Patent Publication Number: US-9903556-B2

Title: Light assembly with concurrently rotating masks

Description:
TECHNICAL FIELD 
     The disclosure generally relates to a light assembly, and more particularly to a headlamp assembly for a vehicle. 
     BACKGROUND 
     Vehicles may include a light assembly disposed near a forward end of the vehicle for illuminating the forward direction of the vehicle. These forward facing light assemblies may be referred to as a headlamp assembly or a headlight. Each light assembly may be equipped with multiple LED light modules used for a high beam function, and multiple LED light modules used for a low beam function. The light assembly is an important part of the aesthetics of the vehicle. Many drivers desire that the light assembly provides a unique and distinctive look to the vehicle. 
     SUMMARY 
     A headlamp assembly is provided. The headlamp assembly includes a carrier, and at least one light module attached to the carrier and operable to emit light. A stationary bezel is attached to the carrier. The stationary bezel defines an opening, through which light from at least one light module passes. A first rotating mask is rotatably attached to the carrier for rotation about a rotation axis, relative to the stationary bezel. A second rotating mask is rotatably attached to the carrier for rotation about the rotation axis, relative to the stationary bezel. A drive system is coupled to and interconnects the first rotating mask and the second rotating mask. The drive system is operable to rotate the first rotating mask between an open position and a closed position, and rotate the second rotating mask between an open position and a closed position. The first rotating mask and the second rotating mask are positioned clear of the opening in the stationary bezel when disposed in their respective open positions, to allow light from at least one light module through the opening. The first rotating mask and the second rotating mask are positioned in the opening of the stationary bezel to conceal the light modules when disposed in their respective closed positions. 
     A light assembly is also provided. The light assembly includes a carrier, and a plurality of light modules that are attached to the carrier. The light modules are operable to emit light, and are stacked relative to each other along a rotation axis. A stationary bezel is attached to the carrier. The stationary bezel defines an opening, through which light from the plurality of light modules passes. A first rotating mask is rotatably attached to the carrier for rotation about the rotation axis, relative to the stationary bezel. A second rotating mask is rotatably attached to the carrier for rotation about the rotation axis, relative to the stationary bezel. A drive system is coupled to and interconnects the first rotating mask and the second rotating mask. The drive system includes a drive gear in meshing engagement with each of the first rotating mask and the second rotating mask. The drive gear is operable to simultaneously rotate the first rotating mask between an open position and a closed position, and the second rotating mask between an open position and a closed position. 
     Accordingly, the first rotating mask and the second rotating mask may be rotated between their respective open positions to allow light through the opening of the stationary bezel when light is required, and their respective closed positions to conceal the light modules, and provide unique aesthetics to the vehicle when light from the light modules is not required. 
     The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the teachings when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic, partially cut away side view from a side of a light assembly. 
         FIG. 2  is a schematic plan view from a front of the light assembly, showing a first rotating mask and a second rotating mask in respective open positions. 
         FIG. 3  is a schematic cross sectional view of the light assembly showing the first rotating mask and the second rotating mask in their respective open positions. 
         FIG. 4  is a schematic plan view from the front of the light assembly, showing the first rotating mask and the second rotating mask in respective closed positions. 
         FIG. 5  is a schematic cross sectional view of the light assembly showing the first rotating mask and the second rotating mask in their respective closed positions. 
         FIG. 6  is a schematic, partial cross sectional view of the light assembly. 
         FIG. 7  is a schematic, partial cross sectional view of the light assembly. 
         FIG. 8  is a schematic, partial perspective view of the light assembly showing a lower rack gear of the first rotating mask in meshing engagement with a drive gear of a motor. 
         FIG. 9  is a schematic, partial perspective view of the light assembly showing an upper rack gear of the second rotating mask in meshing engagement with the drive gear of the motor. 
         FIG. 10  is a schematic cross sectional view of the light assembly from a first direction. 
         FIG. 11  is a schematic cross sectional view of the light assembly from a second direction. 
     
    
    
     DETAILED DESCRIPTION 
     Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are used descriptively for the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. 
     Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a light assembly is generally shown at  20 . The light assembly  20  may be configured for any suitable use. For example, the light assembly  20  may be configured as a front headlamp for a vehicle, such as shown in the Figures. However, it should be appreciated that the light assembly  20  may be configured for some other application, such as but not limited to a boat, a motorcycle, a streetlight, etc. 
