Abstract:
A headlamp and integral mounting assembly having three peripherally spaced integrally formed mounting means, which cooperate with headlamp support means to provide three suspension points from which the lamp is pivotally mounted for independent adjustment from two of the points for limited pivotal rotative movement about a pair of coplanar, orthogonally related and intersecting axes, one of which axes is contained in an axial plane passing through the geometric center of the lamp unit and the other of which axes is displaced from the geometric center and located outwardly of the lamp unit.

Description:
BACKGROUND AND FIELD OF THE INVENTION 
     This invention relates to vehicle headlamps and more particularly, to an adjustable headlamp and mounting assembly specially suited for use in automotive-type vehicles. 
     The invention seeks to provide an improved form of vehicle headlamp and adjustable mounting assembly, which eliminates the multiplicity of separate mounting components, including mounting rings, shells, attachment screws, etc. heretofore employed in present forms of vehicle headlamp mounting assemblies. 
     Other objects are to provide a light weight, low cost vehicle headlamp and adjustable mounting therefor that uses a minimum number of parts and is of economical manufacture. 
     A headlamp and mounting assembly according to the invention includes a plastic headlamp unit having three peripherally spaced mounting means integrally formed on and projecting outwardly from its periphery. The mounts cooperate with headlamp support means to provide three suspension points to which the lamp is unyieldably positively secured and is mounted for independent adjustment from two of the points for limited rotative movement about a coplanar pair of orthogonal intersecting axes, one of which is contained in the axial plane passing through the geometric center of the unit and the other of which axes is displaced from the geometric center thereof and located outwardly of the lamp unit. 
    
    
     One example of the invention is illustrated in the accompanying drawings wherein: 
     FIG. 1 is a front elevational view of a headlamp unit and mounting assembly in accordance with the invention; and 
     FIG. 2 is a side elevation and sectional view taken along the line 2--2 of FIG. 1; 
     FIG. 3 is a fragmentary view of a part of FIG. 1 showing the shape of a slot therein; and 
     FIG. 4 is an enlarged sectional view taken in the direction of 4--4 of FIG. 1. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to the drawings, the headlamp unit 10 is shown as a rectangular headlamp, which is received in a generally similarly shaped indentation or opening 61 in a headlamp support or mounting panel 60, affixed to or forming a part of the forward portion of a motor vehicle. 
     The lamp unit 10, which may be of the sealed beam or separate bulb variety, includes a generally parabolic dish-shaped reflector 12 and a translucent lens element 14, which are preferably formed of a synthetic inorganic based plastic, such for example as polycarbonate, instead of vitreous or glass, material. Interiorly, the reflector has a highly polished, reflecting silvered or aluminized coated surface and recieves one or more incandescent lamp filaments positioned at the focal point of the reflector and which may be exposed or enclosed in a glass, quartz, gas or halogen filled single or multiple filament lamp bulb suitably supported or mounted in the reflector and electrically energizable through terminals, as 16, shown at the rear of the reflector. Lens 14, which may be formed of a clear plastic polycarbonate material as Lexan for example, has a generally rectangular configuration with a curved frontal surface in accordance with the desired lens prescription and is shown as having a peripheral bead or edge 18 by which it is suitably affixed, as by sealing, to close the open end of the reflector. 
     In accordance with the invention, the lamp unit is attached by a three point suspension mounting to the mounting panel in which its attitude may be separately and independently adjusted about a generally vertically oriented axis passing through two of the three suspension points, and about a generally horizontally extending axis passing through a third and one of the first two suspension points by portions of the lamp cooperating with the mounting panel. The portions of the lamp mounting carried on or formed on the lamp include a pair of radially outwardly extending flanges 20, 21 and one element 23 of a universal pivot, joint or ball or socket mounting 22 whose other element 24 is affixed to the mounting panel. 
     Mounting flange 20 is of generally L-shaped formation and is shown positioned between the two shorter parallel sides 30 and 31 of the lamp unit and located on the upper longer side 32 thereof and on the vertical axis 34 passing through the geometric center 0 of the lamp unit. Mounting flange 21 is laterally displaced from the vertical axis 34 and is shown located at the southwest corner and at the intersection of the sides 30 and 33 of the lamp unit. 
     Each of the mounting flanges 20 and 21 has a thick planar frontal surface, which is structurally reinforced as by a pair of rearwardly extending spaced apart webs 36, 37 and 38, 39 integrally molded with the respective flanges on the reflector, and has an elongated slotted opening as 40, 41 therein. The slots may be shaped as shown in FIG. 3, in which they are shown as being of a slightly reduced dimension at the respective entrances thereof so as to provide a snap-in fit or retention for a respective one of a pair of headlamp aiming adjusting screws 42, 43. Each adjusting screw has a circumferentially extending, V-shaped annular groove as 44, 45 therein by which it is retained in the aforesaid slot 40, 41 in a respective one of the mounting flanges 20, 21 and further has a threaded body which is threadably received in a flanged fastening nut 46, 47 molded of plastic material, as Nylon, for example. 
     As illustrated in FIG. 4 herein, each fastening nut is of a generally rectangular cross section and has a blunt tapered rearward portion by which it is inserted through a rectangular shaped opening 61 in a rearwardly displaced upstanding portion 62 of the mounting panel 60. Each of the nuts is further characterized by a pair of inwardly yieldable shoulders 48, 49 on opposite sides of the nut and includes a pair of outwardly extending yieldable flanges or ears as 51, 52 that bear against the front face of the aforesaid upstanding portion 62 of the mounting panel in which the nut is thus securely retained. 
     Ball element 23 of the pivotable or ball and socket mounting 22 is shown located on the longer lower side 33 of the headlamp unit in the vertical axial plane thereof and is formed on a depending conical base or pedestal 25, which is suitably affixed to and preferably integrally molded with the reflector 12. The ball element cooperates with the aforesaid ball shaped, resilient socket element 24 in which it is received with a snap-in type and frictional retention and is universally moveable in or with three directions of rotational freedom. The ball socket element 24, which may be formed of plastic or metallic material preferably of a different frictional coefficient than the spherical ball element, is shown as having a threaded body or pedestal portion 26 by which its elevation may be adjusted for or relative to different sized openings 61 in the mounting panel to which it is adjustably fastened and locked, as by and between a pair of threaded nuts 27, 28 on opposite sides of the lower wall or floor 63 of the mounting panel. 
     As shown in FIG. 4, the sidewalls of the annular grooves 44 and 45 in the heads of the adjusting screws 42, 43 have a generally curved or spherical contour to cooperate with a dished spherically contoured indentation or depression 53, 54 formed in the frontal face of the mounting flanges 20, 21 and surrounding the slots 40, 41 in the mounting flanges to facilitate limited rotary movement of the lamp unit mounting flanges about the respective adjusting screws when the latter are independently moved to adjust the attitude of the lamp unit for automotive headlamp aiming purposes. 
     Inward or outward movement of the upper adjusting screw 42, for example, by insertion of a cross-splined drive tip into the cross-slotted head of the screw, pivotally moves the entire lamp unit about a horizontal axis 35 located externally of the lamp unit and passing through the center of the ball and socket pivot mounting 22 and the center of the lower adjusting screw 43 at the corner mounting flange 21. While inward or outward movement of the corner adjusting screw 43 pivotally moves the entire lamp unit about the central vertical axis 34 passing through the center of the adjusting screw 42 at the upper mounting flange 20 and the center of the ball and socket mounting 22. 
     While the lamp unit has been shown of rectangular configuration, it is apparent that the mounting arrangement discussed herein may be used with the other forms of lamps and lamp shapes.