Abstract:
A mounting plug for pivotably connecting a first component to a second component. The mounting plug comprises a ball stud portion comprising a ball and a post. The post comprises means for attaching the ball stud portion to the first component. The mounting plug further comprises a base and a socket chamber integrally molded on top of the base. The socket chamber is adapted to removably and pivotably retain the ball stud portion. The mounting plug further comprises a channel integrally molded to the base adjacent to the socket chamber, with the channel adapted to allow the ball to be inserted there through and into the socket chamber. The mounting plug further comprises a retainer portion integrally molded below the base. The retainer portion comprises at least one tab integrally molded to the retainer portion and adapted to removably secure the socket portion to the second component.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates generally to ball and socket mounting arrangements. More specifically, the present invention relates to a ball and socket assembly for pivotally mounting a vehicular headlamp.  
           [0002]    Motor vehicles are legally required to have external illumination provided by headlamps for illuminating oncoming road or terrain and to make their vehicle visible to the drivers of other vehicles. Headlamps illuminate approaching roadway or terrain by projecting a light in front of a vehicle. Indeed, headlamps are a significant safety feature of modern vehicles, and their use is both common and well known in the art.  
           [0003]    Headlamps are often designed as sealed assemblies. The assemblies are designed such that they can be incorporated into a vehicle&#39;s front end. To this end, headlamp assemblies must be shaped and constructed to conform to the space limitations, the aerodynamic requirements, and the aesthetic requirements of each vehicle model. To maintain proper angular orientation of the lamps with respect to the vehicle, headlamps are provided with aiming mechanisms. These mechanisms often serve to both aim and support the lamp.  
           [0004]    Aimable headlamps may be divided into two broad categories. This classification is made based on the member that must be tilted to aim the beam, i.e. the aimable component. In the first of these categories the complete headlamp unit, comprising an electric lighting bulb or bulbs, a reflector or reflectors, and a lens, is tilted relative to the vehicle or to a lamp housing fixed to the vehicle. In the second of these categories only the bulb(s) and reflector are tilted relative to the rest of the lamp assembly which is fixed to the vehicle.  
           [0005]    In either case, a typical aiming mechanism comprises three supports: one horizontal adjusting mechanism, one vertical adjusting mechanism, and one pivotal connection. The relative placement of the pivotal connection, the horizontal adjusting mechanism, and the vertical adjusting mechanisms are such that the horizontal adjuster adjusts horizontally and the vertical adjuster adjusts vertically, from the pivotal connection. This allows the two adjustment mechanisms to serve the function of providing means for adjusting the position of the lamp unit along both vertical and horizontal axes in relation to a support frame attached to the vehicle. In this manner, the direction of a light beam emanating from the lamp unit can be adjusted in a horizontal plane and in a vertical plane to achieve a desired direction of aim. Both the aiming adjustment mechanisms and the pivot connection are load-bearing in that they bear the weight of the lamp unit while supporting it within the support frame.  
           [0006]    Generally, the horizontal and vertical adjustment mechanisms comprise screws which support the lamp unit in a cantilevered relationship where one end of the screw is attached to the support frame while the other end is attached to the lamp unit. By axially rotating the screw, the point at which the screw is attached to the lamp unit is either moved towards or away from the support frame, depending on the direction of rotation. When the horizontal adjusting screw is thus rotated, the lamp pivots about the vertical adjusting screw and the pivot. Together, the vertical adjusting screw and pivot define the vertical axis of adjustment. In a similar fashion, when the vertical adjusting screw is axially rotated, the lamp unit pivots about its horizontal axis of adjustment, which is defined by the horizontal adjustment screw and the pivot.  
           [0007]    In the design and manufacture of vehicle lamps, it has been long recognized that even relatively small, incremental installation cost savings are desirable. This is so because lamp components are typically mass produced and installed. Consequently, over the long run these small savings may add up to substantial amounts. It is this savings that may differentiate one unit from the competition. Therefore, headlamp assemblies are designed to be economical from materials, parts, and installation perspectives.  
           [0008]    It has also been recognized that a pivot connection comprised of a ball and socket joint mounted to an appropriate housing part is effective for the purpose of providing pivotable retention. Such connectors are both economical to manufacture and easy to install. In addition, such assemblies provide the capability for removable and pivotable retention of the ball end, a characteristic useful during headlamp repair. Therefore, such arrangements are generally regarded as being particularly well suited for use as pivot connections in headlamps.  