     Referring to  FIG. 1 , the light assembly  20  includes a housing  22 . As shown in the exemplary embodiment of the Figures, the housing  22  is configured for attachment to a body of a vehicle. However, other applications may require that the housing  22  be configured differently than shown herein. The housing  22  is manufactured from a rigid material, such as but not limited to a plastic material. The housing  22  supports the various components of the light assembly  20 , and provides a rearward or back cover for the components. A lens  24  is attached to and supported by the housing  22 . The lens  24  is manufactured from a clear material, such as but not limited to a polycarbonate material. The lens  24  provides a front cover for the components of the light assembly  20 , and allows the light to pass through. The housing  22  and the lens  24  cooperate to define an enclosed interior region  26  therebetween, which encloses the components of the light assembly  20  and protects them from moisture, dirt, and debris. 
     The light assembly  20  includes a carrier  28 . The carrier  28  is attached to and supported by the housing  22 . As shown in the Figures, the exemplary embodiment of the light assembly  20  is configured in a generally vertical orientation, such that the carrier  28  extends along a rotation axis  30 , between a lower end  32  and an upper end  34 . As shown in the exemplary embodiment of the Figures, the upper end  34  of the carrier  28  is disposed at a higher elevation than the lower end  32  of the carrier  28 . However, it should be appreciated that the light assembly  20  may be configured in a horizontal arrangement, in which case the upper end  34  and the lower end  32  of the carrier  28  would be disposed at generally the same elevation. The carrier  28  may be attached to the housing  22  in any suitable manner. For example, the carrier  28  may be rotatably attached to the housing  22  to allow for aiming the light assembly  20 . Alternatively, the carrier  28  may be fixedly attached to the housing  22 , i.e., non-rotatable relative to the housing  22 . 
     The light assembly  20  includes at least one light module  36 . Preferably, and as shown, the light assembly  20  includes a plurality of light modules  36  stacked relative to each other along the rotation axis  30 . As shown in the Figures, the exemplary embodiment of the light assembly  20  includes at least one low beam light module  36 A, and at least one high beam light module  36 B. More specifically, the exemplary embodiment includes two low beam light modules  36 A and three high beam light modules  36 B. Each of the light modules  36  (including the low beam light modules  36 A and the high beam light modules  36 B shown in the Figures) is attached to the carrier  28 , and is operable to emit light. The light modules  36  may be attached to the carrier  28  in any suitable manner. The light modules  36 , including both the low beam light modules  36 A and the high beam light modules  36 B are referred to generally by the reference numeral  36 , whereas the low beam light modules  36 A are referred to specifically with the reference numeral  36 A, and the high beam light modules  36 B are referred to specifically by the reference numeral  36 B. In the exemplary embodiment, each of the low beam light modules  36 A and the high beam light modules  36 B include a Light Emitting Diode (LED). However, the low beam light modules  36 A and the high beam light modules  36 B may each include other types of light producing modules, other than the LED modules described herein. 
     Referring to  FIG. 2 , a stationary bezel  38  is fixedly attached to the carrier  28 . The stationary bezel  38  is non-rotatable relative to the carrier  28 . The stationary bezel  38  extends along the rotation axis  30 , and defines an opening  40  through which light from the light modules  36  passes. The opening  40  is sized to generally frame the light modules  36 . Accordingly, the exact size of the opening  40  depends on the number and size of the light modules  36 . 
     Referring to  FIGS. 3 and 5 , the light assembly  20  includes a first rotating mask  42 , and a second rotating mask  44 . The first rotating mask  42  is rotatably supported for rotation about the rotation axis  30 , relative to the stationary bezel  38 . Referring to  FIG. 11 , the first rotating mask  42  includes a lower arm portion  46 A, an upper arm portion  48 A, and a wall portion  50 A. The upper arm portion  48 A and the lower arm portion  46 A of the first rotating mask  42  each extend generally transverse to and away from the rotation axis  30 . The wall portion  50 A of the first rotating mask  42  extends between the lower arm portion  46 A and the upper arm portion  48 A of the first rotating mask  42 , generally parallel with the rotation axis  30 . The wall portion  50 A of the first rotating mask  42  is radially spaced from the rotation axis  30 , and is disposed adjacent a first edge  52  of the opening  40  in stationary bezel  38 , shown in  FIGS. 4 and 5 . 
