Clutching lamp adjuster

An adjuster adjusts the position of a fog lamp, headlamp, or other form of adjustable, automotive lamp. The adjuster includes a side-opening retainer screw interface. The side-opening retainer allows the adjuster to provide clutching throughout travel. In addition, a distal end of the retainer includes a set of retainer snap fingers and a separate set of spring fingers. The snap fingers and spring fingers allow for a strong, elastic connection to a lamp mating panel and allow the retainer to securely connect to lamp mating panels of various thicknesses.

FIELD OF THE INVENTION

The present invention relates generally to the field of adjusters. More particularly, the present invention relates to an adjuster for fog lamps, headlamps, and other forms of adjustable automotive lamps that allows clutching throughout travel.

BACKGROUND

It is common, in automobiles, to use internal adjusters to adjust the position of certain automotive lamps, such as fog lamps or headlamps. Such internal adjusters include multiple parts and can easily grow complex. Hence, simplicity is an important facet when designing an adjuster. Additionally, lamp adjusters are often required to absorb high levels of system vibration, which can cause unwanted reorientation of the adjuster, damage to adjuster components, such as through stripping, and even, in some instances, disengagement of the adjuster. Therefore, it is valuable for an adjuster to be configured to maintain its orientation while undergoing system vibrations and to form a mating connection that is elastic enough to absorb vibrations without disengagement of or damage to either mated component. It may further be valuable for an adjuster to provide clutching throughout travel to eliminate stripping damage, especially in situations where it is required to accommodate higher system weights or operating temperatures.

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.

SUMMARY

In certain aspects, the present invention provides an adjuster for adjusting automotive lamps. In accordance with some forms of the invention such adjuster includes a retainer and a base screw configured in a manner that permits clutching throughout travel. Accordingly, in one embodiment, the present invention provides an adjuster for adjustable automotive lamps. The adjuster comprises a base screw and a retainer. The base screw includes a threaded shaft. The retainer connects to the threaded shaft and includes a semicircular sidewall, a plurality of retainer snap fingers, and a plurality of retainer spring fingers. The semicircular sidewall includes interior threads that correlate to the threads of the threaded shaft. The semicircular sidewall further surrounds at least a portion of the threaded shaft and defines a clutching opening. The clutching opening permits expansion of the semicircular sidewall when the threaded shaft slips with respect to the interior threads. The retainer snap fingers are located proximate to a distal end of the retainer and are configured to mate to a lamp mating portion of the adjustable automotive lamp. The retainer spring fingers are positioned within such proximity to the retainer snap fingers as to further secure the lamp mating portion against substantial sliding movement along the adjuster after the retainer snap fingers mate with the lamp mating portion.

In another embodiment, the invention provides an adjuster assembly for adjustable automotive lamps. The adjuster assembly comprises a housing mating portion connected to a lamp housing, a lamp mating portion forming part of the adjustable automotive lamp, and a lamp adjuster connected to both the housing mating portion and the lamp mating portion. The lamp adjuster comprises a base screw and a retainer. The base screw includes a threaded shaft. The retainer connects to the threaded shaft and includes a semicircular sidewall, a plurality of retainer snap fingers, and a plurality of retainer spring fingers. The semicircular sidewall includes interior threads that correlate to the threads of the threaded shaft. The semicircular sidewall further surrounds at least a portion of the threaded shaft and defines a clutching opening. The clutching opening permits expansion of the semicircular sidewall when the threaded shaft slips with respect to the interior threads. The retainer snap fingers are located proximate to a distal end of the retainer and are configured to mate to a lamp mating portion of the adjustable automotive lamp. The retainer spring fingers are positioned within such proximity to the retainer snap fingers as to further secure the lamp mating portion against substantial sliding movement along the adjuster after the retainer snap fingers mate with the lamp mating portion.

