MXPA00008666A - Headlamp adjustor and method - Google Patents

Abstract

A headlamp adjustor which includes an adjustor output shaft that is engageable with a reflector of a headlamp assembly. The adjustor output shaft extends from a housing, and a worm gear generally in the housing is spur gearably engaged with the adjustor output shaft. Drive structure is engaged with the worm gear such that actuation of the drive structure causes at least a portion of the drive structure to thread into at least a portion of the worm gear, thereby causing the adjustor output shaft to translate relative to the housing and adjust the position of the headlamp reflector.

Description

ADJUSTER AND METHOD FOR FRONT HEADLIGHT DESCRIPTION OF THE INVENTION The present invention is generally related to headlight adjusters that are used to adjust the position of a reflector of a headlight assembly, and is more specifically related to a headlight adjuster that includes a self-tapping screw. The present invention is also generally related to methods for adjusting the position of a reflector of a headlight assembly, and is more specifically related to a method for adjusting the position of a reflector of a headlight assembly where the method includes a stage to rotate a driving screw to form a thread or helical gear and to effect the rotation of the helical gear to obtain a change in the position of the reflector. The present invention is also generally related to methods for making headlight adjusters, and is more specifically related to a method of making a headlight adjuster wherein the method includes a step for screwing a helical gear using the initial engagement of the drive screw. to form a coupling thread in the helical gear that allows operation thereof, and then apply a retaining member to the drive screw. The modern headlights for vehicles are designed - and subjected to technical study to be aerodynamically efficient. In this regard, the headlights are designed as sealed assemblies wherein the portion of the headlight that approaches the exterior surface of the automobile is relatively static, and is aerodynamic. A typical modern headlight assembly 12 is illustrated in a plan view as illustrated in FIGURE 1, and typically includes: a fixed housing 20, to which an outer front headlight lens 22 is attached; a mobile reflector 24, which is mounted inside the fixed housing 20, and a static headlight bulb (not shown) which is placed inside the mobile reflector 24. Typically the mobile reflector 24 is mounted in the housing 20 by a universal or spherical pivot 26 that is fixed or static, in the housing 20. The first pivot point 28 is generally arranged vertically of the fixed pivot 26 and a second pivot point 30 of The pivot is generally arranged horizontally of the fixed pivot 26. As such, the movable reflector 24 can pivot about the fixed pivot 26 in the vertical and horizontal planes to aim the light beam of the headlight.

Adjustment mechanisms or headlight adjusters 40 and 42 are typically provided at the first and second pivot points 28 and 30, commonly referred to as the vertical pivot and the horizontal pivot, the headlight adjusters 40 and 42 can be operated to effect the movement of the reflector 24 in the vertical and horizontal planes. The headlight adjusters 40 and 42 are typically mounted in the housing 20 of the headlight assembly 12 and have adjusting output shafts 44 and 46 operatively connected to the mobile reflector 24 by spherical ball-type pivot, or the like, so that the movement linear of the adjuster output shafts 44 and 46 produce the pivoting of the moving reflector in the vertical and horizontal planes. Specifically, each headlight adjuster 40 and 42 typically includes a drive structure 48, 50 for receiving a tool, and typically the drive structure 48.50 is precisely coupled to the adjuster output shaft 44.46. The gear provides that using the tool to rotate the drag structure 48.50 causes the linear translation of the adjusting output shaft 44.46 and therefore the adjustment of the position of the headlight reflector 24. Before a car is put on sale to the consumer, the moving reflectors of the headlamp assemblies are adjusted to a desired position so that the BMOiM light beams of the headlight are properly directed in both the vertical and horizontal directions. At this point, headlight adjusters are normally operated in an