     The second rotating mask  44  is rotatably supported for rotation about the rotation axis  30 , relative to the stationary bezel  38 . Referring to  FIG. 10 , the second rotating mask  44  includes a lower arm portion  46 B, an upper arm portion  48 B, and a wall portion  50 B. The upper arm portion  48 B and the lower arm portion  46 B of the second rotating mask  44  each extend generally transverse to and away from the rotation axis  30 . The wall portion  50 B of the second rotating mask  44  extends between the lower arm portion  46 B and the upper arm portion  48 B of the second rotating mask  44 , generally parallel with the rotation axis  30 . The wall portion  50 B of the second rotating mask  44  is radially spaced from the rotation axis  30 , and is disposed adjacent a second edge  54  of the opening  40  in stationary bezel  38 , shown in  FIGS. 4 and 5 . The first edge  52  and the second edge  54  of the opening  40  are parallel with each other, are disposed on opposite sides of the opening  40 , and extend along and generally parallel with the rotation axis  30 . 
     The light assembly  20  includes a drive system  56  that is coupled to and interconnects the first rotating mask  42  and the second rotating mask  44 . The drive system  56  is operable to rotate the first rotating mask  42  between an open position, best shown in  FIGS. 2 and 3 , and a closed position, best shown in  FIGS. 4 and 5 , and rotate the second rotating mask  44  between an open position, best shown in  FIGS. 2 and 3 , and a closed position, best shown in  FIGS. 4 and 5 . The drive system  56  simultaneously rotates the first rotating mask  42  and the second rotating mask  44  between their respective open positions and closed positions. Accordingly, the drive system  56  simultaneously rotates both the first rotating mask  42  and the second rotating mask  44  into their respective open position, or operates in reverse to simultaneously rotate the first rotating mask  42  and the second rotating mask  44  into their respective closed position. 
     Referring to  FIGS. 2 and 3 , the first rotating mask  42  and the second rotating mask  44  are positioned clear of the opening  40  in the stationary bezel  38 , when disposed in their respective open positions, to allow light from the light modules  36  to shine through the opening  40 . When disposed in their respective open positions, the first rotating mask  42  and the second rotating mask  44  are positioned behind respective sides of the stationary bezel  38 , so as to not block the opening  40  in the stationary bezel  38 . As shown in  FIGS. 3 and 5 , in the cross sections perpendicular to the rotation axis  30 , each of the stationary bezel  38 , the first rotating mask  42  and the second rotating mask  44  include an arcuate cross sectional shape, so that the first rotating mask  42  and the second rotating mask  44  may nestle closely against the stationary bezel  38  when disposed in their respective open positions. Referring to  FIGS. 4 and 5 , the first rotating mask  42  and the second rotating mask  44  are positioned in the opening  40  of the stationary bezel  38  to conceal the light modules  36  when disposed in their respective closed positions. Accordingly, when the first rotating mask  42  and the second rotating mask  44  are positioned in their respective closed position, the light modules  36  are not visible from the exterior of the light assembly  20 . 
     Referring to  FIG. 7 , the drive system  56  includes a motor  58 . The motor  58  includes an output  60  that is rotatable about a drive axis  62 . The drive axis  62  is substantially perpendicular to the rotation axis  30 . Preferably, the motor  58  includes an electric motor. However, it should be appreciated that the motor  58  may include some other device capable of providing a rotational output  60 , such as a pneumatic device, a hydraulic device, or a vacuum operated device. A drive gear  64  is attached to the output  60  of the motor  58 . The drive gear  64  is rotatably driven by the output  60  of the motor  58  for rotation about the drive axis  62 . 
     Referring to  FIG. 8 , the first rotating mask  42  includes a lower gear rack  66  that is disposed in meshing engagement with the drive gear  64 . It should be appreciated that  FIG. 8  shows the first rotating mask  42  and the stationary bezel  38 , and omits other components of the light assembly  20 , such as the second rotating bevel, for clarity. Referring to  FIG. 9 , the second rotating mask  44  includes an upper gear rack  68  that is disposed in meshing engagement with the drive gear  64 . It should be appreciated that  FIG. 9  shows the second rotating mask  44  and the stationary bezel  38 , and omits other components of the light assembly  20 , such as the first rotating mask  42 , for clarity. As best shown in  FIG. 7 , the upper gear rack  68  and the lower gear rack  66  are disposed opposite each other, with the drive gear  64  disposed between the upper gear rack  68  and the lower gear rack  66 . Accordingly, rotation of the drive gear  64  in one direction simultaneously rotates the first rotating mask  42  and the second rotating mask  44  in opposite rotational directions about the rotation axis  30 . 
