U.S. patent number RE32,088 [Application Number 06/438,682] was granted by the patent office on 1986-02-25 for snap in coupling assembly for a vehicle headlamp.
This patent grant is currently assigned to General Electric Company. Invention is credited to Jiri G. Sip.
United States Patent |
RE32,088 |
Sip |
February 25, 1986 |
Snap in coupling assembly for a vehicle headlamp
Abstract
This invention relates to sealed beam headlamp units and more
particularly to a unitary coupling assembly for securing these
headlamp units to vehicles. The assembly includes a headlamp having
a plurality of couplers secured to the exterior surface thereof.
The couplers have curved mating surfaces, centered about point for
pivotal movement, which engage the surfaces of complementary
couplers secured to a vehicle. The couplers are lockingly secured
to each other and form a coupling for attaching the lamp to a
vehicle. In a preferred embodiment the assembly employs adjustable
couplers for the adjustable and/or preaimed attachment of a
headlamp to a vehicle.
Inventors: |
Sip; Jiri G. (Brunswick,
OH) |
Assignee: |
General Electric Company
(Schenectady, NY)
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Family
ID: |
26772618 |
Appl.
No.: |
06/438,682 |
Filed: |
November 3, 1982 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
085354 |
Oct 16, 1979 |
04318162 |
Mar 2, 1982 |
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Current U.S.
Class: |
362/549; 313/113;
362/273; 362/289; 362/350; 362/368; 362/427; 362/430; 362/528;
362/656 |
Current CPC
Class: |
B60Q
1/0683 (20130101) |
Current International
Class: |
B60Q
1/04 (20060101); B60Q 1/068 (20060101); F21V
019/02 () |
Field of
Search: |
;362/226,61,306,350,80,83,368,273,289,427,430 ;313/113 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2410073 |
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Sep 1975 |
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DE |
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1958761 |
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Nov 1978 |
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DE |
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2910489 |
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Oct 1979 |
|
DE |
|
1203574 |
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Mar 1958 |
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FR |
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2280026 |
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Feb 1976 |
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FR |
|
2421757 |
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Jul 1979 |
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FR |
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Primary Examiner: Nelson; Peter A.
Attorney, Agent or Firm: McDevitt; John F. Schlamp; Philip
L. Jacob; Fred
Claims
What I claim as new and desire to secure by United States Letters
Patent is: .[.1. A sealed beam vehicle headlamp assembly comprising
a lamp unit having a light source sealed within and focused
relative to an envelope including a reflector and a light
transmissive lens for producing a light beam having an axis
substantially parallel to the optical axis of said lamp unit, three
couplers directly and fixedly secured to the exterior surface of
said envelope in a triangular configuration, each of said couplers
having a curved mating surface which is substantially centered for
pivotal movement about a point, the points defining a plane
substantially perpendicular to the axis of said beam..]. .[.2. The
vehicle headlamp assembly of claim 1 wherein said couplers are
integral of said lamp envelope..]. .[.3. The vehicle headlamp
assembly of claim 2 wherein said couplers are integral with the
reflector portion of said envelope..]. .[.4. The vehicle headlamp
assembly of claim 1 wherein said couplers are attached to said lamp
envelope..]. .[.5. The vehicle headlamp assembly of claim 1 wherein
said couplers include receptacles for recessively
receiving and engagingly securing complementary vehicle
couplers..]. 6. .[.The.]. .Iadd.A sealed beam .Iaddend.vehicle
headlamp assembly .[.of claim 1.]. .Iadd.comprising a lamp unit
having a light source sealed within and focused relative to an
envelope including a reflector and a light transmissive lens for
producing a light beam having an axis substantially parallel to the
optical axis of said lamp unit, three separate couplers integral
with the exterior surface of said envelope and disposed about said
envelope in a triangular configuration, each of said couplers
having a substantially spherical mating surface defined by a ball
and socket joint which is substantially centered for pivotal
movement about a point, the points defining a plane substantially
perpendicular to the axis of said light beam, and said couplers
being disposed to provide both horizontal and vertical adjustment
of said light beam, .Iaddend.wherein said lamp couplers .[.are
fixed in relation to said lamp unit and.]. .Iadd.further
.Iaddend.include adjustment access openings .[.therethrough.].
.Iadd.extending through the socket element of the ball and socket
joint but not through the ball element of said joint.Iaddend..