automotive assembly plant. Once adequate steering and vertical guidance of the headlights is achieved and before the car is put on sale to the consumer, the vertical and horizontal indicators on each headlight adjuster are manipulated to provide a visual indication that each reflector mobile is in the desired position or in the "zero" position. The indicators transmit either naturally, or are adjusted in some way to be able to transmit, a visual indication of the zero position. Next, if a moving reflector moves from the desired position due to, for example, vibration, jerking or the vehicle being in an accident, a mechanic can use the visual indication to determine whether the moving reflector is no longer in the desired position . Then, the mechanic can operate the headlight adjusters to be able to return the vertical and horizontal indicators to the positions, zero that should properly re-align the reflector. The Department of Transportation of the Government of the United States has established specific guidelines for the distribution of indicator and pointer mechanisms for the headlight of vehicles in both horizontal and vertical directions. The guidelines establish the degree of accuracy that is required for horizontal and vertical indicators. It is advantageous to provide a headlight adjuster that is inexpensive, easy to use, easy to make, and complies with government guidelines. Accordingly, it is an object of one embodiment of the present invention to provide a headlamp adjuster that is relatively inexpensive. Another object of one embodiment of the present invention is to provide a headlight adjuster that is easy to use and easy to make. Another embodiment of the present invention is to provide a method for adjusting the position of a reflector of a headlight assembly, wherein the method is relatively easy to perform. Still another object of one embodiment of this invention is to provide a method for making a headlight adjuster wherein the method is relatively easy to perform. Briefly and in accordance with one or more of the foregoing objects, one embodiment of the present invention provides a headlight adjuster that includes an adjusting output shaft that can be engaged with a reflector of a headlight assembly. The adjusting output shaft extends from a housing, and is coupled to a helical gear / tandem straight gear with a portion of the gear rack of the adjusting output shaft. The drive structure engages with the helical gear so that activation of the drive structure causes at least a portion of the drive structure to thread at least a portion of the helical gear, thereby causing the drive shaft adjusting output moves relative to the housing and adjust the position of the headlight reflector BRIEF DESCRIPTION OF THE DRAWINGS The organization and form of the structure and function of the invention, together with the additional objects and advantages thereof, can be understood with reference to the following description taken in conjunction with the accompanying drawings, wherein: FIGURE 1 is a plan view of a typical headlight assembly, FIGURE 2 is a top plan view of a headlight adjuster that is according to one embodiment of the present invention, FIGURE 3 is a top plan view similar to that of FIGURE 2, but showing a helical gear unit of the headlight adjuster in cross section; "FIGURE 4 is a side elevational view of the headlight adjuster illustrated in FIGURE 2; FIGURE 5 is a front elevational view of the adjuster shown in FIGURE 2; FIGURE 6 is a rear elevational view of the adjuster shown in FIGURE 2; FIGURE 7 is a side elevational view of an output shaft of the adjuster illustrated in FIGURES 2-6; FIGURE 8 is a side elevational view of a helical gear of the headlight adjuster illustrated in FIGURES 2-6. FIGURE 9 is a side elevational view of a driving member of the headlight adjuster illustrated in FIGURES 2-6; FIGURE 10 is a top plan view of a headlight adjuster that is in accordance with another embodiment of the present invention; FIGURE 11 is a side elevational view of a helical gear of the illustrated headlight adjuster, in FIGURE 10; FIGURE 12 is an exploded view of a headlight adjuster that is in accordance with yet another embodiment of the present invention; and FIGURES 13 and 14 are side elevational views of the headlight adjusters that are in accordance with still other embodiments of the present invention.