     Referring to  FIG. 7 , the lower gear rack  66  and the upper gear rack  68  are each radially spaced from the rotation axis  30  a rack distance  70 . Additionally, as best shown in  FIGS. 8 and 9 , the lower gear rack  66  and the upper gear rack  68  are each disposed in an arcuate configuration perpendicular to the rotation axis  30 . As shown in  FIG. 7 , the wall portion  50 A of the first rotating mask  42  is radially spaced from the rotation axis  30  a wall distance  72  that is greater than the rack distance  70  between the rotation axis  30  and the lower gear rack  66  of the first rotating mask  42 . Similarly, the wall portion  50 B of the second rotating mask  44  is radially spaced from the rotation axis  30  the wall distance  72  that is greater than the rack distance  70  between the rotation axis  30  and the upper gear rack  68  of the second rotating mask  44 . This relative spacing difference increases or magnifies the circumferential distance that the wall portions  50 A,  50 B are moved relative to the movement of the gear racks. In other words, a small movement of the upper gear rack  68  and the lower gear rack  66  around the rotational axis provides a greater movement in the wall portions  50 A,  50 B of the first rotating mask  42  and the second rotating mask  44 . 
     As noted above, the first rotating mask  42  and the second rotating mask  44  are each rotatably supported for rotation about the rotation axis  30 . As shown in the exemplary embodiment described herein, the first rotating mask  42  and the second rotating mask  44  are each rotatably attached to the stationary bezel  38  for rotation about the rotation axis  30 . However, it should be appreciated that the first rotating mask  42  and the second rotating mask  44  may be rotatably supported for rotation about the rotation axis  30  in some other manner not shown or described herein. The first rotating mask  42  and the second rotating mask  44  may be rotatably attached to the stationary bezel  38  in any suitable manner. For example, and as shown in  FIG. 7 , the light assembly  20  may include a lower pin  74  that is concentric with the rotation axis  30 , and interconnects the first rotating mask  42  and the second rotating mask  44  with the stationary bezel  38 , to form a lower rotatable connection. A bushing  76  may be disposed between the lower pin  74  and the first rotating mask  42 , and the second rotating mask  44 . The lower pin  74  may include, but is not limited to, a bolt, threaded rod, or other similar device capable of securing the first rotating mask  42  and the second rotating mask  44  to each other and to the stationary bezel  38 . Similarly, referring to  FIG. 6 , the light assembly  20  may include an upper pin  78  that is concentric with the rotation axis  30 , and interconnects the first rotating mask  42  and the second rotating mask  44  with the stationary bezel  38 , to form an upper rotatable connection. The upper pin  78  may include, but is not limited to, a bolt, threaded rod, push pin, or other similar device capable of securing the first rotating mask  42  and the second rotating mask  44  to each other and to the stationary bezel  38 . 
     In operation, rotation of the drive gear  64  about the drive axis  62  in an opening rotational direction  80  rotates the first rotating mask  42  about the rotation axis  30  in a first rotational direction  82 , and rotates the second rotating mask  44  about the rotation axis  30  in a second rotational direction  84 . The second rotational direction  84  is opposite the first rotational direction  82 . Rotation of the drive gear  64  in the opening rotational direction  80  moves the first rotating mask  42  and the second rotating mask  44  into their respective open positions. In contrast, rotation of the drive gear  64  bout the drive axis  62  in a closing rotational direction  86 , opposite the opening rotational direction  80 , rotates the first rotating mask  42  about the rotation axis  30  in the second rotational direction  84 , and the second rotating mask  44  about the rotation axis  30  in the first rotational direction  82 . Rotation of the drive gear  64  in the closing rotational direction  86  moves the first rotating mask  42  and the second rotating mask  44  into their respective closed positions. 
     The detailed description and the drawings or figures are supportive and descriptive of the disclosure, but the scope of the disclosure is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed teachings have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims.