Joints and connections – Including frangible component
Reexamination Certificate
2002-04-02
2004-02-17
Cottingham, John R. (Department: 3679)
Joints and connections
Including frangible component
C403S122000, C403S135000, C411S040000
Reexamination Certificate
active
06692176
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates generally to pivot joints, and in particular to a pivot joint useful for connecting a headlamp adjuster to a reflector inside a headlamp assembly.
Pivotable spherical joints, commonly referred to as ball joints, include a ball stud engaged in a socket. Such joints have a wide variety of applications where a pivotable connection between two parts is desirable. For example, they may be used in many types of linear actuators and have been found to be particularly useful in automotive lamp assemblies. As disclosed in FIGS. 17 and 23 of U.S. Pat. No. 6,247,868, the disclosure of which is hereby incorporated by reference, automotive lamp assemblies used as headlights typically comprise several basic parts: a support frame, a reflector, a lens, a bulb, and one or more adjusters. The support frame houses the reflector and the bulb on a pivotable mounting to allow the aim of the light to be adjusted using the adjuster. The lens seals the front of the assembly to protect it from the elements assailing the front end of the vehicle and provides an aerodynamic shape and attractive appearance. The reflector mounts inside the housing on a fixed ball joint and is adjustable horizontally and vertically using adjusters that interface with the reflector through moving ball joints. The moving ball joints are moveable by actuating the adjusters connected to the moving ball joints by a ball stud having a head and a shaft. In some automotive lamp assemblies, two fixed ball joints and one moving ball joint may be used.
As is known in the art, ball studs interface with plastic sockets, such as the one shown in FIG.
7
. This is just one example of a prior art automobile headlight
10
having a reflective mirror tiltably mounted in a lamp space which is defined by a lamp body
12
and a lens
14
. Lamp body
12
is formed of a synthetic resin material and defines a recess
16
which opens in the forward direction. The lens
14
is mounted on the lamp body
12
to cover the recess
16
. A reflective mirror
18
is tiltably disposed in a lamp space
20
which is defined between the lamp body
12
and the lens
14
.
The reflective mirror
18
is supported on the lamp body
12
at three points. At one point
22
in particular, the reflective mirror
18
is supported on the lamp body
12
through a ball socket assembly
24
. Socket assembly
24
comprises a ball stud
26
mounted on the lamp body
12
, and a ball socket
28
supported on the reflective mirror
18
by a pair of flexible arms or locking tabs
19
. The spherical portion
30
of the ball stud
26
engages with the spherical recess
32
of the ball socket
28
, thereby the mirror is pivotably connected to the lamp body
12
.
While functionally quite effective, there is at least one shortcoming to using ball studs with locking tabs. This shortcoming is that the locking tabs
19
can be pulled out of reflector wall
21
under certain conditions of operation, leaving the adjuster non-operational. This unexpected pull-out generally occurs because the locking tabs
19
are necessarily flexible. Tabs
19
must be flexible enough to allow the tabs
19
to be inserted into an aperture in the reflector wall
21
, while at the same time resist pull-out. Though pull-out of the ball stud is resisted to some degree of success, if enough force is applied, tabs
19
slip inward toward the center of the aperture and the socket
28
“pops out” of the wall
21
. Reducing the flexibility of tabs
19
has not been found an effective option because it becomes too difficult to insert the socket
28
into the wall
21
, or the elasticity of the tabs
19
is lessened to the degree that they break off during insertion of the socket
28
.
Accordingly, the need exists for an improved ball socket that can be securely retained in a wall or other structure, can be adapted for use in connection with various ball stud designs, is cost effective, and resists accidental pull-out. The present invention relates to an improved ball joint which is capable of being used in automotive lamp assemblies and solves the problems raised or not solved by existing ball joints. Of course, the present invention may be used in a multitude of non-automotive lamp situations where similar performance capabilities are required.
SUMMARY OF THE INVENTION
The present invention provides a ball socket that is cost-effective, easily installed in the lamp where it is securely retained, and is adaptable for use in connection with various ball studs.
The ball socket of the present invention has at least a pair of locking tabs or snap locks extending therefrom. These locking tabs have an outwardly extending lip on the end opposite to where a ball stud is attached to the socket, which creates a necked portion on the locking tabs. The locking tabs elastically deflect inward when inserted into an aperture in a wall or the like, and return to their original position once the locking tab lips are completely through the aperture.
The ball socket further includes a sleeve that is located in the socket cup. When a ball stud is inserted into the socket cup, the sleeve is driven to a location between the locking tabs. This prevents the locking tabs from deflecting inward, and secures the ball socket to the wall or a mounting plate. The sleeve may be connected to the ball socket with by a shear tab that is sheared off by dislocating the sleeve. Alternatively, the sleeve may be separate from the ball socket, and temporarily seated by shear tabs that are also sheared off by dislocating the sleeve.
The ball socket can be designed to accept different types of ball studs, either conventional or disengageable, such as the one disclosed in U.S. Pat. No. 6,113,301. The ability to use the socket with a wide variety of ball studs provides a significant benefit to headlamp assemblers because it allows the use of one style of socket with a number of types of ball stud.
While one possible application of the present invention is in headlamp assemblies, many other applications are possible and references to use in a headlamp assembly should not be deemed to limit the uses of the present invention. The terms “ball stud,” or “head” as used herein should not be interpreted as being limited to spherical or semispherical shapes, rather, the heads of ball studs in accordance with the present invention may have a wide variety of shapes and may include protrusions having semispherical or otherwise pivotably-shaped tips. These and other objects and advantages of the present invention will become apparent from the detailed description, claims, and accompanying drawings.
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Asyst Technologies LLC
Cottingham John R.
Gilpin Brian G.
Godfrey & Kahn S.C.
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