While the present invention may be susceptible to modalities in different forms, the embodiments of the invention are shown in the drawings, and herein will be described in detail, taking into account that the present description will be considered as an exemplification of the principles of the invention. the invention and is not intended to limit the invention to that illustrated and described herein. FIGURE 2 illustrates a headlight adjuster 60 that is in accordance with one embodiment of the present invention. The headlight adjuster 60 includes an adjusting output shaft 62 that is configured for gearing with a reflector 24 of a headlight assembly 12. Specifically, the adjusting output shaft 62 includes a ball portion 64 at one end 66 for engagement in a socket with a reflector 24 (see FIGURE 1 and previous description, for example). The headlight adjuster 60 also includes a housing 70, and the adjusting output shaft 62 extends from a shaft bore 72 in the housing 70. The housing 70 is preferably mounted in the headlight assembly 12 or some other structure , such as a frame type structure, which is generally close to the headlight assembly 12. Preferably, the headlight adjuster 60 is mounted on the "attachment piece", so that the headlight adjuster 60 can be mounted on a headlight assembly 12 by inserting an end 74 of the housing into an opening in a housing 20 of the headlight assembly 12 (see FIGURE 1), and rotate the housing 70 of the headlight adjuster 60 relative to the headlight assembly 12 to a 120 ° (one third) turn. As shown in FIGURES 2,4 and 5, preferably a sealing member 76, such as an elastomeric sealing ring formed of Silicone R 7744, is generally positioned near the end 74 of the housing 70. Preferably when the adjuster 60 of The headlight is installed in the opening in the housing 20 of the headlight assembly 12, the sealing member 76 engages the housing 20 of the headlight assembly 12 to provide an axial force between the housing 20 of the headlight assembly 12 and the headlight assembly 12. housing 70 of the headlight adjuster 60 and generally reduces the amount of moisture entering the front head assembly 12 through the opening in the housing 20 of the headlight assembly 12, and provides an axial catch force for blocking rotation. As will be fully described hereinafter, once the headlight adjuster 60 is properly mounted and engaged with the reflector 24, the headlight adjuster 60 can be manipulated to cause the adjusting output shaft 62 to be move relative to the housing 70 and make an adjustment in the position of the reflector 24. The housing 70 can be formed of, for example, Zytel 70G13HSlL, and the adjusting output shaft 62 can be formed of, for example, Delrin 570 or Zamac-3 (die-cast part) with a yellow / Zinc bichromate finish. Independently, preferably the adjusting output shaft 62 is easy to mold with plastic or cast, and is relatively inexpensive. In FIGURE 7, the adjuster output shaft 62 is shown insulated from the rest of the headlight adjuster 60. As shown, the adjusting output shaft 62 preferably includes a gear portion 78, and the gear portion 78 can be near an end 80 of the adjusting output shaft 62, where the end 80 is opposite the end 66 of the actuator. adjusting output shaft 62 in which the ball portion 64 is disposed. The gear portion 78 of the adjusting output shaft 62 may comprise, for example, a coupled rack having thirteen teeth, a diametrical pitch 48 and a pressure angle of 20 °. As shown, preferably the adjusting output shaft 62 includes a notch 84 for receiving a sealing member 86 (see specifically FIGURE 4), such as an O-ring, wherein the sealing member 86 tends to create a seal between the adjusting output shaft 62 and an inner wall 88 of the housing 70, thereby reducing the amount of moisture entering the interior of the housing 70. As shown in FIGURE 4, as in FIGURE 7, the gear portion 78 of the adjuster output shaft 62 engages a straight gear portion 90 of a helical gear 96. Preferably, the portion 98 of the adjusting output shaft 62 extending between the ball portion 64 and the notch 84 has a generally round cross section, and the coupling between the adjusting output shaft 62 and the helical gear 96 prevents the the adjusting output shaft 62 rotates relative to the housing 70. The hole 72 of the shaft in the housing 70 also has a generally round shape, which generally corresponds to the generally round cross section of the portion 98 of the adjusting output shaft 62 that is between the portion 90 of gear and portion 64 of ball. The helical gear 96 is also shown insulated in FIGURE 8. The helical gear 96 may be formed of plastic. As shown in FIGURES 3, 4 and 8, the helical gear 96 not only includes a straight gear portion 90 but is configured to engage with a straight gear portion 78 of the adjusting output shaft 62, but also includes another portion. 