.[.7. The vehicle headlamp assembly of claim 1 wherein said lamp
couplers include bosses for entrantly and lockingly engaging
complementary vehicle couplers..]. .[.8. The vehicle headlamp
assembly of claim 1 wherein said lamp couplers are adjustable
relative to said lamp unit..]. .[.9. The vehicle headlamp assembly
of claim 1 wherein the axes of at least two of said couplers are
substantially parallel to the optical axis of said lamp..]. .[.10.
The vehicle headlamp assembly of claim 1 wherein the axis of at
least one coupler is perpendicular to the beam axis..]. .Iadd.11. A
vehicle headlamp assembly comprising a lamp unit having a light
source within and focused relative to an envelope, a plurality of
lamp couplers on the exterior surface of said envelope, each of
said couplers having a substantially spherical mating surface
defined by a ball and socket joint, and at least one of said
couplers including an adjustment access opening extending through
the socket element of said ball and socket joint but not through
the ball element of said joint, and said couplers being disposed to
provide both horizontal and vertical adjustment of the light beam
emerging from said headlamp assembly. .Iaddend. .Iadd.12. The
vehicle headlamp and coupler assembly comprising a lamp unit having
a light source within and focused relative to an envelope, and a
plurality of lamp couplers on the exterior surface of said
envelope, each of said couplers having a substantially spherical
mating surface defined by a ball and socket joint, and at least one
of said couplers including an adjustment access opening extending
through the socket element of said ball and socket joint but not
through the ball element of said joint, said couplers being
disposed to provide both horizontal and vertical adjustment of the
light beam emerging from said headlamp assembly, and adjustment
means for receiving an adjustment tool through said adjustment
access opening of said lamp coupler. .Iaddend. .Iadd.13. The
vehicle headlamp assembly of claim 12, in which said adjustment
means comprises a notch. .Iaddend.
.Iadd.14. The vehicle headlamp assembly of claim 12, in which said
mating surfaces of the lamp couplers are concavely spherical, and
in which said vehicle couplers comprise spherical end regions
engaged in said mating surfaces. .Iaddend. .Iadd.15. The vehicle
headlamp assembly of claim 11 wherein said couplers include
receptacles for recessively receiving and engagingly securing
complementary snap-in vehicle couplers. .Iaddend.
Description
This application relates to co-pending applications Ser. Nos.
85,454, Oct. 16, 1979, 896,707, Apr. 17, 1978, now U.S. Pat. No.
4,210,841 issued July 1, 1980, 85,369, Oct. 16, 1979, 85,353, Oct.
16, 1979, 85,368, Oct. 16, 1979, the disclosures of which are
incorporated herein by reference.
This invention relates to sealed beam headlamp units and more
particularly to a unitary coupling assembly for securing these
headlamp units to vehicles. The assembly includes a headlamp having
a plurality of couplers secured to the exterior surface thereof.
The couplers have curved mating surfaces, centered about a point
for pivotal movement, which engage the surfaces of complementary
couplers secured to a vehicle. The couplers are lockingly secured
to each other and form a coupling for attaching the lamp to a
vehicle. In a preferred embodiment the assembly employs adjustable
couplers for the adjustable and/or preaimed attachment of a
headlamp to a vehicle.
Headlamp mounting arrangements customarily comprise a number of
heavy metal brackets and rims which structurally secure a headlamp
to a vehicle. The lamp envelope is clamped at the lens reflector
interface between a series of mounting rims, which are subsequently
attached to a mounting plate, which in turn is attached to the
vehicle. The headlamp is first attached to the vehicle and then
aimed relative thereto by turning the horizontal and vertical
adjustment screws located on the assembly. The mountings are
complicated and employ a considerable number of heavy metal parts
which add substantially to both vehicle weight and cost. The labor
costs of aiming and attaching a headlamp by these mounting
arrangements are substantial and further contribute to vehicle
costs.
The present invention provides an inexpensive headlamp assembly
which securely couples a lamp directly to a vehicle and eliminates
the need for more complicated constructions. The assembly provides
a simple low cost mounting which utilizes a minimum number of parts
and enables the one step attachment and aiming of a headlamp. The
assembly further provides for the snap fit assembly of the headlamp
to the vehicle to reduce labor costs.
The mounting assembly of the present invention and alternate
embodiments thereof provide a preaimed lamp assembly which
eliminates adjustment of the lamp after it has been attached to the
vehicle and hence reduces assembly costs.
