Patent Publication Number: US-2007121337-A1

Title: Headlamp reflector linkage

Description:
FIELD OF THE INVENTION  
      This invention relates to a headlamp assembly for a motor vehicle. More particularly, the invention relates to a headlamp assembly including a connecting bar for allowing simultaneous pivotal adjustment of high and low beam reflectors.  
     DESCRIPTION OF THE RELATED ART  
      A headlamp assembly for a motor vehicle generally includes high and low beam reflectors disposed within a housing for aiming and shaping light from the headlamp. The headlamp assembly also includes two adjustment systems, one for the high beam reflector and the other for the low beam reflector, for adjusting the position, and thus aim, of the high and low beam reflectors. Each adjustment system typically includes a hinge secured to the housing and an adjustment mechanism for pivoting the reflector about the hinge.  
      The use of separate adjustment mechanisms presents, however, a problem when adjusting the position of the high and low beam reflectors. Since each reflector must be adjusted independently, it is difficult to accurately position the high and low beam reflectors relative to one another. Also, since many motor vehicles have two headlamp assemblies, a total of four reflectors must be independently adjusted. This independent adjustment can result in variation between the positions of the various reflectors.  
      The multiple adjustment mechanisms also add to the cost and complexity of the headlamp assembly. Reducing the number of adjustment mechanisms in the headlamp assembly would, therefore, be cost-effective and more efficient from a manufacturing standpoint.  
      Thus, there remains a need for a headlamp assembly having a single adjustment mechanism for simultaneously adjusting a high and a low beam reflector.  
     SUMMARY OF THE INVENTION  
      According to one aspect of the invention, a headlamp assembly for a motor vehicle includes a housing, and first and second reflectors pivotally secured to the housing. Additionally, the headlamp assembly includes a connecting bar extending between the first and second reflectors for pivotally adjusting the first reflector in response to pivotal adjustment of the second reflector. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:  
       FIG. 1  is a perspective view of a motor vehicle including a headlamp assembly according to the invention;  
       FIG. 2  is a perspective view of the headlamp assembly; and  
       FIG. 3  is an exploded, perspective view of the headlamp assembly. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
      Referring to  FIG. 1 , a headlamp assembly for a motor vehicle  11  is generally shown at  10 . The headlamp assembly  10  provides illumination of a road surface immediately in front of the motor vehicle  11 .  
      Referring to  FIG. 2 , the headlamp assembly  10  includes a housing  12 . The headlamp assembly  10  also includes first  14  and second  16  reflectors disposed within the housing  12 . In a preferred embodiment, the first reflector is a high beam reflector  14  and the second reflector is a low beam reflector  16 . Bulbs  15 ,  17 , mounts inside each of the high  14  and low  16  beam reflectors. The high  14  and low  16  beam reflectors focus and aim the light emitted by the electric lamps.  
      The housing  12  is generally concave and is molded to provide mounting surfaces for the beam reflectors  14 ,  16 . Additionally, the housing  12  is configured to enable light bulbs or other suitable light sources to be mounted thereon. The general contouring of housing  12  is dictated primarily by the vehicle styling. The housing  12  has a plurality of high beam reflector mounting clips  18 ,  20  fixedly secured thereto and located relative to a high beam mounting embossment  19 . In the preferred embodiment, the plurality of high beam reflector mounting clips  18 ,  20  is integrally formed as part of the housing  12 .  
      The housing  12  further includes a plurality of low beam reflector mounting clips  30 ,  32  fixedly secured thereto and mounted relative to a low beam light source mounting embossment  21 . In the preferred embodiment, the plurality of low beam reflector mounting clips  30 ,  32  is integrally formed as part of the housing  12 .  
      Referring to  FIG. 3 , the high beam reflector  14  is generally concave and is coated with a reflective coating. The base of the reflector  14  has a plurality of hinge posts  24 ,  26 , which together define a high beam reflector rotation axis  28 . Each of the plurality of hinge posts  24 ,  26  is pivotally secured to the housing  12  at one of the plurality of high beam reflector mounting clips  18 ,  20 . The high beam reflector  14  also includes a connecting bar mount  22  at an end opposite the hinge post  24 ,  26 . A ball socket  50  is fixedly secured to the connecting bar mount  22 .  