100 including a peripheral edge 102 that is configured to engage with a drive structure, such as with a drive screw member 104 (FIGURES 3 and 4 illustrate the engagement between the helical gear 96 and the drive member 104). The helical gear 96 and the drive member 104 are mounted in the gear configuration much like a standard helical gear in which the drive member 104 acts as the worm and the worm gear 96 becomes such only when the The threads are formed by the worm 104 which would simulate the teeth of the helical gear after the repeated turns of the worm. Although the helical gear initially has no teeth, the helical gear disciplines such as; (with reference to FIGURE 8) the shape and circumference of the annular ring 110 must accommodate the worm pin 104 so that multiple turns of the worm result in more than a single turn of the helical gear 96 that will put the teeth of the endless screw in the same previously formed tooth. The radius of the ring accommodates the contact radius of the worm 104. The drive member 104 is initially driven tangentially against the helical gear by forming-threads as a thread-forming screw, without causing any helical gear rotation. The drive member 104 advances into the housing via the thread formed by the helical gear until a flange 130 of the screw member 104 (see FIGURES 4 and 9) reaches the bottom of the housing. It is at this point that the rotational movement of the screw imparts rotary motion to the helical gear while forming helical gear teeth circumferentially in the annular channel 110. Preferably, the helical gear 96 is disposed in a hole 112 in the housing 70, and provides a flange 114 at the end 116 of the helical gear 96. It is preferred that the flange 114 at the end 116 of the helical gear 96 is configured such that there is a slight tortuous path between the housing 70 and the flange 114, thereby providing a seal which generally reduces the amount of contaminants, such as dust , which enter between the rim 114 and the housing 70 and make contact with the interior machinery of the headlight adjuster 60. The pull member 104 is shown insulated in FIGURE 9. As shown, the pull member 104 preferably includes a head portion 118, a threaded portion 108 extending from the head portion 118 within the opening 120 in the accommodation 70. Preferably, the drag member 104 is formed of metal, and has a zinc plating finish with yellow dichromate, with a thickness of 0.005 to 0.007 cm (0.002-0.003 inches). It is preferred that the threaded portion 108 comprises a standard thread K50 PT and, generally, consists of that which is described in US Pat. No. 4,544,313, which is hereby incorporated by reference. As shown in FIGS. 2-6, when the drive member 104 is coupled with the helical gear 96, the head portion 118 the drive member 104 extends from the housing 70. Preferably, the head portion 118 is generally accessible from the outside of the housing 70, so that a tool can be engaged with the head portion 118 and used to rotate the head portion 118, thereby urging the drive member 104 and causing the helical gear 96 to rotate. Because the helical gear 96 is coupled to the adjusting output shaft 62, the rotation of the helical gear 96 causes the adjusting output shaft 62 to move relative to the housing 70, thereby changing the position of the reflector 24 of the assembly 12 of headlight As shown in FIGURE 4 preferably a notch 122 is provided in an exterior surface 124 of the housing 70, and the head portion 118 of the member 1 04 is generally received in the notch 122, with the ^ MM-itf threaded portion 108 of drag member 104 extending into opening 120 in housing 70; Engaged with the peripheral surface 102 of the portion 100 of the helical gear 96. As shown, the flange 130 of the pull member 104 reaches the bottom in the groove 122 to initiate the rotation and thread formation of the helical gear 96. Also as shown in FIGURE 4, preferably the outer surface 124 of the housing 70 provides another opening 132 and a notch 134, and one end 136 of the drive member 104 extends through the housing 70 and through another opening 132. Preferably, a retaining member 140 engages the end 136 of the drive member 104. The end 136 of the driving member 104 can be hammered to retain the holding member 140 so that the driving member 104 can rotate in both directions. The retaining member 140 may be, for example, "a retaining washer formed of 1018 CR Steel, and may be finished with a Zinc plating with