The vehicle headlamp assembly also exhibits improved shock and
vibration absorption characteristics as compared with those of
customary mounting arrangements.
The assembly in a preferred embodiment comprises a sealed beam lamp
unit having a glass and/or polymer envelope which comprises a
reflector and a light transmissive face. A light source is sealed
within the envelope and focused relative thereto for producing a
desired beam pattern. A plurality of couplers are directly and
fixedly secured to the exterior surface of the envelope in a
triangular configuration. Each of the couplers has a curved mating
surface which is substantially centered about a point for pivotal
movement. The pivot points in combination define a plane
substantially perpendicular to the axis of the beam. The individual
couplers are alternately molded integral with the lamp envelope or
attached thereto by fasteners or cement.
The pivotal surfaces of the lamp couplers secured to the rim
lockingly engage the mating surfaces of complementary couplers
secured to a vehicle and thereby fixedly attach the lamp to the
vehicle.
Either or both the lamp and vehicle couplers can be adjustable,
and, as is apparent, a variety of pivotal couplers can be employed
in the assembly of the present invention.
In a preferred embodiment, the engaged complementary couplers form
a coupling which is generally described as a ball and socket joint.
Coupling provides a low cost light weight assembly which
predeterminedly aligns a lamp within a vehicle. The coupling thus
provides a snap fit connection which thereby reduces material and
labor costs.
In these embodiments the couplers positionally interface the lamp
and the forward vehicle structure. In still further embodiments
either some or all of the vehicle couplers and lamp couplers are
adjustable to enable optical alignment or realignment of the lamp
relative to the vehicle. Particularly, by referentially locating
the light source relative to the lamp envelope, having the lamp
couplers referentially secured thereto, and knowing the referential
disposition of the vehicle couplers, it is possible to optically
preaim the lamp assembly prior to its application to vehicle.
Replacement lamps are also preaimed or adjustably preaimed.
Additional means is provided for use in combination with the
coupling assembly for securing the lamp coupling and aim.
These other objects and features and a more complete understanding
of the aspects of this invention will be apparent from the
following detailed description which taken in conjunction with the
drawings represents a preferred embodiment of this invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of an assembly of the present invention
securing a rectangular headlamp to a vehicle.
FIG. 2 is a side perspective view of the assembly of the present
invention shown in exploded form.
FIG. 3 is a side perspective view of an embodiment of one of the
couplings.
DETAILED DESCRIPTION
Referring now to FIG. 1, a headlamp assembly 10 in accordance with
the present invention is shown in a front view. A sealed lamp unit
11 comprising an envelope 12 having a light source 13 sealed
therein and focused relative thereto, produces a light beam having
an axis substantially parallel to the axis of the lamp. The
headlamp assembly of the present invention secures the unit 10 to a
vehicle 14 such that a desired illumination pattern is directed
ahead of the vehicle 14. In particular embodiments of the present
invention, the headlamp assembly 10 securely and/or demountably
and/or adjustably couples the lamp unit 11 to the vehicle 14 such
that the lamp beam is aimed relative to the vehicle 14.
More particularly the headlamp unit 11 comprises a light source 13
sealed within an envelope 12, a reflector portion 15 of which is
particularly configured and reflectorized for the directional
control of reflected light and a further portion of which is
configured as a light transmissive face or lens 16. Lamps of this
type are disclosed in U.S. Pat. Nos. 2,148,314, 3,989,451 and
copending application Ser. No. 896,707 assigned to the assignee of
the present invention, the disclosures of which are incorporated
herein by reference. The envelopes 12 are formed from glass and/or
polymer materials.
The beam pattern produced by the lamp unit 11 is the combined
result of the interaction of the light source 13 with the envelope
12. Specifically, the light source 13 is positioned within the
envelope 12 to achieve an optically optimal light distribution and
hence the light source 13 is focused relative to the envelope 12
regardless of whether the light source 13 is located at the exact
geometric focus of the conical reflector 15. In particular, the
headlamp light source 13 is focused relative to the reflector 15
alone or alternatively is focused relative to the reflector 15 and
lens 16 in combination. In the former instance an optimal beam
pattern is established by the reflector 15 which is subsequently
modified by the lens prescription. The reflector 15 thus
structurally references the beam without regard for lens
tolerances. The beam axis thus substantially coincides with the
lamp axis. In the latter case, the light source 13 is adjusted
within an envelope 12 comprising both a lens 16 and reflector 15 to
produce an adequate beam pattern. Although the envelope focused
beam pattern is inherently less precise than the reflector focused
beam pattern the beam axis remains substantially parallel to the
optical axis of the envelope.