           [0009]    Unfortunately, ball and socket arrangements are not without disadvantages. One significant disadvantage of these arrangements is that they comprise multiple parts. The assembly and installation of ball and socket arrangements can be both difficult and time consuming. Typically, the socket and ball stud portions are installed separately, aligned, and then joined. While successful, this approach is inefficient. Further, it may be difficult if space is limited within the vehicle. Thus, manufacturers have endeavored to arrange the components of such assemblies such that their installation is simplified. Further, manufacturers have endeavored to accomplish this goal in light of the previously mentioned business considerations.  
           [0010]    Accordingly, it is desirable to provide a ball and socket assembly wherein the socket may be mounted to the housing or mounting bracket with the ball stud already engaged in the socket basket. Additionally, it is desirable to provide a ball and socket assembly wherein the socket may be affixed to a ball-ended stud which is already threadedly retained to a reflector, and then locked to the housing or mounting bracket in some fashion. Moreover, it is desirable to provide a pivot assembly for use in a headlamp which is effective for its intended purpose, low in cost to manufacture, and simple to install. Finally, it is also desirable to provide a pivot assembly comprising the fewest components necessary to suitably retain the headlamp while providing for the desired adjustment.  
         BRIEF SUMMARY OF THE INVENTION  
         [0011]    The present invention comprises a mounting plug for pivotably connecting a first component to a second component. For example, in an exemplary embodiment described herein, the present invention comprises a mounting plug for pivotably connecting an aimable component of a headlamp of a vehicle to a fixed component of the vehicle, with the fixed component formed with an opening there through. An exemplary embodiment of the present invention further comprises a ball stud portion comprising a ball and a post. The post comprises means for attaching the ball stud portion to the aimable component of the headlamp. In an exemplary embodiment, such means comprises a threaded post.  
           [0012]    In an exemplary embodiment, the mounting plug further comprises a base, and a socket chamber integrally molded on top of the base. The socket chamber is adapted to removably retain the ball and to allow the ball stud portion to pivot. Moreover, an exemplary embodiment of the present invention further comprises a channel integrally molded to the base adjacent to the socket chamber. The channel is adapted to allow the ball to be inserted through the channel and into the socket chamber. A portion of the channel may be tapered.  
           [0013]    An exemplary embodiment of the present invention further comprises a retainer portion integrally molded below the base. The retainer portion comprises at least one tab integrally molded to the retainer portion and adapted to removably secure the socket portion to the fixed component of the vehicle. Furthermore, in exemplary embodiments of the present invention, the at least one tab may comprise a tapered ramp, a bridge section adjacent to the tapered ramp, and a vertical stop wall adjacent to the bridge section. In such exemplary embodiments, the socket portion is removably secured to the fixed component by twist-lock engagement of the tapered ramp and the bridge section of the at least one tab below the opening through the fixed component.  
           [0014]    Exemplary embodiments of the present invention may also comprise means for facilitating manual rotation of the retainer portion. For example, in the exemplary embodiment described herein, such means comprises a fin integrally molded on top of the base adjacent to the socket chamber and distal from the channel. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]    [0015]FIG. 1 is a front view of one exemplary embodiment of a headlamp mounting plug in accordance with the present invention;  
         [0016]    [0016]FIG. 2 is a side view of the exemplary embodiment of the headlamp mounting plug of FIG. 1;  
         [0017]    [0017]FIG. 3 is a front cross-sectional view of the exemplary embodiment of the headlamp mounting plug of FIG. 1;  
         [0018]    [0018]FIG. 4 is a side cross-sectional view of the exemplary embodiment of the headlamp mounting plug of FIG. 1;  
         [0019]    [0019]FIG. 5 is a top cross-sectional view of the exemplary embodiment of the headlamp mounting plug of FIG. 1;  
         [0020]    [0020]FIG. 6 is a bottom view of the exemplary embodiment of the headlamp mounting plug of FIG. 1;  
         [0021]    [0021]FIG. 7 is a side view of a ball socket portion of the exemplary embodiment of the headlamp mounting plug of FIG. 1;  
         [0022]    [0022]FIG. 8 is a front view of a socket portion of the exemplary embodiment of the headlamp mounting plug of FIG. 1;  
         [0023]    [0023]FIG. 9 is side view of the socket portion of the exemplary embodiment of the headlamp mounting plug of FIG. 1; and  
         [0024]    [0024]FIG. 10 is an exploded, perspective view of the exemplary embodiment of the headlamp mounting plug of FIG. 1. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0025]    [0025]FIGS. 1 through 6 show an exemplary embodiment of the headlamp retaining plug  10  of the present invention comprising a ball stud portion  30  and a socket portion  20 . An enlarged view of ball stud portion  30  is shown in FIG. 7. As can be seen in FIG. 7, ball stud portion  30  comprises ball  40 , post  50 , and washer  60 . In the exemplary embodiment of the present invention, ball  40  is substantially spherical in shape. At one end of ball  40 , distal from post  50 , is notch  65 . Notch  65  may be configured to accept any one of a number of driving mechanisms known in the art, such as a screwdriver. The specific configuration of notch  65  will be determined by the driving mechanism selected, but may, for example, be a slot, a phillips-head, a hexagon shape or a star shape.  