yellow dichromate." Independently, preferably the retaining member 140 does that when using a tool to rotate the drive member 104, the drive member 104 does not generally translate axially as the drive member 104 is screwed into the peripheral surface 102 of the drive member 104. the portion 100 of the helical gear 96. Instead, the rotation of the drive member 104 causes the threaded portion 108 of the drive member 104 to thread into the peripheral surface 102 of the portion 100 of the helical gear 96, causing the helical gear 96 to rotate in the housing 70. and the adjusting output shaft 62 is moved relative to the housing 70. The translation of the adjusting output shaft 62 causes the position of the reflector 24 of the headlight assembly 12 to change. As mentioned, previously the drive member 104 and the portion 100 of the helical gear 96 are preferably configured in such a way that when the drive member 104 is driven or rotated, the threaded portion 108 of the drive member 104 is threaded or cut. within the peripheral surface 102 of the portion 100 of the helical gear 96. In this way, a profile of the helical gear 96 is provided without having a tool portion 100 of the helical gear 96 to meet the accuracy requirements. As a result, the headlight adjuster 60 is less expensive to provide. Preferably, the headlight adjuster 60 illustrated in FIGURES 2-6 is generally easy to manufacture and inexpensive. In the method for assembling the headlight adjuster 60 shown in FIGURES 2-6, each of the components is preferably formed, and i ^ «and then the components are assembled. The method for manufacturing and assembling and installing the headlight adjuster 60 will now be described. The helical gear 96 is inserted into the hole 112 in the housing 70 and then the adjusting output shaft 62 (with the sealing member 76 thereon, if provided) is positioned within the hole 72 of the shaft at the end 74 of the housing 70 so that the gear portion 78 of the adjusting output shaft 62 engages the gear portion 90 of the helical gear 96. Next, the driving screw 104 is inserted into the opening 120 in the housing 70 and urged to enter the gear with the portion 100 of the helical gear 96 until the end 136 of the driving member 104 comes out of the other opening. 132 in the housing 70. As the end 136 of the driving member 104 is urged to the other opening 132 in the housing 70, the portion 100 of the helical gear 96 generally acts as the portion of a hole in a plastic until it the head portion 118 and the flange 130 reach the bottom of the opening 120 (the surface 124 of the housing 70 adjacent to the opening 120.) The initial gearing of the drive screw 104 will thread or otherwise cold-form a coupling thread. or a gear profile in the portion 100 of the helical gear 96. The continuous rotation of the drive member 104 causes the helical gear 96 to rotate as the teeth are turned. fallen, cut or otherwise formed within the peripheral surface 102 of the portion 100 of the helical gear 96. Then, the retaining member 140 is coupled with the end 136 of the driving member 104 so that the driving member 104 can not move generally axially relative to the housing 70. Therefore, the headlight adjuster 60 It is easy to assemble, and preferably does not require -welding. Additionally, the automation can be used to mass assemble a plurality of such headlight adjusters. To install the assembled headlight adjuster 60, the ball portion 64 of the adjusting output shaft 62 engages a reflector 24 of a headlight assembly 12, and the housing 70 of the headlight adjuster 60 is secured to a housing 20 of the headlight assembly 12 or some other nearby surface, such as a frame-like surface (see FIGURE 1 for example). To manipulate the headlight adjuster 60 to effect a change in the position of the reflector 24 of the headlight assembly 12, one simply needs to apply a tool to the head portion 118 of the drive member 104 and rotate the drive member 104. As shown in FIGURE 2, a mark 142 is preferably provided in the housing 70 that makes the headlight adjuster 60"non-manual". Such mark 142 is described in the North American patent application Serial No. 09 / 293,853, which is hereby incorporated by reference. The mark 142, by arrows 144, and a centerline indicator 146, indicate in which direction the pull member 104 rotates to effect movement of the reflector 24 in one direction either toward or away from a vehicle centerline. in which the corresponding front headlight assembly 12 is installed. The mark 142 effectively causes the headlight adjuster 60 to be usable with the vehicle's headlight assemblies that are both to the right and to the left of the vehicle's center line, and the mark 142 is accurate with respect to the rotation of the drag member 104 and results in the movement of the reflector regardless of whether the headlamp adjuster is "engaged with a headlight assembly that is to the left or right of the center line of the vehicle. 104 causes the drag member 104 to cold-form or cut a mating thread within the peripheral surface 102 of the portion 100 of the helical gear 96, thereby causing the helical gear 96 to rotate. gear of the adjusting output shaft 62 engages with the gear portion 90 of the helical gear 96, rotation of the helical gear 96 causes the adjusting output shaft 62 moves relative to the housing 70 and adjusts the position of the reflector 24 of the headlight assembly 12. Preferably, the headlight adjuster 60 is configured so that there is no clearance or axial clearance with respect to the adjusting output shaft 62. The headlight adjuster 60 is generally reliable and has a generally good resolution. Preferably, the headlight adjuster 60 is configured to provide that full rotation of the driving member 104 causes the adjusting output shaft 62 to translate approximately 1mm. Since other resolutions are also possible. FIGURE 10 depicts a headlight adjuster 60a according to another embodiment of the present invention. The headlight adjuster 60a is very similar to that shown in FIGURES 2-6, and therefore similar reference numbers are used to identify similar parts and an "a" alphabetic suffix is used. The headlight adjuster 60a shown in FIGURE 10 differs from that shown in FIGURES 2-6 in that the headlight adjuster 60a includes an indicator 150, such as a horizontal indicator that is provided in an extension 152 of the portion 100a of the helical gear 96a. As shown in FIGS. 10 and 11, the headlight gear 96a includes an extension portion 152 extending from the housing 70a (see FIGURE 10). Preferably, the degree marks 154 are provided in the extension portion 152 as shown in FIGURE 10, and a pointer 156 is provided in the housing 70a generally adjacent the degree markings 154 to indicate the position of the reflector 24 ( see FIGURE 1). Preferably, after the headlight adjuster 60a has been assembled and installed, the drive member 104 is rotated so that the reflector 24 of the headlight assembly 12 can be positioned in the desired position. Next, the degree marks 154 are applied to the extension portion 152 of the helical gear 96a. Specifically, the degree marks 154 can be printed on a label 160, and the label 160 can be attached to the extension portion 152 of the helical gear 96a so that a "zero" mark 162 is generally aligned with the pointer 156 in the housing 70a (as shown in FIGURE 10). Ideally, any subsequent unwanted movement of the reflector 24 by the rotation of the driving member 104a subsequent to the calibration will cause the "zero" mark 162 to be misaligned from the pointer 156 in the housing 70a and indicate that the reflector 24 has become misaligned from the desired position. Preferably, the label 160 containing the 154 degree marks has ¡U has | MU evidence of improper handling. Evidence of improper handling would be that the label is delaminated with removal, making the printed legend illegible. Due to the similarity between the two front head adjusters 60 and 60a, the headlight adjuster 60a generally provides the same characteristics as the headlight adjuster 60, but also provides the characteristic of indication as well as the evidence of driving evidence. undue, if desired. FIGURE 12 illustrates, in an exploded view, a headlight adjuster 60b that is in accordance with yet another embodiment of the present invention. Because the headlight adjuster 60b is similar to those already described and which use similar reference numbers to identify similar parts, and the alphabetic suffix "b" is used. Like the headlamp adjusters 60 and 60a already described, the headlight adjuster 60b shown in FIGURE 12 also includes an adjusting output shaft 62b, a housing 70b, a drive member 104b, a retaining member 140b and a helical gear 96b. The headlight adjuster 60b is different than the headlight adjusters 60 and 60a already described in that the drive member 104b is generally parallel to (as opposed to being generally perpendicular to) the adjusting output shaft 62b, and meets a requirement "d" of required distance between the drive member and the output shaft. Up to this point, the housing 70b is configured differently than the housings 70 and 70a of the headlight adjusters 60 and 60a shown in FIGURES 2-6 and 10 respectively. As shown, the housing 70b has two generally parallel holes 170 and 180, a hole 170 for receiving the adjusting