Abstract:
A headlamp assembly typically includes a high beam reflector and a low beam reflector. A linkage synchronizes the aim of a high beam reflector with a low beam reflector while also providing damping for both reflectors to stop them from visibly shaking or fluttering the light beam under vibration in actual use. The damping linkage could also be employed in a single reflector environment.

Description:
PRIORITY CLAIM/CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. Provisional Patent Application No. 61/894,676, filed Oct. 23, 2013, which is incorporated herein by reference for all purposes. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the field of motor vehicle headlamps with internal reflectors contained within a headlamp housing and lens, and mechanisms for damping fluttering of the reflectors. The present invention also relates to a linkage that synchronizes the aim of a high beam reflector with a low beam reflector while also providing damping for both reflectors to stop them from visibly shaking or fluttering the light beam under vibration in actual use. 
     BACKGROUND 
     Vehicle headlamps designed with two independent reflectors, typically one used for the low beam and one used for the high beam, are also typically aim adjusted from a single adjustment location outside the headlamp. A linkage bracket can be used inside the headlamp to connect the low and high beam reflectors and synchronize aim. However, preventing reflector flutter under vibration can be difficult in this situation, due in part to the mass of each reflector independently being suspended about separate pivot points, in addition to other reflector design variables. 
     As such, there is a need for a linkage bracket to connect and synchronize independently pivoting reflectors for aiming, while also providing damping to prevent beam flutter for one or both reflectors during vibration in actual use. There is also a need for an improved mechanism for providing damping to prevent beam flutter in individual reflectors during vibration in actual use. 
     SUMMARY 
     Disclosed is a reflector damper bracket comprising a link damper, and a link bracket in frictional sliding engagement with the link damper. The link bracket includes at least one ball adapted for attachment to at least one reflector, and the link damper includes a post adapted for attachment to a headlamp housing. 
     It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view cross section of a headlamp that includes one embodiment of a reflector damper bracket in accordance with the invention. 
         FIG. 2  is a perspective view cross section of a headlamp that includes the reflector damper bracket of  FIG. 1 . 
         FIG. 3  and  FIG. 4  are exploded perspectives view of the reflector damper bracket of  FIG. 1 . 
         FIG. 5A  is a bottom view of the reflector damper bracket of  FIG. 1 . 
         FIG. 5B  is a side view of the reflector damper bracket of  FIG. 1 . 
         FIG. 5C  is a top view of the reflector damper bracket of  FIG. 1 . 
         FIG. 6A  is a perspective view and  FIG. 6B  is a cross section of the reflector damper bracket of  FIG. 1 . 
         FIG. 7  is an enlarged perspective view of the reflector damper bracket of  FIG. 1 . 
         FIG. 8  is a partial perspective view of the rear of a reflector with another embodiment of a reflector damper bracket in accordance with the invention. 
         FIG. 9  is a partial cross sectional view through the housing boss, link damper, link bracket, and ball socket shown in  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION 
     The embodiment of a reflector damper bracket  200  shown in  FIG. 1  and  FIG. 2  consists of a link bracket  6  and a link damper  7  located inside a headlamp assembly  100 . The link bracket  6  is connected to an upper reflector  2  and a lower reflector  3  using ball sockets  5  located at each end of the link bracket  6 . The upper reflector  2  and lower reflector  3  also have additional ball sockets  5  for fixed pivots arranged in a manner such that when the adjuster  4  moves right or left, as shown in  FIG. 1 , the link bracket  6  moves up and down, synchronizing the rotation of upper reflector  2  and lower reflector  3  about their respective fixed pivots. 
     The link bracket  6  has an up and down sliding fit with the link damper  7  which is attached to the headlamp housing  1  using a post  12  that is inserted into a boss hole  1   a  inside a headlamp housing boss  1   b.    