      The low beam reflector  16  is generally concave and is coated with a reflective coating. The base of the low beam reflector  16  has a plurality of hinge posts  38 ,  40 , which together define a low beam reflector rotation axis  42 . Preferably, the axis  42  is staggered rearwardly of the low beam rotation axis  28 , enabling the low beam reflector to be positioned outboard and rearwardly of the high beam reflector  14 . Each of the plurality of hinge posts  38 ,  40  is pivotally secured to one of the plurality low beam reflector mounting clips  30 ,  32  to pivot the low beam reflector  16  about the low beam reflector rotation axis  42 . The low beam reflector  16  also includes a hinge pin  34  and an adjustment mechanism mount  36  opposite the hinge posts  38 ,  40 . A ball socket  62  is fixedly secured to the adjustment mechanism mount  36 .  
      Although mounting clips and hinge posts are shown for pivotally mounting the high  14  and low  16  beam reflectors relative to the housing  12 , it will be appreciated that numerous alternative pivotal attachment systems could be used to pivot the high  14  and low  16  beam reflectors.  
      A connecting bar  44  extends between the high  14  and low  16  beam reflectors. The connecting bar  44  includes a spherical ball at one end thereof  46  and a hinge clip  48  at an opposing end. The spherical ball  46  is connected to the ball socket  50  to pivotally secure the connecting bar  44  to the high beam reflector  14 . Although a ball and socket connection is shown, it will be appreciated that any pivotal attachment system could be used to mount the connecting bar  44  to the high beam reflector  14 .  
      The hinge clip  48  of the connecting bar  44  is connected to the hinge pin  34  of the low beam reflector  16  to pivotally secure the connecting bar  44  to the low beam reflector  16 . Although a hinge clip and a hinge pin are shown, it will be appreciated that any pivotal attachment system could be used to mount the connecting bar  44  to the low beam reflector  16 .  
      An adjustment mechanism  52 , as commonly known to those skilled in the art, is fixedly secured to the housing  12 , and includes a control rod  54  and a crank  56 . The control rod  54  has a spherical ball  58  at a distal end  59 , and defines a control rod axis  60 . The ball  58  is secured to the ball socket  62  to pivotally mount the adjustment mechanism  52  to the low beam reflector  16 .  
      In operation, movement of the high  14  and low  16  beam reflectors is accomplished by varying the position of the control rod  54  of the adjustment mechanism  52  longitudinally along the control rod axis  60 . Turning the crank  56  clockwise causes the control rod  54  to extend outward from the adjustment mechanism  52  along the control rod axis  60 . The movement of the control rod  54  along the control rod axis  60  causes the low beam reflector  16  to rotate counterclockwise about the low beam reflector rotation axis  42 . The movement of the low beam reflector  16  compresses the connecting bar  44 . In response, the high beam reflector  14  rotates in a counterclockwise direction about the high beam reflector rotation axis  28 .  
      Conversely, turning the crank  56  of the adjustment mechanism  52  counterclockwise causes the control rod  54  to retract inward towards the adjustment mechanism  52  along the control rod axis  60 . The inward movement of the control rod  54  along the control rod axis  60  causes the low beam reflector  16  to rotate clockwise about the low beam reflector rotation axis  42 . The movement of the low beam reflector  16  tensions the connecting bar  44 . In response, the high beam reflector  14  rotates in a counterclockwise direction about the high beam reflector rotation axis  28 .  
      Thus, the single adjustment mechanism  52  allows for simultaneous pivotal adjustment of both the high  14  and low  16  beam reflectors. More importantly, the single adjustment mechanism enables the light assembly  10  to have a high aspect ratio to accommodate the sweep design trend in current vehicle styling.  
      Alternatively, the adjustment mechanism  52  could replace the connecting bar  44  and extend between the high  14  and low  16  beam reflectors. The adjustment mechanism  52  is provided with an extended control rod  54  that extends between the high  14  and low  16  beam reflectors. Activation of the adjustment mechanism  52  simultaneously pivots the high  14  and low  16  beam reflectors to aim the light beams projected by light bulbs  15 ,  17 .  
      The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.