         [0026]    In the present exemplary embodiment, post  50  is threaded and configured to be screw-engaged to an aimable component of a headlamp, which could be any movable/pivotable headlamp component known in the art, such as a reflector in a reflector movable-type headlamp (not shown) or a headlamp housing in an aimable headlamp of the type where the entire headlamp is pivoted to aim (not shown). Additionally, post  50  could be configured to attach to these components using a number of fastening schemes known in the art, such as, for example, the threaded screw mechanism shown, a nut and bolt configuration, or a press fit configuration.  
         [0027]    Referring again to FIGS. 1 through 6, socket portion  20  comprises base  70 , socket chamber  80 , channel  90 , retainer portion  100 , fin  110 , and gasket  120 , each of which form one integrally molded piece. Socket chamber  80  is dimensioned and configured to accept ball  40  of ball stud portion  30  from channel  90  and to removably retain it as shown in FIG. 5. Socket chamber  80  is open on the side opposite base  70  to allow pivotable movement of ball stud portion  30 . This opening in socket chamber  80  is slightly smaller in diameter than ball  40 . Therefore, ball  40  is only insertable and removable horizontally via channel  90  and cannot be inserted or removed vertically.  
         [0028]    At the closed end, channel  90  has a substantially spherical cross-section dimensioned to accommodate ball  40  and is molded into the top surface of base  70 . Channel  90  is open on the side opposite base  70  to allow for passage of post  50  as ball  40  is slid horizontally through channel  90  and into socket chamber  80 . As shown in FIG. 5, the open top side of channel  90  is slightly tapered to further retain ball stud portion  30 .  
         [0029]    Socket portion  20  is integrally formed with and further comprises fin  110  extending radially outwardly from the side of socket chamber  80  directly opposite channel  90 . Fin  110  is configured to facilitate manual rotation of the socket portion to accomplish twist-lock engagement with a lamp housing as described below. While fin  110  is utilized in the exemplary embodiment described herein, it will be appreciated by those of ordinary skill in the art that other embodiments of the present invention may utilize other structure or means for facilitating manual rotation of the socket portion. By way of nonlimiting example, a post or small handle could be utilized instead of fin.  
         [0030]    As shown in FIG. 6, retainer portion  100  is integrally formed as the bottom of socket portion  20 . In the exemplary embodiment described herein, retainer portion  100  is circular in shape with a diameter slightly smaller than base  70 . Retainer portion  100  is configured to engage a housing or other fixed portion of the vehicle in a twist-lock fashion as described below. In the exemplary embodiment described herein, retainer portion  100  comprises two radially outwardly extending tabs  130  identical in size and configuration. Tabs  130  extend along the same axis as channel  90  and fin  110 . As shown in FIG. 9, each tab  130  comprises three sections, a tapered ramp  140 , a bridge section  150 , and a vertical stop wall  160 . Bridge section  150  joins tapered ramp  140  and vertical stop wall  160 . Tapered ramp  140  extends from bridge section  150  downwardly to its end. While the exemplary embodiment uses two tabs  130 , the number of tabs  130  used can be varied in other embodiments from one tab to any plurality of tabs.  