In either case the lamp beam is characterized by a plane which is
approximately orthogonal to the beam axis (Z axis, axis in the
major direction of its propogation). The reference plane is defined
conventionally, by the forward surfaces of the reference beads 18
located on the face of lamp 11. The bead surfaces are ground to
definitely establish a reference plane which orthogonally
characterizes the lamp beam. In particular, three beads are
employed on the lamp face wherein the surface of three beads
determine the plane.
The headlamp assembly 10 of the present invention is equally
applicable to either the above-focused headlamps although a
preferred embodiment employs the focused reflector lamp unit
inasmuch as the focused reflector unit optimizes the light output
of the lamp and always enables the exterior of the reflector to be
used as a reference.
The assembly 10 rigidly disposes the lamp unit 11 in the X-Y plane
while the Z disposition of the unit is either rigid, adjustable or
resilient.
The headlamp assembly 10 is generally comprised of a plurality of
discrete couplings which are secured to the exterior surface o the
lamp unit. The couplings comprise complementary lamp and vehicle
couplers which are secured to each other. Although one or two
complex-multi axis couplings can be employed in alternate
embodiments of the headlamp assembly 10, three single axis
couplings are preferred to inexpensively and rigidly dispose the
lamp unit 11 in a securely aimed position relative to the vehicle
14. In alternate embodiments, the individual couplers are
adjustable or nonadjustable, integral with or attached to their
respective structures. In particular, the lamp couplers are secured
directly to the envelope 12 of the lamp unit 11. Generally the axis
of the couplers is parallel to the beam axis through the axis of
one or more couplers can be perpendicular to the beam axis.
In FIG. 1, a front view of the coupling assembly 10 of the present
invention is disclosed wherein three couplings 21, 22 and 23
directly attach the lamp unit 11 to the vehicle 14 in a triangular,
planar reference such that the lamp beam is aimed to produce the
desired illumination ahead of the vehicle.
An individual coupling, for instance coupling 22, is either
stationary or adjustable and comprises a lamp coupler 25 and a
complementary vehicle coupler 26.
The lamp coupler 25 is alternatively integrally molded with the
lamp unit 10 or attached hereto by cement and/or other fasteners.
The lamp coupler 25 as shown is referentially disposed relative to
the reflector 15 of the envelope 12, however it is equally possible
to referentially dispose the lamp coupler 25 relative to the
envelope lens 16. The lamp coupler 25 generally comprises a support
27 having a curved mating surface 28 for lockingly engaging the
complementary mating surface 31 of a vehicle coupler 26 to
lockingly secure the lamp unit 11 to the vehicle 14. The curved
mating surfaces 28 and 31 are substantially centered for pivotal
movement about a point. The pivot points of the couplings 21, 22,
and 23 taken in combination define a reference plane substantially
orthogonal to the axis of the beam. Specifically the pivot points
are not constrained to be points within the interior of couplers 25
or 26 but are any points which establish a reference plane which is
substantially orthogonal to the beam axis. Accordingly, the
couplers 25 and 26 and their respective mating surfaces 28 and 31
can be formed in a number of different configurations provided the
configuration is centered about a point. In a preferred embodiment,
the surfaces 28 and 31 are curved to facilitate pivotal movement of
the couplers 25 and 26 during adjustment.
In the particular embodiment shown in FIG. 1, the lamp coupler 25
comprises a support 27 and socket 29 having a substantially
spherical mating surface 28 for receiving a portion of the vehicle
coupler 26 therein.
The vehicle coupler 26 comprises a cylindrical shaft 30 having an
anterior boss 32 which complements and is snuggly received within
the lamp coupler 25 to lockingly secure the lamp unit 11 to the
vehicle 14. The cylindrical shaft 30 is permanently or adjustably
secured to the vehicle 14 by, for instance, welding or threading
the shaft to the vehicle 14. The vehicle coupler 26 is shown as
being adjustable. The cylindrical shaft 30 is threaded at its
posterior end to snuggly engage an opening in the vehicle 14. The
boss 32 has a notch 33 for receiving a tool therein for axially
rotating the vehicle coupler 26 such that the vehicle coupler 26
and particularly boss 32 having a lamp coupler 25 secured thereto
is axially moved closer to or farther from the vehicle 14. The
referential disposition of the lamp 11 relative to the vehicle 14
is thus adjusted and hence the lamp beam is aimed or reaimed
relative to the vehicle 14. An access channel 34 through the lamp
coupler 25 enables the vehicle coupler to be adjusted from the
front of the lamp 11.