output shaft 62b (and the portion 90b of the helical gear 96b) and another hole 180 for receiving the drive member 104b (and the portion 100b of the helical gear 96b). The helical gear 96b includes an elongated portion 182 that is disposed between the gear portion 90b and the portion 100b that is engaged with the drive member 104b. When the helical gear 96b is properly installed in the housing 70b, the gear portion 90b of the helical gear 96b engages with the gear portion 78b of the adjusting output shaft 62b, and the portion 100b is engaged with the drive member 104b. Preferably, the helical gear 96b includes a notch 184 for receiving a sealing member 186, and the sealing member 186 is sealed against an interior wall of the housing 70b to work together with a microfilter 188 that provides controlled ventilation of the housing 20 of lamp. As shown, the vent 188 is preferably provided in the housing 70b, generally near the end 80b of the adjusting output shaft 62b to seal the hole 170. Controlled ventilation as mentioned in US Pat. No. 5,775,794, incorporated therefore in FIG. The present by reference, is an alternative for the hermetic sealing of the housing 20 of the lamp, by the seal 86 of the output shaft seen in FIGURE 4. FIGURE 12 also illustrates a shaft extension that is permanently attached to the portion 118b of the driving member 104b to rotate the driving member 104b, thereby driving the helical gear 96b and causing the adjusting output shaft 62b to move relative to the housing 70b and change the position of the reflector 24. As shown in FIG. FIGURE 12, preferably the headlight adjuster 60b includes a cap 192 which is attached to the end 116b of the helical gear 96b. Preferably, the lid 192 provides a surface 194 on which degree marks are located (see FIGURE 10). At this point, a label 160 can be applied to the surface 194 of the lid 192, wherein the label 160 is described above together with the headlight adjuster 60a illustrated in FIGURE 10. Preferably, the headlight adjuster 60b illustrated in FIGURE 12 is generally easy to manufacture and inexpensive. By making the headlight adjuster 60b illustrated in FIGURE 12, preferably each of the components is formed and then the components are assembled. The assembly and installation of the headlight adjuster 60b will now be described. Preferably, the cap 192 is assembled in the helical gear 96b by a snap fit or welding, and the vent 188 is welded to the housing 70b. The sealing member (if provided) 186 engages the helical gear 96b, and the helical gear 96b inserted in the housing 70b. Next, the adjusting output shaft 72b is inserted into the hole 170 so that the gear portion 78b of the adjusting output shaft 62b couples the portion 90b of the helical gear 96b. Next, the drive member 104b with the attached extension 190 is inserted into the hole 180 in the housing 70b and is urged into engagement with the portion 100b of the helical gear 96b, until the end 136b of the drive member 104b comes out. of the opening 132b in the housing. As the end 136b of the driving member 104b is urged into the opening 132b, the portion 100b of the helical gear 96b generally acts as a portion of a hole in a plastic until the head portion 118b and the flange 130b reach the bottom of the opening 120b (the surface of the housing 70b adjacent the opening 120b). The continuous rotation of the driving member 104b causes the helical gear 96b to rotate as the teeth intersect within the peripheral surface 102b of the portion 100b of the helical gear 96b. The retaining member 140b is then coupled to the end 136b of the driving member 104b so that the driving member 104b does not generally move axially relative to the housing 70b when the driving member 104b is rotated. Like the previously described headlight adjusters 60 and 60a, the headlight adjuster 60b is easy to assemble. Additionally, automation can be used to mass assemble a plurality of such headlight adjusters. FIGURES 13 and 14 illustrate two additional headlight adjusters 60c and 60d, each of which is in accordance with another embodiment of the present invention. Preferably, each generally includes the same components as the headlight adjuster shown in FIGURES 2-6, but causes the driving member 104c and 104d to be angled relative to the adjusting output shaft 62c and 62d. Specifically, FIGURE 13 depicts a front head adjuster wherein the drive member 104c is provided at an angle of 67.5 ° relative to the adjusting output shaft 62c, and FIGURE 14 depicts a front head adjuster 60d where the member 104d drag is provided at an angle of 112.5 ° relative to the adjusting output shaft 62d. Since, other angles are also possible.

U ^ M ^ _ ^ M * AA _ ^^ _ MAM * MM-aÉÉÁ ^ ttÉÍHÉMtkM > While the embodiments of the present invention are shown and described, it is envisioned that those skilled in the art can devise various modifications without departing from the spirit of scope of the foregoing description.

Claims (14)

1. CLAIMS 1. A headlight adjuster configured to engage with a reflector of a headlight assembly, the headlight adjuster characterized in that it comprises an adjusting output shaft that can be engaged with the reflector of the headlight assembly; a housing, the adjusting output shaft extends from the housing; a gear member disposed in the housing and having a straight gear portion, the adjusting output shaft includes a gear rack portion, the straight gear portion of the gear member coupled with the rack portion of the output shaft adjuster; the drive structure engages with the gear member so that activation of the drive structure causes at least a portion of the drive structure to be threaded into at least a portion of the gear member, thereby forming threads on the gear member.
2. 2. The front head adjuster according to claim 1, characterized in that the headlight adjuster is configured so that a helical gear profile is cut within the gear member upon activation of the drive structure.
3. 3. The headlight adjuster according to claim 1, characterized in that the member of ^^ "A-KUJUUHU gear includes a peripheral edge, the drag structure is coupled with the peripheral edge, the drag structure forms threads in the peripheral bofde when activating the drag structure.
4. The headlight adjuster according to claim 3, characterized in that the drive structure is generally tangential to the peripheral edge of the gear member.
5. The headlight adjuster according to claim 3, characterized in that the peripheral edge includes an annular channel, the drive structure engages the annular channel.
6. The headlight adjuster according to claim 1, characterized in that at least a portion of the gear member is comprised of plastic.
7. The headlight adjuster according to claim 1, characterized in that the drive structure includes a threaded portion and a flange, the threaded portion is disposed in the housing and the flange external to the housing, wherein the initial activation of the The drag structure causes the threaded portion of the drive structure to be threaded into the gear member, thereby forming threads in the gear member, while the gear member does not substantially rotate in the housing, where the activation of the drag structure causes the flange to contact the housing after which further activation of the drag structure causes the gear member to rotate thereby causing the adjusting output shaft to move relative to the housing and adjust the position of the headlight reflector.
8. The headlight adjuster according to claim 7, further characterized in that it comprises a retainer member coupled with the drive structure, the drive structure includes a first end and a second end which is generally opposite the first end, the The first end is configured to be coupled with a tool for driving the drive structure, the retaining member is coupled with the second end of the drive structure.
9. 9. The headlight adjuster according to claim 1, further characterized in that it comprises shakers in the housing, the markings indicate in which direction the pulling structure rotates to effect the movement of the reflector in a direction that is either toward or away from. away from a central line of a vehicle.
10. The headlight adjuster according to claim 1, further characterized in that it comprises means in the gear member and housing for indicating the position of the reflector.
11. 11. The headlight adjuster according to claim 10, characterized in that the means for indicating the position of the reflector comprise degree marks on the gear member and a pointer on the housing.
12. The headlight adjuster according to claim 10, characterized in that the means for indicating the position of the reflector comprises a label fixed to an extension of the gear member, the label having degree markings thereon.
13. 13. The headlight adjuster according to claim 1, characterized in that the driving structure has a longitudinal axis and the adjusting output shaft has a longitudinal axis, the longitudinal axis of the driving structure is generally parallel to the longitudinal axis of the driver. adjuster output shaft. The headlight adjuster according to claim 13, characterized in that the gear member has a longitudinal axis, the longitudinal axis of the gear member is generally perpendicular to the longitudinal axis of the adjusting output shaft and to the longitudinal axis of the structure of drag.