       FIG. 3  and  FIG. 4  show the separate parts of the link damper bracket  200  before they are put together. The link bracket  6  includes spaced apart ball pivots  8  at each end, a body  10  and a plate  11 . The link damper  7  includes the post  12  extending from a channel or C-shaped guide  15 , and a slot  9 . The slot  9  of the link bracket  7  receives the plate  11  of the link bracket  6  when the two parts are assembled in the direction of the arrow as shown in  FIG. 4 , and creates a tight sliding friction fit. Once assembled, the link damper  7  remains attached to the link bracket  6  in the desired position, due to the friction fit. 
       FIGS. 5A, 5B and 5C  show several views of the link damper bracket  200  with the link bracket  6  and link damper  7  assembled together and ready for assembly to the headlamp  100 . Both parts may be molded from any number of plastics suitable for the headlamp such as, but not limited to, Polycarbonate, PP or Nylon. 
       FIGS. 6A and 6B  show the detail of the sliding friction fit between the link bracket plate  11  and the link damper slot  9 . The inside of the slot  9  can be tapered to a desired angle A to aid in creating a friction fit. The slot  9  and plate  11  can be nearly any shape or angle to suit the application, or can be reversed so that the slot  9  is formed in the link bracket  6  and the plate  11  is formed in the link damper  7 , without departing from the invention. To prevent unwanted beam flutter during vibration, a minimum friction force in the direction of arrows FD is needed. To allow adjustment function and prevent undue stress on components, a maximum friction force FD is also needed. The interference fit between the plate  11  and slot  9  creates a clamp force F. Angle A (see  FIG. 6B ) of plate edge  25  (see  FIG. 7 ) between the plate  11  and slot  9  creates a wedge fit which helps to achieve a desired friction force FD, without the need for excessive interference between parts and related material stress. Therefore a desired friction force FD can be achieved at relatively low clamp forces F. 
     As illustrated in  FIG. 8 , one reflector is shown mounted by four connections. One is a reflector adjuster  31  shown in the upper left corner of  FIG. 8 . The adjuster  31 , when its top mounted gear is turned, results in reverse or forward movement of a plunger  33  pivotally connected to the reflector  3 . This in turn results in the back or forth movement of the top of the reflector  3 . The reflector  3  is also mounted at two fixed pivot points  35  and  37 , at the left lower corner and right lower corner of the reflector  3 . Thus, the back and forth movement of the top of the reflector  3  by the adjuster  31  results in the tilting up or down of the reflector  3 . 
     Because of the mass of the reflector  3 , as described above, jolting or vibrating of a vehicle in which the reflector  3  is mounted can result in the fluttering of the reflector  3  and its included light beam. In order to limit this fluttering, the reflector  3  is also connected to a link damper  7  according to this disclosure. More particularly, an embodiment of a link bracket  6   a  is shown in  FIG. 9 . The link bracket  6   a  is identical to the link bracket  6 , except now it has a single ball pivot  8   a . As described above, the link damper  7  includes a slot  9 . The slot  9  of the link bracket  7  receives a plate  11   a  of the link bracket  6   a  when the two parts are assembled in the direction of the arrow as shown in  FIG. 4 , and creates a sliding friction fit. Once assembled, the link damper  7  remains attached to the link bracket  6   a  in the desired position, due to the friction fit. 
     As a result of the mounting of the link bracket  6   a  in the link damper  7 , movement of the reflector  3  and the link bracket  6   a  in a vertical direction, as shown in  FIGS. 8 and 9 , is dampened by the link damper  7 . In other embodiments (not shown), where other pivot mountings of the reflector may be used, the link bracket  6   a  and link damper  7  can be rotated ninety degrees relative to the housing boss  1   b  so that the reflector  3  can also be dampened when there is movement in a horizontal direction. In still other embodiments (not shown), more than one link damper and one link bracket can be used with each reflector in order to provide damping in both a vertical and horizontal direction, if desired. 
     Although the invention has been herein described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description of the invention herein.