold
`in accordance with the present invention;
`FIG. 6 is a perspective representation of a portion of a two
`piece mold in accordance with the present invention:
`FIG. 7 is a perspective representation ofnew component of
`a vehicular light assembly in accordance with the present
`invention: and
`
`FIG. 8 is a comparative perspective representation of
`undamaged and damaged vehicular light assemblies in accor-
`dance with the present invention.
`
`DESCRIPTION OF THE DRAWINGS
`
`While this invention is susceptible of embodiment itt litany
`different to nits. tltere is shown iii the drawings and will herein
`be described in detail several specific embodiments with the
`understanding that the present disclosure is to be considered
`as an exemplification of the principles ofthe invention and is
`not intended to limit the invention to the embodiments illus-
`trated.
`
`In accordance with the present invention a vehicular light
`assembly is provided which comprises a housing. a lens cover
`and optionally a reflector andl'or bulb. wherein at least one of
`the housing and lens cover includes at least one previously
`damaged sub-component which has been repaired utilizing a
`mold from a vehicular light assembly andi’or assembly sub-
`componcnt void of damage relative to the repaired sub-cont-
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`US 8,136,971 B2
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`ponent. Such a sub-component may include, for example, a
`securement member. an alignment member. andi'or combina-
`tions thereof—including. but not limited to. a tab. a slot. a
`prong, a detent. andi’or combinations thereof.
`It will be further understood that the lens cover may be at
`least partially coated with a protectant. such as, for example.
`UVI'lC-SOOU. which is conn‘nercially available from Gl'i Sili-
`cones. Preferably, the lens cover is at least partially coated
`with a UV-cured protectant having been thermally flashed
`between approximately 150 and 175 degrees Fahrenheit prior
`to exposure to a UV—curing source.
`A method for repairing a vehicular light assembly is also
`disclosed which comprises the following steps: (a) providing
`a vehicular light assembly having at least one damaged sub-
`component. such as a tab. slot. etcetera (F1G3. 1-3); (h) pro-
`viding a mold from at least one of a vehicular light assembly
`and vehicular light assembly sub-component void oi‘damage
`relative to the at least one damaged sub-coniponent—prefer-
`ably the mold is a silicone mold (FIGS. 4-6); and (c) gener-
`ating a new sub—component from the mold to. in turn. repair
`the at least-one damaged sub—component (FIG. 7). A new
`sub-component may be generated with or without preparing
`the area of the damaged sub-component. such as grinding
`down the damaged sub-component andr‘or applying an adhe-
`sion promoter to the same. Typically the mold is filled with.
`for example. a liquid urelllane based resin which cures within
`approximately less than 24 hours.
`It will be understood that additional steps may include: (a)
`cleaning the vehicular light assembly. such as by conven-
`tional wet andi’or dry cleaning methods: (b) sanding a lens
`cover of the vehicular light assembly. which may include dry
`sanding {80-1000 gritfniesli paper) as well as wet sanding
`[1000-4000 micro-mesh paper): (c) buffing a lens coverol‘the
`vehicular light assembly using conventional buffing com~
`pounds: (d) annealing the vehicular light assembly with. for
`example. an IR light source andi’or other heat source: and (e)
`curing a lens cover ol'the vehicular light assembly, optionally
`wherein the vehicular light assembly is hilly fabricated and
`includes.
`for example, a housing (fabricated from.
`for
`example. ABS. ABS-PC blend). a reflector. a bulb. andfor a
`lens cover (fabricated from, for example. PC). It will be
`understood that curing the lens cover may include flashing the
`entire vehicular light assembly at a temperature of between
`approximately [20 and approximately 250 degrees l-Tahren-
`heit (more preferably approximately 1 60 degrees Fahrenheit]
`prior to. or concurrent with exposure to a UV- light source.
`
`The following patentsfpublications are hereby incorpo~
`rated herein by reference in their entirety. including the ref-
`erences cited therein, namely: US. Pat. Nos. D520.157:
`4.325.105: 4.924.359: 4.922.388: 7.052.165: 4.967.319:
`4.967.318: and [1.5. Pal. Pub. No. 200710141242 A1.
`The foregoing description merely explains and illustrates
`the invention and the invention is not limited thereto except
`insofar as the appended claims are so limited. as these skilled
`in the art who have the disclosure before them will be able to
`
`ll]
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`make modifications without departing the scope ol'the inven-
`tion.
`What is claimed is:
`
`l. A method for repairing a vehicular light assembly. com—
`prising the steps of:
`providing a Vehicular light assembly having at least one
`damaged sub-component:
`providing a mold from at least one of a vehicular light
`assembly and vehicular light assembly sub-component
`void of damage relative to the at least one damaged
`sub-component; and
`generating a new sub—component from the mold to. in turn.
`repair the at least-one damaged sub-component.
`2. The method according to claim 1. further comprising the
`step ofcleaning the vehicular light assembly.
`3. The method according to claim 1. further comprising the
`step of sanding a lens cover of the vehicular light assembly.
`4. The method according to claim 1. further comprising the
`step of buffing a lens cover of the vehicular light assembly.
`5.'f11e111etliod according to claim 1. further comprising the
`step of annealing the vehicular light assembly.
`6. The method according to claim 1 . further comprising the
`step of curing a lens cover of the vehicular light assembly.
`wherein the vehicular light assembly is fully fabricated.
`7. The method according to claim 6. wherein the fully
`fabricated vehicular light assembly comprises a housing. a
`reflector. a bulb. and a lens cover.
`8. A method for repairing a vehicular light assembly. con-
`sisting of the steps of:
`providing a vehicular light assembly having at least one
`damaged sub-component:
`providing a mold from at least one of a vehicular light
`assembly and vehicular light assembly subvcomponent
`void of damage relative to the at least one damaged
`sub-component; and
`generating a new sub-component from the mold to, in turn.
`repair the at least one damaged sub-component.
`*$***
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