Headlamp adjustor and method

Details Headlamp adjustor and method Headlamp adjustor and method

2000-05-18

2001-11-13

Cariaso, Alan (Department: 2875)

Illumination

Supported by vehicle structure

Adjustable lamp or lamp support

C362S514000, C362S289000, C362S428000, C362S463000, C074S089140

Reexamination Certificate

active

06315439

ABSTRACT:

BACKGROUND
The present invention relates generally to headlamp adjustors which are used to adjust the position of a reflector of a headlamp assembly, and relates more specifically to a headlamp adjustor which includes a selftapping drive screw.
The present invention also relates generally to methods for adjusting the position of a reflector of a headlamp assembly, and relates more specifically to a method for adjusting the position of a reflector of a headlamp assembly where the method includes a step of rotating a drive screw to form a thread or worm gear and effect rotation of said worm gear to attain a change in the position of the reflector.
The present invention also relates generally to methods for making headlamp adjustors, and relates more specifically to a method for making a headlamp adjustor where the method includes a step of threading a worm gear using the initial engagement of the drive screw to form a mating thread on the worm gear that allows for operation thereof, and thereafter applying a retaining member to the drive screw.
Modern day headlamps for vehicles are engineered and designed to be aerodynamically efficient. In this regard, the headlamps are designed as sealed assemblies wherein the portion of the headlamp approximate the outer surface of the automobile is relatively stationary, and is aerodynamic.
A typical modern day headlamp assembly
12
is illustrated in a plan view seen as
FIG. 1
, and normally includes: a fixed housing
20
, to which an outer headlamp lens
22
is affixed; a movable reflector
24
, which is mounted within the fixed housing
20
; and a stationary headlamp bulb (not shown), which is positioned within the movable reflector
24
. Typically, the movable reflector
24
is mounted to the housing
20
by a universal or ball-type pivot
26
which is stationary, or fixed, on the housing
20
.
A first pivot point
28
is disposed generally vertical of the fixed pivot
26
, and a second pivot point
30
is disposed generally horizontal of the fixed pivot
26
. As such, the movable reflector
24
may be pivoted about the fixed pivot
26
in the vertical and horizontal planes to aim the headlamp beam. Adjustment mechanisms, or headlamp adjustors,
40
and
42
are typically provided at the first and second pivot points,
28
and
30
, normally termed the vertical pivot and the horizontal pivot, and the headlamp adjustors
40
and
42
can be operated to effect movement of the reflector
24
in the vertical and horizontal planes.
The headlamp adjustors
40
and
42
are typically mounted to the housing
20
of the headlamp assembly
12
and have adjustor output shafts
44
,
46
operatively connected to the movable reflector
24
by ball and socket type pivots, or the like, such that linear movement of the adjustor output shafts
44
,
46
produces pivoting of the movable reflector in the vertical and horizontal planes. Specifically, each headlamp adjustor
40
,
42
typically includes drive structure
48
,
50
for receiving a tool, and typically the drive structure
48
,
50
is precision geared to the adjustor output shaft
44
,
46
. The gearing provides that using the tool to rotate the drive structure
48
,
50
causes linear translation of the adjustor output shaft
44
,
46
and therefore adjustment of the position of the headlamp reflector
24
.
Before an automobile is released to the consumer, the movable reflectors of the headlamp assemblies are adjusted to a desired position so that the headlamp beams are properly aimed in both the vertical and horizontal directions. To this end, headlamp adjustors are normally operated at the automobile assembly plant. Once proper vertical and horizontal aiming of the headlamps are attained and before the automobile is released to the consumer, vertical and horizontal indicators on each headlamp adjustor are manipulated to provide a visual indication that each movable reflector is in the desired, or “zero”, position. The indicators either naturally transmit, or are adjusted in some manner in order to transmit, a visual indication of the zero position. Thereafter, if a movable reflector moves from its desired position, due, for example, to vibration, jarring, or the vehicle being in an accident, a mechanic can use the visual indication to determine that the movable reflector is no longer in its desired position. Then, the mechanic can operate the headlamp adjustors in order to return the horizontal and vertical indicators to the zero positions, which should properly re-align the reflector.
The Department of Transportation of the United States Government has set forth specific guidelines dealing with vehicle headlamp aiming and indicating mechanisms in both the horizontal and vertical directions. The guidelines set forth the degree of accuracy which is required of horizontal and vertical indicators. It is advantageous to provide a headlamp adjustor which is low cost, easy to use, easy to make, and which meets the government guidelines.
OBJECTS AND SUMMARY
Accordingly, it is an object of an embodiment of the present invention to provide a headlamp adjustor which is relatively low cost.
Another object of an embodiment of the present invention is to provide a headlamp adjustor which is easy to make and easy to use.
Still another object of an embodiment of the present invention is to provide a method for adjusting the position of a reflector of a headlamp assembly, where the method is relatively easy to perform.
Still yet another object of an embodiment of the present invention is to provide a method for making a headlamp adjustor, where the method is relatively easy to perform.
Briefly, and in accordance with one or more of the foregoing objects, an embodiment of the present invention provides a headlamp adjustor which includes an adjustor output shaft which is engageable with a reflector of a headlamp assembly. The adjustor output shaft extends from a housing, and a tandem spur gear/worm gear is engaged with a gear rack portion of the adjustor output shaft. Drive structure is engaged with the worm gear such that actuation of the drive structure causes at least a portion of the drive structure to thread into at least a portion of the worm gear, thereby causing the adjustor output shaft to translate relative to the housing and adjust the position of the headlamp reflector.


REFERENCES:
patent: 4544313 (1985-10-01), Grossberndt
patent: 5285360 (1994-02-01), Kanner
patent: 5309780 (1994-05-01), Schmitt
patent: 5508896 (1996-04-01), Suehiro et al.
patent: 5613754 (1997-03-01), Dobler et al.
patent: 5707133 (1998-01-01), Burton
patent: 5758943 (1998-06-01), Shirai et al.
patent: 5775794 (1998-07-01), Schmitt
patent: WO9906719 (1999-11-01), None
patent: WO9906715 (1999-11-01), None

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