In a further embodiment, the invention provides a lamp adjuster for adjustable automotive lamps. The lamp adjuster includes a base screw and a retainer. The base screw has a threaded shaft and a plurality of base screw snap fingers configured to mate to a housing mating portion of a lamp housing in a manner that permits rotation of the base screw with respect the housing mating portion. The base screw also has a securement mechanism configured to secure the housing mating portion against substantial longitudinal movement after the plurality of snap fingers mates with the housing mating portion and an orientation tab located on a distal end of the base screw. The orientation tab is configured to signal proper orientation of the lamp adjuster to a user installing the lamp adjuster. The retainer connects to the threaded shaft of the base screw and includes a semicircular sidewall, a pair of opposing retainer snap fingers, a pair of opposing retainer spring fingers. The sidewall partially surrounds at least a portion of the threaded shaft and has a series of interior threads that correlate to the threads of the threaded shaft. Additionally, the semicircular sidewall defines a clutching opening that permits expansion of the semicircular sidewall when the threaded shaft slips with respect to the interior threads. The pair of retainer snap fingers are located proximate to a distal end of the retainer and are configured to mate to a lamp mating panel of an automotive lamp heat sink in a manner that fixes the retainer against rotation. The pair of opposing retainer spring fingers are positioned within such proximity to the plurality of retainer snap fingers as to secure the lamp mating portion against substantial longitudinal movement along the length of the adjuster after the plurality of snap fingers mates with the lamp mating portion.

Other objects and advantages of the present disclosure will become apparent hereinafter.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While the description herein refers mainly to fog lamps, the term “fog lamp,” as used in this application, can be applied equally well to other adjustable lamps, such as headlamps. References to fog lamps hereinafter should not be read as limiting the device for use solely with fog lamps.

FIG. 1shows one embodiment of a clutching fog lamp adjuster assembly10. In the embodiment shown, the adjuster assembly10includes a clutching fog lamp adjuster12, a housing mating portion14, and a lamp mating panel16. The housing mating portion14may form a portion of a broader lamp housing, and the lamp mating panel16may form a portion of a broader lamp heat sink (not shown), but for convenience and clarity, the remainder of the housing and of the lamp heat sink are omitted from the drawings of this embodiment. In the present embodiment, the adjuster12includes a base screw20, a retainer18that screws or snaps onto the base screw20, and an O-Ring22that wraps around a portion of the base screw20(seeFIG. 2). In this embodiment, the adjuster12mates with the housing mating portion14at a housing mating end, and with the lamp mating panel16at an opposing, retainer mating end.FIG. 2shows the adjuster12in greater detail. With the housing mating portion14and the lamp mating panel16removed, the O-Ring22is now visible.

FIGS. 3-6show one manner of assembling the adjuster assembly10.FIG. 3is an exploded view of the adjuster12. In the embodiment shown, the base screw20includes an O-Ring channel23near the housing mating end of the adjuster12. The O-Ring channel23allows for proper positioning of the O-Ring22and aids in maintain the position of the O-Ring22at the housing mating end of the base screw20.FIG. 4shows the adjuster12fully assembled before being mated with the housing mating portion14. Here, the O-Ring22is positioned in the O-Ring channel23, and the retainer18is snapped onto the base screw20.

A ridged sidewall15defines an opening in the housing mating portion14, sized to permit the adjuster12to pass through the opening, beginning at the retainer mating end, until the opposing housing mating end is reached. At the housing mating end, the base screw20snaps into place against the ridged sidewall15, such that the base screw20may no longer move in a forward or a rearward direction through the housing mating portion14, but may still rotate within the opening defined by the ridged sidewall15. Although the ridged sidewall15, in this embodiment, forms a substantially circular shape, the ridged sidewall in other embodiments may form other shapes, corresponding to other mating ends of other base screws. In this embodiment, after the adjuster12is mated with the housing mating portion14, the O-Ring22may act as a seal, may aid in isolating vibrations, and/or may help to secure the connection between the base screw20and the housing mating portion14. Other embodiments, such as the embodiment shown inFIGS. 23-46, may operate without an O-Ring.FIG. 5shows the adjuster12mated with the housing mating portion14, separated from the lamp mating panel16. When fully assembled, the lamp mating panel16snaps into place at the retainer mating end of the adjuster12.

FIGS. 6-8show top views of various elements of the adjuster assembly10.FIG. 6shows the adjuster12mated with the housing mating portion14. The lamp mating panel16is not shown.FIG. 7shows the complete adjuster assembly10. AndFIG. 8shows only the lamp mating panel16. In this embodiment, the mating geometry24is formed in the shape of a plus symbol. In other embodiments, the mating geometry may form other shapes, corresponding to other mating ends of other adjusters.

FIGS. 9-10respectively show bottom views of the adjuster assembly10and of the housing mating portion14, alone. In the embodiment shown, a distal end of the base screw20includes a combination hexagonal-cross recessed interface25, which allows for multiple component installation and adjustment options. However, in other embodiments, the distal end of the base screw20may include different forms of interfaces. In this embodiment, the distal end of the base screw20additionally includes orientation tabs26. The orientation tabs26allow an assembler to correctly orient the adjuster12, even when the assembler cannot see beyond the housing mating portion14, for instance, during a blind assembly. The embodiment shown inFIG. 9includes two orientation tabs26, and proper installation is signaled by a horizontal orientation of the orientation tabs26. However, in other embodiments, a different number of orientation tabs may be utilized and proper orientation of the adjuster12may be signaled by a different orientation of the orientation tabs26. Further,FIG. 10shows the ridged sidewall15extending continuously around the opening formed in housing mating portion14. The continuity of the ridged sidewall15may permit rotation of the base screw20within the housing mating portion14.

FIG. 11shows the base screw20in greater detail. The base screw20may include base screw snap fingers30that snap into the ridged sidewall15, contributing to a resilient, but rotatable mating connection with the housing mating portion14. The base screw20may additionally include a threaded section28, to which the retainer18connects.

FIGS. 12-13show the retainer18in greater detail. The retainer18includes a semicircular retainer sidewall40. In this embodiment, the retainer sidewall40defines a clutching opening42. Additionally, a portion of the retainer sidewall40may be threaded to form a retainer interface section38, where the retainer18may interact with the threaded section28of the base screw20. The unique composition of the retainer sidewall40allows for clutching at any point throughout travel. When the base screw20rotates in a manner that would not otherwise be permitted by the retainer interface section38, rather than stripping the threaded section28, the retainer sidewall40expands, widening the clutching opening42to an extent sufficient to permit slippage of the base screw20along the base screw interface38without significant damage to the threads of the threaded section28until the threaded section28once again fits properly within the retainer interface section38, but not so far as to permit the threaded section28to dislodge from the retainer interface section38. Integrated full-travel clutching provides a more robust adjustment solution for systems having increased weight and/or temperatures.

The retainer18additionally includes retainer snap fingers32to engage the lamp mating panel16and retainer spring fingers34to secure the connection to the lamp mating panel16. In the embodiment shown, there are two retainer snap fingers32and two retainer spring fingers34, each retainer spring finger34located directly below a respective retainer snap finger32. In other embodiments, there may be a greater number of retainer snap fingers32and/or retainer spring fingers34. Direct engagement of the retainer18with the lamp mating panel16eliminates the need for installation of a secondary mating socket, simplifying assembly and reducing component count.

In this embodiment, both the retainer snap fingers32and the retainer spring fingers34are made of an elastic material. Securing the lamp mating panel16between multiple, elastic elements, versus a single element or small number of rigid elements, allows the adjuster assembly10both to withstand greater system vibrations with decreased likelihood of damage or dislodging, and to accommodate lamp mating panels, or equivalent lamp mating elements, of various thicknesses without requiring higher installation forces or creating a loose joint. Finally, a travel restriction lug36may be attached to the retainer sidewall40directly below each retainer spring finger34. The travel restriction lug36limits the distance that the corresponding retainer spring finger34may be stretched during installation and general usage, reducing the risk of permanent spring finger deformation.

FIGS. 14-18show the various components of the full adjuster assembly10interacting with one another. For instance, the cutaway view inFIG. 15shows the O-Ring22in place between the base screw20and the ridged sidewall15, as well as showing the lamp mating panel16locked in place by the retainer snap fingers32and further secured by the retainer spring finger34, also shown in the cross-sectional view inFIG. 18. Further, the custom fit of the retainer mating end within the mating geometry24(shown inFIG. 8) helps control insertion location, promoting proper retainer18orientation, and aids in limiting unwanted vibration. Additionally, the ability to connect the mating end of the retainer18directly to the lamp mating panel16of the lamp heat sink, due to the mating geometry24(shown inFIG. 8), eliminates the need for additional mating components, such as a secondary mating component, simplifying the adjuster assembly10.

FIGS. 19-22illustrate how the lamp mating panel16tilts as the retainer18is retracted (as shown inFIGS. 19-20) or extended (as shown inFIGS. 21-22). Notice that the retainer18does not rotate as it extends or retracts, but rather, maintains a substantially constant orientation, with the clutching opening42facing outwards. This orientation ensures that general usage loads will occur on the retainer sidewall40, rather than on or opposite the clutching opening42, which helps prevent dislodging. The mating geometry24of the lamp mating panel16ensures this constant orientation, preventing substantial twisting of the retainer18.

In the present embodiment, the retainer18is caused to extend or retract by the interaction between the threaded section28of the base screw20and the retainer interface section38of the retainer18as the base screw20rotates. Here, when the base screw20rotates, the rotational energy translates through the rotationally fixed retainer18to the lamp mating panel16, causing the lamp mating panel16to pivot. In this embodiment, when the retainer18is in a retracted position (as shown inFIGS. 19-20), the lamp mating panel16is tilted in a forward direction, whereas when the retainer18is in an extended position (as shown inFIGS. 21-22), the lamp mating panel16is tilted in a rearward direction.

FIGS. 23-24show a clutching fog lamp adjuster assembly110according to a second embodiment of the present disclosure, with expanded views of a lamp housing104and a lamp heat sink106shown. A housing mating portion114is attached to the housing104, and a lamp mating portion116is attached to the lamp heat sink106. In this embodiment, the housing mating portion114is formed as a part of the housing104and the lamp mating panel116is formed as a part of the lamp heat sink106, although other means of attachment could be implemented. Additionally, while the lamp mating panel116is shown in this embodiment to resemble a flat panel, in other embodiments, the mating portion of the lamp heat sink may take on other shapes. In the present embodiment, the clutching lamp adjuster112connects to both the housing104, at the housing mating portion114, and to the lamp heat sink106, at the lamp mating panel116.

FIG. 25shows the clutching lamp adjuster assembly110including the clutching lamp adjuster112, the housing mating portion114, and the lamp mating panel116. The remainder of the housing104and lamp heat sink106are removed for clarity in this and the remaining figures. In this embodiment, the adjuster112mates with the housing mating portion114at a housing mating end, and with the lamp mating panel116at an opposing, retainer mating end.FIG. 26shows the adjuster112in greater detail, with the housing mating portion114and the lamp mating panel116removed. In the present embodiment, the adjuster112includes a base screw120and a retainer118that screws or snaps onto the base screw120.

FIGS. 27-29show one manner of assembling the adjuster assembly110.FIG. 27is an exploded view of the adjuster112.FIG. 28shows the adjuster112fully assembled, with the retainer118snapped onto the base screw120, before being mated with the housing mating portion114. A sidewall115defines an opening in the housing mating portion114, sized to permit the adjuster112to pass through the opening, beginning at the retainer mating end, until the opposing housing mating end is reached. At the housing mating end, the base screw120snaps into place against the sidewall115, such that the base screw120may no longer move in a forward or a rearward direction through the housing mating portion114, but may still rotate within the opening defined by the sidewall115. Although the sidewall115, in this embodiment, forms a substantially circular shape, the sidewall in other embodiments may form other shapes, corresponding to other mating ends of other base screws. Further, the present embodiment depicts an adjuster assembly110in which no seal is required between the housing mating portion114and the base screw120. Therefore, an O-ring is not included in this embodiment. However, should a seal be desired between the housing mating portion114and the base screw120, an O-ring, for instance an O-ring similar to the O-Ring22shown and described in the previous embodiment, may be included in this embodiment.FIG. 29shows the adjuster112mated with the housing mating portion114, but separated from the lamp mating panel116. When fully assembled, the lamp mating panel116snaps into place at the retainer mating end of the adjuster112.

FIGS. 30-32show top views of various elements of the adjuster assembly110.FIG. 30shows the adjuster112mated with the housing mating portion114. The lamp mating panel116is not shown.FIG. 31shows the complete adjuster assembly110. AndFIG. 32shows only the lamp mating panel116. In this embodiment, the mating geometry124is formed in the shape of a plus symbol. In other embodiments, the mating geometry may form other shapes, corresponding to other mating ends of other adjusters.

FIGS. 33-34respectively show bottom views of the adjuster assembly110and of the housing mating portion114, alone. In the embodiment shown, a distal end of the base screw120includes a combination hexagonal-cross recessed interface125, which allows for multiple component installation and adjustment options. However, in other embodiments, the distal end of the base screw120may include different forms of interfaces. The distal end of the base screw120may further include deformable fingers122, which aid in securing the base screw120to the housing mating portion114. As can be seen inFIG. 33, the deformable fingers122extend beyond the opening defined by the sidewall115, such that the housing mating portion114may not be moved in a rearward direction beyond the deformable fingers122. The deformable fingers122are sufficiently deformable to absorb system vibrations without breaking from the base screw120, but maintain sufficient rigidity to prevent disconnection of the housing portion114from the base screw120.

In this embodiment, the distal end of the base screw120additionally includes orientation tabs126. The orientation tabs126allow an assembler to correctly orient the adjuster112, even when the assembler cannot see beyond the housing mating portion114, for instance, during a blind assembly. The embodiment shown inFIG. 33includes two orientation tabs126, and proper installation is signaled by a horizontal orientation of the orientation tabs126. However, in other embodiments, a different number of orientation tabs may be utilized and proper orientation of the adjuster112may be signaled by a different orientation of the orientation tabs126. Further,FIG. 34shows the sidewall115extending continuously around the opening formed in housing mating portion114. The continuity of the sidewall115may permit rotation of the base screw120within the housing mating portion114.

FIG. 35shows the base screw120in greater detail. The base screw120may include base screw snap fingers130that snap into the sidewall115, contributing to a resilient, but rotatable mating connection with the housing mating portion114. The base screw120may additionally include a threaded section128, to which the retainer118connects. In an embodiment that does not include an O-Ring, an O-Ring channel, such as the O-Ring channel23shown in the previous embodiment, is no longer pertinent and may be eliminated from such an embodiment, which may decrease the overall length of the base screw. For instance, inFIG. 35, the base screw120is shown without an O-Ring channel, as this embodiment does not include an O-Ring. Should a seal be desired between the housing mating portion114and the base screw120, the base screw120may include an O-Ring channel, which may support an O-Ring capable of forming the desired seal between the housing mating portion114and the base screw120when the housing mating portion114mates with the base screw120.

FIGS. 36-37show the retainer118in greater detail. The retainer118includes a semicircular retainer sidewall140. In the present embodiment, the retainer sidewall140defines a clutching opening142. Above the clutching opening142, a first pass core gap144may be defined in the retainer118. The first pass core gap144may be sized to permit a limited amount of retainer spring finger134flexure, while maintaining sufficient retainer spring finger134structural strength and position within an adjustable travel length to avoid permanent deformation of the spring fingers134. Opposite from and, at least in part aligned with, the first pass core gap144, a second pass core gap145may be defined in the retainer118. In this embodiment, the second pass core gap145is defined between the retainer interface section138and the retainer spring fingers134. The second pass core gap145may be sized to provide room for additional snap finger134flexure. Together, the first pass core gap144and the second pass core gap145may form a pass core143. The pass core143, thus, may provide sufficient structure to maintain the mating function of the retainer spring fingers134and retainer snap fingers132, while still allowing a sufficient level of retainer spring finger134flexure for installation and pivoting of the lamp mating portion116.