An alternate embodiment of the present invention is disclosed by
lamp coupling 21 wherein the coupling 22 is reversed such that the
coupling comprising a cylindrical shaft and a boss is adjustably
secured to the lamp unit while the socket coupler is secured to the
vehicle structure. In this embodiment it is possible to preadjust
the lamp couplers such that if the referential positioning of the
vehicle couplers is known, the headlamp is preaimed relative to the
vehicle.
In this embodiment, a single lamp unit is preadjusted to adapt to a
variety of different vehicle structures as might be found on
different model cars.
Referring now to FIG. 3, it will be noted that not all couplers
must be adjustable or axially disposed parallel to the beam axis.
More particularly, the coupling 23 provides a pivot joint having an
axis which is perpendicular to the beam axis. The coupling comprise
a lamp coupler and a vehicle coupler having mating surfaces
centered about a point as described above in connection with
coupling 22. In this particular embodiment, the lamp coupler
comprises a socket 37 integrally molded to the lamp unit 11
perpendicular to the beam axis. The vehicle coupler comprises a
cylindrical shaft 38 having a boss 39 at the anterior end thereof
for lockingly engaging the lamp coupler socket 37 in pivotal
relation. The posterior end 36 of the vehicle coupler is fixedly
attached to the vehicle 14.
The locking engagement of some or all of the couplings 21, 22, and
23 is enhanced by the addition of a retaining means such as a ring
35 which is slipped over the coupling connection and lockingly
engages the exterior surface thereof. Although a variety of
different retaining means may be employed in connection with the
couplings of the present invention, it is advantageous to employ a
removable retaining means such that the couplings can be disengaged
to demount the headlamp to for instance replace the lamp unit.
In a preferred embodiment the couplings 21 and 22 are adjustable
while the third coupling 23 is pivotal. The headlamp 11 is first
snapped onto the coupling 23 and subsequently snapped onto the
couplings 21 and 22. The headlamp 11 is thus rigidly disposed
within the vehicle 14 in a triangular, planar reference such that
the lamp unit 11 is aimed relative to the vehicle 14. Adjustment of
the couplings 21 and 22 permits further reaiming or alignment of
the beam to provide the desired illumination ahead of the
vehicle.
The system of three couplings has particular utility in that a
minimum number of couplers is employed to attach and aim the
headlamp 11. More particularly, if the pivot points of couplers 21
and 23 are in a line parallel to the horizontal axis of the
reference plane of the lamp, adjustment of coupling 22 rotates the
lamp unit 11 about this axis such that the beam is moved up or down
along the vertical axis. Similarly, the pivot points of couplings
22 and 23 establish an axis about which coupling 21 rotates the
lamp. As shown, coupling 21 effects both horizontal and vertical
adjustment of the lamp 11. Coupling 21 can be dedicated to
horizontal adjustment by for instance moving coupling 22 to the
corner of the lamp unit adjacent to pivotal coupling such that
couplings 22 and 23 have point contacts along an axis parallel to
the vertical axis of the lamp.
It will be appreciated that the present invention provides an
extremely quick simple and economical assembly for mounting a lamp
to a vehicle forward structure. Although the present invention has
been described with reference to a seal beam lamp unit, it is
readily apparent that the coupling assembly of the present
invention may be used in combination with a variety of lamp unit
where a precise positioning is needed. In the particular vehicle
structure environment of the present lamp assembly, the present
coupled headlamp assembly yields surprising advantages. The
assembly provide a quick and inexpensive means for demountably and
fixedly attaching a lamp unit to the forward structure of a
vehicle. Further, in alternate embodiments of the present
invention, the lamp unit assembly can provide for the adjustable
and aimable positioning of the lamp unit relative to the forward
vehicle structure.
Although the invention has been described in its preferred form
with a certain degree of particularity, it is understood that the
present disclosure of the preferred embodiment has been made only
by way of example and that various changes in the details of
construction may be resorted to without departing from the true
spirit and scope of the invention as hereinafter claimed. It is
intended that the patent shall cover, by suitable expression in the
appended claims, whatever features of patentable novelty exist in
the invention disclosed.
* * * * *