LKQ CORPORATION EX. 1028
`LKQ CORPORATION v. CLEARLAMP, LLC
`Trial IPR2013-00020
`
`001
`
`

`

`US. Patent
`
`Sep. 24, 2002
`
`Sheet 1 0f 8
`
`US 6,454,449 32
`
`
`
`002
`002
`
`

`

`US. Patent
`
`Sep. 24, 2002
`
`Sheet 2 0f 8
`
`US 6,454,449 32
`
`
`
`003
`003
`
`

`

`US. Patent
`
`Sep. 24, 2002
`
`Sheet 3 0f 8
`
`US 6,454,449 32
`
`
`
`004
`004
`
`

`

`US. Patent
`
`Sep. 24, 2002
`
`Sheet 4 0f 8
`
`US 6,454,449 B2
`
`
`
`005
`005
`
`

`

`US. Patent
`
`Sep. 24,2002
`
`Sheet 5 0f 8
`
`US 6,454,449 B2
`
`
`
`
`006
`006
`
`

`

`US. Patent
`
`Sep. 24, 2002
`
`Sheet 6 of 8
`
`US 6,454,449 B2
`
`
`
`007
`007
`
`

`

`US. Patent
`
`Sep. 24, 2002
`
`Sheet 7 of 8
`
`US 6,454,449 32
`
`{I
`
`,III.MMaaaM
`
`/
`
`E3‘.
`
`Ma.
`””241.
`
`008
`008
`
`

`

`US. Patent
`
`Sep. 24, 2002
`
`Sheet 8 0f 8
`
`US 6,454,449 32
`
`
`
`
`PRIOR ART
`
` FIG. 14A
`
`110
`
`009
`009
`
`