Additionally, a portion of the retainer sidewall140may be threaded to form a retainer interface section138, where the retainer118may interact with the threaded section128of the base screw120. The unique composition of the retainer sidewall140allows for clutching at any point throughout travel. When the base screw120rotates in a manner that would not otherwise be permitted by the retainer interface section138, rather than stripping the threaded section128, the retainer sidewall140expands, widening the clutching opening142to an extent sufficient to permit slippage of the base screw120along the base screw interface138without significant damage to the threads of the threaded section128until the threaded section128once again fits properly within the retainer interface section138, but not so far as to permit the threaded section128to dislodge from the retainer interface section138. The pass core143is sized such that the retainer sidewall140maintains a sufficient degree of grip strength to prevent the base screw120from dislodging from the retainer118. Integrated full-travel clutching provides a more robust adjustment solution for systems having increased weight and/or temperatures.

The retainer118additionally includes retainer snap fingers132to engage the lamp mating panel116and retainer spring fingers134to secure the connection to the lamp mating panel116. In the embodiment shown, there are two retainer snap fingers132and two retainer spring fingers134, each retainer spring finger134located directly below a respective retainer snap finger132. In other embodiments, there may be a greater number of retainer snap fingers132and/or retainer spring fingers134. Direct engagement of the retainer118with the lamp mating panel116eliminates the need for installation of a secondary mating socket, simplifying assembly and reducing component count.

In this embodiment, both the retainer snap fingers132and the retainer spring fingers134are made of an elastic material. Securing the lamp mating panel116between multiple, elastic elements, versus a single element or small number of rigid elements, allows the adjuster assembly110both to withstand greater system vibrations with decreased likelihood of damage or dislodging, and to accommodate lamp mating panels, or equivalent lamp mating elements, of various thicknesses without requiring higher installation forces or creating a loose joint. This embodiment does not include travel restriction lugs as shown in the previously described embodiment, but travel restriction lugs could be included if desired.

FIGS. 38-42show the various components of the full adjuster assembly110interacting with one another. For instance, the cutaway view inFIG. 39shows housing mating portion114locked in place between the deformable fingers122and base screw snap fingers130, as well as showing the lamp mating panel116locked in place by the retainer snap fingers132and further secured by the retainer spring fingers134, also shown in the cross-sectional view inFIG. 42. Further, the custom fit of the retainer mating end within the mating geometry124(shown inFIG. 32) helps control insertion location, promoting proper retainer118orientation, and aids in limiting unwanted vibration. Additionally, the ability to connect the mating end of the retainer118directly to the lamp mating panel116of the lamp heat sink106, due to the mating geometry124(shown inFIG. 32), eliminates the need for additional mating components, such as a secondary mating component, simplifying the adjuster assembly110.

FIGS. 43-46illustrate how the lamp mating panel116tilts as the retainer118is retracted (as shown inFIGS. 43-44) or extended (as shown inFIGS. 45-46). Notice that the retainer118does not rotate as it extends or retracts, but rather, maintains a substantially constant orientation, with the clutching opening142facing outwards. This orientation ensures that general usage loads will occur on the retainer sidewall140, rather than on or opposite the clutching opening142, which helps prevent dislodging. The mating geometry124of the lamp mating panel116ensures this constant orientation, preventing substantial twisting of the retainer118.

In the present embodiment, the retainer118is caused to extend or retract by the interaction between the threaded section128of the base screw120and the retainer interface section138of the retainer118as the base screw120rotates. Here, when the base screw120rotates, the rotational energy translates through the rotationally fixed retainer118to the lamp mating panel116, causing the lamp mating panel116to pivot. In this embodiment, when the retainer118is in a retracted position (as shown inFIGS. 43-44), the lamp mating panel116is tilted in a forward direction, whereas when the retainer118is in an extended position (as shown inFIGS. 45-46), the lamp mating panel116is tilted in a rearward direction.

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.