         [0031]    As shown in FIG. 6, socket portion  20  is also provided with gasket  120  to provide a weather-tight seal. Gasket  120  is generally ring-like in shape with an inner diameter and an outer diameter suitably sized to rest adjacent to base  70 . Gasket  120  is constructed from a flexible material such as, for example, rubber. The inner diameter of gasket  120  is approximately equal to the diameter of retainer portion  100 . The outer diameter is approximately equal to the diameter of base  70 . Base  70  is molded with two arc-shaped gasket seating features  190  which raise slightly off the bottom and outer edge surface of base  70 . During assembly, gasket  120  is stretched over tabs  130  and retainer portion  100  so that it is seated flat against base  70  and held in correct position by retainer portion  100 , gasket seating features  190 , and the top side of vertical stop wall  160 .  
         [0032]    [0032]FIG. 10 illustrates the assembly of ball stud portion  30  and socket portion  20  and their subsequent attachment to a representative fixed component  200 . Fixed component  200  is an example of a fixed piece to which the aimable component of the headlamp is anchored. For example, in an aimable headlamp where only a part of the headlamp is pivoted to aim, fixed component  200  is usually the headlamp housing. In a vehicle in which the entire headlamp assembly is pivoted to aim the light beam, fixed component  200  is usually a mounting bracket on the vehicle.  
         [0033]    Fixed component  200  contains opening  210 . Opening  210  is substantially circular with a diameter roughly equal to the diameter of retainer portion  100 . The diameter of opening  210  must be smaller than the diameter of base  70 . Opening  210  also includes two circumferentially spaced rectangular cutouts  220  dimensioned and configured to accommodate tabs  130 . The number of cutouts  220  in the exemplary embodiment is two, however, as noted previously, as the number of tabs  130  varies, the number of cutouts  220  will necessarily vary to correspond.  
         [0034]    Referring to FIG. 8 and FIG. 10, during assembly ball stud portion  30  is inserted into socket portion  20  along path A. Ball  40  is slid down channel  90  and into socket chamber  80 . Once in place, ball  40  is frictionally and removably retained in socket chamber  80 . Once ball stud portion  30  is in position, it is still allowed to pivot freely within socket chamber  80 . Then socket portion  20  is aligned such that tabs  130  align with cutouts  220 . Next, retainer portion  100  of socket portion  20  is inserted into opening  210  of fixed component  200  along path B. When retainer portion  100  is inserted into opening  210 , tabs  130  insert through cutouts  220 . The size of base  70  prevents socket portion  20  from being inserted too far into opening  210 .  
         [0035]    Once retainer portion  100  is inserted into opening  210 , socket portion  20  is rotated clockwise along arc-shaped path C, approximately one-quarter turn, by applying manual force to fin  110  and the walls of socket portion  20 . Initially this rotation causes tapered ramps  140  of tabs  130  to contact the edges of cutouts  220 . As socket portion  20  is rotated further, tapered ramps  140  force socket portion  20  toward fixed component  200 . This compresses gasket  120  between base  70  and fixed component  200  to form a tight environmental seal. Upon further clockwise rotation of socket portion  20 , stop walls  160  contact the edges of cutouts  220  and further retention is prevented. In this manner, twist-lock engagement of headlamp retaining plug with fixed component  200  is achieved. In the final engaged position of socket portion  20 , the edges of cutouts  220  are compressed against bridge section  150  of tabs  130 .  
         [0036]    The shape of socket portion  20  is advantageous in that it does not require a complex mold. Additionally, the twist-lock design of retainer portion  100  allows socket portion  20  to be mounted without the use of any additional mounting hardware, such as mechanical fasteners or adhesives, and without the use of any additional processes such as heat or sonic welding. By eliminating the need for additional components or assembly processes, the present invention improves the economic efficiency of production and assembly.  
         [0037]    The design of the present invention also allows flexibility in the manufacturing process. The design allows headlamp retaining plug  10  to be either fully assembled before connection of retaining portion  100  to the housing and before attachment of post  50  to the moveable portion of the headlamp, or it allows either of these connections to be completed before ball stud portion  30  is attached to socket portion  20 .  
         [0038]    Although the present invention has been described in considerable detail with reference to a certain exemplary embodiment thereof, such is offered by way of non-limiting example of the invention, as other versions are possible. It is anticipated that a variety of other modifications and changes will be apparent to those having ordinary skill in the art. Therefore, the spirit and scope of the appended claims should not be limited to the description of the exemplary embodiment contained herein, and the claims should be given the broadest possible interpretation to protect the novel features of the present invention.