`

`US 6,454,449 B2
`
`1
`VEHICULAR COMPONENT ASSEMBLY
`WITH HARD COATEl) ELEMENT
`
`This is a continuation application of application Ser. No.
`09f332,632, filed Jun. 14, 1999, by David E. Nestell and
`James ’I'. Ainsworth, entitled VEHICULAR COMPONENT
`ASSEMBLY WITH HARD COATED ELEMENT, which is
`a continuation application of application Ser. No. 08895,
`955, filed on Jul. 17, 1997, now us. Pat. No. 6,000,814,
`which are incorporated by reference herein in their entire-
`ties.
`
`TECHNICAL FIELD AND BACKGROUND OF
`THE INVENTION
`
`This invention relates to vehicle components incorporat-
`ing polymeric elements with members, casings or gaskets
`formed thereon and, more particularly, to vehicle component
`assemblies including vehicle exterior lighting assemblies
`such as a composite headlamp assembly incorporating a
`hard coated polycarbonate lens element bonded to a molded
`polymeric gasket.
`In recent years, vehicle headlamp assembly designs have
`been driven by body styling demands. The lenses of the
`newer headlamp assemblies are more contoured so that they
`follow the contours of the vehicle body. Traditiona] head-
`lamp assemblies typically included a stainless steel beret
`which permitted the lens to be mounted in an opening in the
`vehicle body. More recently, headlamp assemblies include a
`preformed gasket which is subsequently attached.
`for
`example by an adhesive to the peripheral portion of the lens,
`which permits the lens to be fitted more closely with the
`body of the vehicle. Such preformed gaskets are, however,
`diflicult
`to tool and,
`in some cases,
`their installation is
`diliicult and labor intensive. Moreover, conventional lenses
`are now typically molded from a polycarbonate resin. Since
`polycarbonate lenses are vulnerable to abrasion from road
`debris and the elements and to discoloration from ultraviolet
`radiation. the lenses are coated with a hard coat to provide
`a durable outer surface which is resistant to scratching and
`which protects the polycarbonate lens from ultraviolet radia-
`tion. Herctofore, these hard matings have inhibited adequate
`adhesion between the preformed gasket material and the
`lens. Consequently, in order to improve the adhesion of the
`gasket
`to the lens, some conventional gaskets and lenses
`include structures to provide mechanical interlocking of the
`gasket to the lens to supplement the bond provided by the
`adhesive.
`
`Referring to FIGS. 14A and 1413, one conventional, prior
`known polycarbonate lens (100)
`includes a first slotted
`groove (102} along its peripheral edge (104) to provide an
`anchorage for a conventional preformed gasket (106}, as will
`be more fully described below, a second slotted groove (108)
`along its peripheral edge for aligning and holding the gasket
`while it is installed on the lens, and a projecting flange (110).
`which also assists in the alignment and retention of the
`gasket (106) on the lens during the installation process. As
`a result, the molding apparatus for the lens requires com-
`plicated tooling, and the lenses are subject
`to tight toler-
`{ll—ICES.
`
`The preformed gasket (106} includes corresponding struc-
`tures that interlock with the lens grooves and flange. To
`install the gasket, an adhesive is applied to the gasket or lens
`perimeter, and a first end (112) ol‘ the gasket is seated in the
`first slotted groove (102) to anchor one end of the gasket
`(106) while the gasket is stretched around the perimeter of
`the lens. As the gasket is stretched around the perimeter, an
`
`ll]
`
`15
`
`3O
`
`35
`
`4U
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`intermediate portion of the gasket is then seated in the
`second slotted groove (108) to align the gasket and provide
`further mechanical
`interlocking of the gasket
`to the lens.
`Then the second of end (114) of the gasket is wrapped
`around the perimeter of the lens and seated in the first slotted
`groove (102) adjacent the first end otthe gasket such that the
`gasket ends define a break or space 115 (FlG. 14A). In this
`manner,
`these gooves and flange of the lens and corre-
`sponding stmctures on the gasket cooperate to align the
`gasket and to mechanically retain the gasket on the lens
`while the adhesive cures and provide mechanical interlock-
`ing of the gasket to the lens. Such process is often difficult
`and time consuming. Also, the retention of the gasket on the
`lens is sometimes less than adequate, as is the adhesion
`between the gasket and lens, While these gaskets have
`improved the lit—up of the headlamp assembly with the
`contoured vehicle body, the apparatus used to form these
`gaskets is also difficult and expensive to too].
`Further, gaskets (106) may be formed with retainers or
`tabs (116). The retainers (116) project from the gasket and
`secure to a housing by fasteners to provide a means for
`temporarily securing the lens and the gasket to the housing
`during installation. These retainers further complicate the
`molding process of the gasket.
`In some applications,
`the
`gasket
`is molded from two materials, with the second
`material forming the retainers having a greater duromcter
`hardness to increase the stiffness of the gasket where the
`retainers project
`from the gasket. Again,
`this process
`increases the cost of the gasket and is also difficult to tool.
`Despite the improved fit up, these preformed gaskets may
`not provide the desired life expectancy and may require
`rcinstallation or replacement. Furthermore, because of the
`geometry of the gasket, there may also be a gap between the
`first and second ends of the gasket such as that shown at 115
`in FIG. 14A. This gap may affect the aerodynamics of the
`vehicle body or the wind noise of the assembly. Moreover.
`installation of these preformed gaskets is labor intensive.
`requiring manual manipulation of the gasket around the lens.
`This manual manipulation may lead to worker fatigue and,
`ultimately, may increase the number of defective installa-
`tions and the cost of the vehicle.
`
`there is a need for vehicle component
`Consequently,
`assemblies which incorporate resinous elements, especially
`hard coated polycarbonate lenses of vehicle headlamp
`assemblies, and cooperating gaskets or molded members
`which will exhibit improved adhesion between the gasket or
`molded member and the resinous element. Moreover, there
`is a need for such assemblies which can be manufactured
`and installed with significantly reduced labor,
`time, and
`costs.
`
`SUMMARY OF THE INVENTION
`
`invention provides a vehicle
`the present
`Accordingly,
`component assembly such as a modular headlamp assembly
`which is ready for installation virtually entirely from the
`exterior of a vehicle or other supporting body in a manner
`which is heretofore been unknown. The headlamp assembly
`combines an optical element, typically formed of a poly-
`meric material, such as a polycarbonate material, which has
`been shaped and coated with a protective coating to be ready
`for application in a headlamp assembly of a vehicle, and a
`flexible, resilient gasket which is integrally molded onto the
`perimeter of the optical element to provide a cover for the
`gap between the optical element and the opening of the
`vehicle body. The invention therefore eliminates the need for
`piecemeal assembly of the optical element and gasket of the
`
`010
`010
`
`

`

`it]
`
`15
`
`According to one aspect of the invention, an optical
`component of a vehicle comprises an optical element having
`a peripheral portion and a gasket. The peripheral portion
`includes inner and outer peripheral side surfaces and a
`peripheral edge surface. The optical element
`includes a
`protective coating on at least one of the inner peripheral side
`surface, the outer peripheral side surface, and the peripheral
`edge surface. and a primer coating over at least a portion of
`the protective coating. The gasket is integrally molded on at
`least a portion of the primed portion on at least one of the
`inner peripheral side surface,
`the outer peripheral side
`surface, and the peripheral edge surface of the optical
`element. The gasket is thus bonded to at least a portion of the
`primed area of the optical element and includes extending
`portions at positions spaced from the optical element
`adapted to cover a gap between the optical element and the
`vehicle body.
`In one form, the optical element comprises a polymeric
`optical element, such as a polycarbonate optical element.
`[in rthermore, the optical element may comprise a lens, such
`as a headlamp lens. Preferably,
`the headlamp lens has a *
`contoured surface wherein the contoured surface follows the
`contour of the body of the vehicle. The peripheral portion of
`the lens may include at least one cooperating structure, for
`example a groove which extends around at least a portion of
`the lens, a through-hole, or a lip, which provides mechanical
`interlocking of the gasket and the lens. to other aspects, a
`conventional
`lens element may be used, which typically
`includes one or more grooves extending into the peripheral
`edge surface of the lens.
`In another form.
`the gasket material may comprise a
`melt-processible gasket material or a non melt-processible
`gasket material. For example, as suitable melt~processible
`material
`includes polyvinyl chloride, styrenct’butadienet‘
`styrene (SBS) elastomers, styreneiethylenefbutadienei
`styrene {SE-BS) elastomers, copolyester elastomers, poly-
`ether blockamides. and thermoplastic urethane. Other
`suitable melt-processible gasket materials include cross-
`linked materials,
`for example styrene butadienc rubber
`(SBR) elastomer, ethylene propylene diene terpolyrner
`(EPDM) elastomer, and ethylene propylene copolymer
`(EPM) elastomer. Suitable non melt-processible gasket
`materials include thermosetting reaction injection molded
`urethanes. Preferably, the gasket material has a hardness in
`a range of about 40 to 100 Shore A durometer. More
`preferably, the gasket material has a hardness in a range of
`about 55 to 100 Shore A durorneter. Most preferably, the
`gasket material has a hardness in a range of about 65 to 85
`Shore A durorneter.
`
`3o
`
`35
`
`40
`
`45
`
`50
`
`4
`porated into the optical element andt‘or the protective coat-
`ing. The ultraviolet radiation absorbers may be incorporated
`into an intermediate primer coating, which is applied to the
`optical element to improve the adhesion between the hard
`coating and the optical element.
`According to another aspect of the invention, a vehicle
`lighting assembly includes a housing adapted for mounting
`in the body of a vehicle and a lens module mounted to the
`housing. The lens module includes a lens and a protective
`coating on at least an exterior surface of said lens, and a
`primer coating over at least a portion the protective coating.
`The lens module further includes a gasket integrally molded
`on at least a portion of the primed area and is adapted to
`cover a gap betwaen the lens and the body of the vehicle.
`The gasket material preferably comprises either a melt—
`processible gasket material or a non melt-processible gasket
`material.
`
`In one form, the lens module is secured to the housing, for
`example by ultrasonic welding or mechanical attachment, to
`provide a water tight seal between the lens module and the
`housing, which eliminates the need for forming or providing
`retainers on the gasket.
`According to a
`further aspect, a vehicle component
`assembly includes a polymeric body having a protective
`coating thereon and at least one primer coating overlaying at
`least a portion of the protective coating. A member is
`integrally molded onto at
`least a portion of the primer
`coating, with the molded member extending away from the
`polymeric body adapted to extend between the body and the
`vehicle.
`
`According to yet another aspect, a method of attaching a
`molded member to a polymeric vehicle element
`includes
`providing a polymeric vehicle element, applying a primer to
`a predetermined area of the element, and forming an inte—
`grally molded member on at least a portion of the predeter»
`mined area from a polymeric material. The vehicle element
`includes a protective coating to protect the vehicle element
`from abrasion and, preferably, ultraviolet absorbers to pro-
`tect the vehicle element from ultraviolet radiation degrada-
`tion.
`
`In one aspect, the molded member is formed by injection
`molding a gasket material onto the vehicle element. Injec—
`tion molding may include reaction injection molding the
`member onto the vehicle element. Preferably, the primer is
`applied to a peripheral portion of the vehicle element
`to
`improve the adhesion between the molded member and the
`vehicle element. More preferably,
`the vehicle element is
`primed with a first primer and then the first primer is primed
`with a second primer. The first primer is provided to increase
`the adhesion between the protective coated vehicle element
`and the second primer which,
`in turn,
`is adhered to the
`molded member.
`
`in other aspects, the method further includes preheating
`the vehicle element, for example by applying warm air to the
`vehicle element. By preheating the vehicle element, the time
`for the primer or primers to flash is reduced, and the
`moldability of the part is improved.
`The vehicle components andior lighting assemblies of the
`present invention overcome the difl'erences of curvature and
`dimensions between the vehicle element and the body panels
`of a vehicle by providing a resilient gasket or member
`formed on the element preferably by molding. The vehicle
`is preferably a polycarbonate element with a protective
`coating and protect
`the element
`from abrasion and,
`preferably, includes ultraviolet radiation absorbers to protect
`the element from ultraviolet radiation damage. The primer
`
`US 6,454,449 B2
`
`3
`headlamp assembly, while also providing a secure bond of
`the gasket material to the hard coated polycarbonate optical
`element to form a lens module, all in a molding process in
`a manner heretofore unknown.
`
`In yet further aspects, the protective coating comprises an
`organic hard coat, such as silicone, an inorganic hard coat,
`such as transition metal compounds, or an organic,l inorganic
`hybrid hard coat, such as organic modified inorganics, for
`example a silicone modified silicon dioxide, which is
`applied to at least the outer, exposed surface of the optical
`element and protects the optical element
`from abrasion.
`Suitable inorganic hard coats include, for example, metal
`oxides, and metal nitrides. For example, metal oxides, such
`as silicon dioxide, may be used.
`In another form,
`the optical component preferably
`includes ultraviolet radiation absorbers to protect the poly-
`carbonate material from radiation damage, which are incor-
`
`55
`
`60
`
`65
`
`011
`Oll
`
`

`

`US 6,454,449 B2
`
`5
`coating increases the adhesion between the molded gasket or
`member and the protective coated element in a manner that
`provides superior adhesion characteristics heretofore
`unknown. Moreover, by molding the gasket or member onto
`the vehicle element, the assembly and installation time is
`significantly reduced thereby saving costs.
`These and other object, advantages, purposes and features
`ot‘the invention will become more apparent from the study
`of the foregoing description taken in conjunction with the
`drawings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a perspective view of a first embodiment of the
`present invention comprising a headlamp assembly installed
`in a vehicle;
`FIG. 2 is a front elevational view of the headlamp
`assembly of FIG. 2;
`FIG. 3 is a top plan view of the headlamp assembly;
`FIG. 4 is a rear elevational view of the headlamp lens
`assembly;
`FIG. 5 is a rear elevational view of the protective coated
`polymeric lens of the present invention before formation of
`the molded member thereon;
`FIG. 6 is a perspective view of the headlamp assembly;
`FIG. 7 is a cross-sectional view taken along line VII—VII
`of FIG. 1;
`FIG. 8 is an enlarged cross-sectional view taken along line
`VIII—VIII of FIG. 1;
`FIG. 9 is an enlarged cross-sectional view taken along line
`lX—IX of FIG. FIG. 1;
`FIG. ll] is a cross-sectional view taken along line X—X
`of FIG. 3;
`FIG. 11 is a cross-sectional view taken along line XI—XI
`of FIG. 5;
`FIG. 12 is a cross-sectional view of a second embodiment
`of the present
`invention comprising a decorative panel
`assembly;
`FIG. 13 is a cross-sectional view of a mold assembly used
`in forming the molded member about the periphery of the
`lens ofthe first embodiment headlamp lens assembly of the
`present invention;
`FIG. 14A is a rear elevational view of a conventional prior
`known, headlight lens assembly with a preformed gasket
`manually installed around the lens perimeter; and
`FIG. 14]? is a rear elevational view of a conventional prior
`known, headlight lens with the gasket removed.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Referring now to the drawings in greater detail, FIG. 1
`illustrates one form of a vehicle component assembly incor-
`porating the present invention. One preferred form of this
`invention is a headlamp assembly 10 installed in the body of
`a vehicle 12. The headlamp assembly may include a lens
`module formed from a polymeric lens, for example a poly-
`carbonate lens, which is coated with a transparent protective
`coating such as a silicone or ceramic hard coat but which
`also includes a molded polymeric member, which forms a
`gasket on the peripheral edge of the lens and is bonded
`securely and uniformly thereto in a heretofore unknown
`manner. As will be explained below, the present invention is
`useful
`for forming a wide range of vehicle component
`assemblies, especially where a gasket or other formed mem-
`
`ll]
`
`15
`
`'
`
`3o
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`6
`her must be securely attached to a protective coated poly-
`meric element to form a complete assembly.
`As shown in FIGS. 2—4, headlamp assembly 10 of the
`preferred embodiment has a peripheral outline or configu-
`ration design to match the contour ofthe body ofvehicle 12.
`Headlamp assembly 10 is positioned in a recessed opening
`14 between a fender 16, a bumper cover 18, and a hood 20
`of the vehicle body. Headlamp assembly 10 includes a
`cylindrical housing 22 (FIGS. 6 and 7) and a lens module 23
`formed from a contoured lens 24 which is mounted to a
`forward open end 22;? of cylindrical housing 22 by welds 26
`formed by ultrasonic welding (FIG. 7}, as will be more fully
`described below. Housing 22 is preferably molded from a
`resinous plastic material such as polyvinyl chloride (PVC),
`and is mounted in the vehicle behind bumper cover 18 and
`adjacent fender 16 using conventional clips or projecting
`bosses 25a and fasteners 25b, so that lens 24 is aligned in
`opening 14 and is substantially flush with and follows the
`contour of the body of vehicle 12. The lamp (not shown} of
`the headlamp assembly is housed and supported in cylin-
`drical housing 22 and is electrically coupled to the vehicle
`battery by wiring that is directed into the housing through a
`flexible conduit 25c, such as a rubber hose, that connects to
`a port {not shown) on the housing.
`Lens 24 is a polymeric lens preferably molded from a
`plastic resin, such as polycarbonate. More preferably, lens
`24 comprises a GE LEXANT'“ polycarbonate lens, available
`from General Electric Plastics. To protect
`lens 24 from
`deterioration from the elements, including rain, snow, ice,
`heat, and from abrasion damage from sand, dirt, cleaning
`cloths or devices, and the like,
`lens 24 is coated with a
`protective outer layer 27o (FIG. 9). Layer 270 may comprise
`an organic hard coat, an inorganic hard coat, or an organic;'
`inorganic compound. Examples of organic hard coats
`include a silicone hard coat, such as AS440“) available from
`GE Silicones of Waterford, NY. or
`from Mitsubishi.
`Examples of an inorganic hard coat include transition metal
`compounds, for example a titanium or silicon dioxide.
`To protect lens 24 from UV radiation degradation, lens
`module 23 preferably includes ultraviolet absorbers or sta-
`bilizers. For example, these ultraviolet radiation absorbersor
`stabilizers may be incorporated into an intermediate primer
`coating 270’, which is typically applied to lens 24 by the
`manufacturer to improve the adhesion between the protec-
`tive hard coat 27a and lens 24. Intermediate primer coating
`27d preferably comprises an acrylic based primer with
`optional UV absorbers or stabilizers incorporated therein,
`which reduce the UW light transmission. Alternatively, UV
`absorbers may be incorporated into the protective outer layer
`27a. which may include a monomer composition that
`includes the UW absorbers. In addition or alternatively, lens
`module 23 may include such UW absorbers in the material
`forming lens 24.
`[1 can be appreciated from the foregoing
`that
`lens 24 may be protected from ultraviolet radiation
`damage either by incorporating UW absorbers into the
`material of the lens,
`in intermediate primer coating 27d,
`andi‘or
`in protective hard coating 27a. Such ultraviolet
`stabilizing agents should be substantially transparent in the
`visible regions and function to absorb ultraviolet radiation,
`quench degradation free radical reaction formation, and
`prevent clegrarlative oxidative reactions.
`Although many materials known to absorb ultraviolet
`radiation may be employed herein, preferred ultraviolet
`stabilizing agents include “UINUL” 400[2, 4-dihydroxy-
`benzophenone (manufactured by BASF Corp., Wyandotte,
`Michigan)], “UVINUI.” D 49[2, 2‘-dihydroxy-4,
`4‘-dimethoxybenzophenone {BASF Corp.)], “VINUL” N
`
`012
`012
`
`

`

`US 6,454,449 B2
`
`7
`35[ethyl-2-cyano-3, 3'-diphenylacrylate [BASF Corp.)],
`" UVINUI." N S39[2-ethylhexyl-2-cyano-3,
`3‘-diphenylacrylate (BASF Corp.)], "UINUU‘ M 40[2-
`hydroxy-4-methoxybenzophenone {BASF Corp.)],
`"UVINUJL" M 408[2—hydroxy—4—octoxybenzophcnone
`(BASF Corp.}}, “TlULlN” P [2-
`(2‘hydroxy-5‘-
`methylphenyl)—triazole] (Ciba Geigy Corp.)], “TINUVIN”
`327[2~ (3', 5'-di—t—butyl—2'~hydroxyphenyl) —5-chloro-
`benzotriazole (Ciba Geigy Corp.)], "TlNUVIN" 328[2- (3',
`5'-di-n-pentyl-2’-hydroxyphcnyl)
`-henzotriazole (Ciba
`Geigy Corp.)] and “CYASORB UV" 24 [2, 2‘dihydroxy-4-
`methoxy—benzophenone (manufactured by American
`Cyanamid Co., Wayne, N..l.)], with "UVINUTL" M 40,
`"UVINUL" M 408, “UlNUL” N 35 an: “UVlNUL” N 539
`being the most preferred ultraviolet absorbingfstabilizing
`agents when used in a by-Weight range of about 0.1% to
`about 15%, with about 4% to about 10% being preferred.
`Ultraviolet radiation absorbing monomers may also be
`advantageously employed herein. Preferred among such
`monomers are l, 3-bis-
`(4-bennoyl-3-hydroxyphenoxy)
`-2-propylacrylate,
`2-hydroxy-4-
`acryloxyethoxybenzophenone, 2-hydroxy-4-
`octoxybenzophenone and 4—methacryloxy—2—
`hydroxybenzophenonc, as they perform the dual function of
`acting as a monomer component, or a portion thereof, and as
`an ultraviolet absorbingfslabilizing agent.
`Further, ultraviolet absorbing layers may be coated onto,
`or adhered to, lens 24 to assist in shielding the lens from the
`degradative effect of ultraviolet radiation. Suitable ultravio—
`let absorbing layers include those recited in US. Pat. No.
`5,073,012 entitled “Anti—Scatter, Ultraviolet Protected, Anti~
`Misting ElectroAOptieal Assemblies", filed Mar. 20, 1990, or
`as disclosed in co-pending US. patent application Ser. No.
`08,647,578 filed Oct. 24, 1995, the disclosures of which are
`hereby incorporated by reference herein.
`Examples of such ultraviolet absorbing layers include a
`layer of Dul’ont BE1028D which is a polyvinylbutyralr'
`polyester composite available from E. I. DuPont de Nem-
`ours and Company, Wilmington, Del., and SORBAIJ'I‘ET”
`polymeric UV blockers (available from Monsanto
`Company, St. Louis, Mo.) which comprise a clear thin
`polymer
`film, with UV absorbing chromophores
`incorporated, such as by covalent bonding, in a polymer
`backbone. The SORBALITETM clear
`thin polymer film
`when placed on a surface of the lens to the source of UV
`radiation (such as the sun), efficiently absorbs UV light
`below about 370 nm with minimal effect on the visible
`region. Thickness of the SORBAIITET“ film is desirably in
`the range of about 0.1 microns to 1,000 microns {or thicker);
`preferably less than 100 microns; more preferably less than
`about 25 microns, and most preferably less than about 10
`microns. Also, UV absorbing thin films or additives such as
`cerium oxide, iron oxide, nickel oxide and titanium oxide or
`such oxides with dopants can be used to protect lens 24 from
`UV degradation. Further, as described above, UV absorbing
`chromophores can be incorporated, such as by covalent
`bonding, into intermediate layer 27d, lens 24 or into pro-
`tective coating 27:? to impart enhanced resilience to UV
`radiation. Also, near-infrared radiation absorbing species
`may be incorporated into lens 24, protective coating 27c, or
`intermediate layer 27d.
`As best seen in FIGS. 2—5, lens module 23 includes an
`integrally molded member defining a gasket 28, which
`extends around the perimeter of lens 24 and projects out-
`wardly from a peripheral edge 30 of lens 24 to cover the gap
`between lens 24 and fender 16, bumper cover 18, and hood
`20 of vehicle 12. Notably, lens module 23 may comprise a
`
`ll]
`
`15
`
`so
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`8
`pre-coated, pre-formed lens in which protective coating 27:?
`has been applied using conventional
`techniques by the
`manufacturer. For example, protective coating 27a may be
`applied using in-molding techniques, Chemical vapor depo-
`sition (CVD)
`techniques,
`for example low pressure or
`plasma enhanced CV1) vacuum deposition techniques, such
`as evaporation or sputtering, or film transfer techniques, or
`the like. Alternatively, lens module 23 may comprise a
`pre-l‘ormed, uncoated lens, which optionally is received
`pre-formed and uncoated at the lens module assembly site,
`and which is then subsequently coated at the lens module
`assembly site with protective layer 27:: using any one ofthe
`above mentioned techniques. For example, organic or inor-
`ganic protective coatings may be applied to the unooated
`pre-formed lens using dip coating, spray coating, meniscus
`coating, spin coating, and [low coating. The inorganic pro-
`tective coating may be additionally applied using vacuum
`deposition, evaporation depositing, sputtering depositing, or
`chemical vapor deposition, such as atmospheric or plasma
`assisted chemical vapor deposition,
`ion deposition
`techniques, or pyrolysis. Alternatively, the inorganic protec-
`tive coating may be applied by a film transfer process. The
`protective coating is preferably cured thermally or by radia—
`tion UV energy.
`Moreover, lens module 23 may be formed by a unitary
`molding operation in which lens 24 is molded from resin
`molded material and with the protective coating and any
`intermediate primer coatings being iii-mold applied in the
`same mold, such as by use oftransfer film, in-mold coating,
`a co-injection process, or the like. As these molding methods
`are conventionally known in the molding art, reference is
`made thereto without further description of the processes
`involved. Optionally, the molded member can be co-injected
`in a unitary molding process or may be molded in an
`adjacent operation immediately subsequently following the
`lens molding process. Whether lens 23 comprises a pre-
`formed, prescoated lens, a pre—formed, uncoated lens, or a
`lens formed in a mold with the protective coating or coatings
`and gasket formed in the same mold,
`the final product
`comprises a lens module with an integrally formed molded
`member.
`
`Gasket 28 may engage or flex and resiliently engage any
`one or more of fender 16, bumper cover 18, and hood 20 to
`enhance the aerodynamics of that portion of the vehicle
`body, cg. hood 20 as in FIG. 9. Gasket 28 is preferably a
`melt processible material, such as a thermoplastic resinous
`material, for example polyvinyl chloride (PVC), or a block
`copolymer such as a styrener’butadiener’styrene {835)
`elastomer, a styreneiethyleneibutadiener’styrcne (SEBS)
`elastomer, a copolyester elastomer, a polyether block amide,
`and a
`thermoplastic urethane. Suitable melt-processible
`materials also include physical blends and alloys such as
`polypropylene and EPDM, polyvinylendene chloride and
`ethylene vinyl acetate, thermoplastic olefins and EPDM, and
`PVC and nitrile rubber. Another class of suitable melt-
`processible materials includes multi-phase graft copolymers
`such as methacrylatet'butadieneistyrene (MBS). Also, blends
`of the above polymers among themselves or with another
`polymer can also be a suitable material.
`Some examples of block copolymers are KRAFONT” D
`(which is SBS) and KRATONT” G (which is SEBS), both
`available from Shell Chemical Company,
`'l‘roy, Mich;
`l-lY'l‘REL'l‘M'm (a copolyester clastomer), available from
`DuPont Chemical, Wilmington, Del.; PEBAXT-‘l (a poly-
`ether block amide), available from Elf Atochem North
`America Incorporated, Philadelphia, Pa.; EIASTOIJANM
`(a thermoplastic urethane), available from BASF.
`
`013
`013
`
`

`

`9
`Wyandotte, Mich.; and FELLETI-IANET (a thermoplastic
`urethane), available from Dow Chemical Company,
`Midland, Mich.
`
`US 6,454,449 B2
`
`10
`coating 27:: extends over both the outer surface and the inner
`surface of lens 24. But it should be understood that it may
`be more typical to provide protective coating 27a only on the
`exposed outer surface of lens 24. Furthermore, as described
`previously, lens module 23 may include intermediate primer
`coating 27d applied to lens 24 to promote the adhesion of
`protective coating 27a to lens 24. Outer peripheral side
`surface 31, inner peripheral side surface 32, and peripheral
`edge surface 33 each include a substantially planar or
`smooth molding surface 31a, 32a, and 33a, respectively,
`(FlG. 11) onto which the gasket material forming gasket 28
`is molded, as will be fully described below.
`[1 should be
`understood that
`lens module 24 may be formed using a
`conventional lens element, such as lens 100 shown in HQ.
`14A, may also be molded with gasket 28.
`Furthermore, lens 24 may be formed or provided with one
`or more through-holes or other cooperating structures, for
`example grooves or channels, which are located in the
`region or area to be molded with molded member 28. The
`cooperating structures may be spaced or extend around at
`least a portion of the periphery of lens 24. The gasket
`material forming the molded member llows into these coop-
`erating structures and thereby forms mechanical interlock—
`ing or bonding of gasket 28 to lens 24 to further enhance the
`integral bond between gasket 28 and lens 24. Referring to
`FIGS. 7—11, in the illustrated embodiment, lens 24 includes
`longitudinally extending ridges or grooves formed on inner
`and outer peripheral side surfaces 31 and 32 of portions of
`peripheral edge 30, with molding surfaces 31:? and 32aI
`defined by the bottom wall of the respective grooves. In this
`manner, the grooves form projecting lips 30a over at least a
`portion of peripheral edge 30 to provide mechanical bonding
`or interlocking of gasket 28 to lens 24.
`As best seen in FIGS. 6—10, gasket 28 may be molded
`onto all three surfaces31, 32, and 33 to provide a continuous
`seal and superior adhesion characteristics to the lens 24.
`However,
`it should be understood that gasket 28 may be
`molded on a single surface, for example inner peripheral
`side surface 32. In this manner,
`lens module 23 may be
`positioned flush with the outer surface and contour of the
`vehicle body and appear to be free lloatirtg in the recessed
`opening of the vehicle. Such a flush mounted application is
`particularly suitable for vehicles where the gap or spacing
`between the lens and the body of the vehicle is minimal. It
`should be also be understood that gasket 28 may be injection
`molded onto two sides of the lens 24, for example, the inner
`peripheral side surface and the peripheral edge surface of
`lens 24.
`In such case,
`the headlamp assembly can be
`positioned to achieve a flush mounting of the lens with
`respect to the body of the vehicle.
`Referring to FIGS. 3—6, lens 24 includes an outer convex
`surface 34 and an inner concave surface 36. Outer concave
`surface 34 includes a transparent, light transmitting region
`38 which is bounded on one side by a crescent shaped,
`non—transparent region 40. The inner surface of light trans—
`mitting region 38 includes a projecting flange 42 which
`extends around the