WO2022003725A1

WO2022003725A1 - A headlamp assembly

Info

Publication number: WO2022003725A1
Application number: PCT/IN2021/050641
Authority: WO
Inventors: Subramani Saravanan; Kaanchi Mohan Srikanth; Tamilkumaran MUTHUSANKARALINGAM SANKARALINGAM; Nagarjun Reddy Mosali
Original assignee: Tvs Motor Company Limited
Priority date: 2020-07-01
Filing date: 2021-07-01
Publication date: 2022-01-06

Abstract

The present invention related to a headlamp assembly (105) comprising of one or more headlamp cover assembly (102) and one or more headlamp (103). One or more said headlamp (103) is attached to one or more said headlamp cover assembly (102). One or more said headlamp (103) includes one or more adjusting screw (302) and having one end connected to one or more said headlamp cover assembly (102). A receptacle (302A) of the adjusting screw (302) is easily accessible to the user from an opening (401A) in a front cover (401). Therefore, a smooth and less time consuming headlamp (105) adjustment operation can be done by ordinary user without use of specialized tools because it doesn't require precise skills and specialized tools for adjustment.

Description

A HEADLAMP ASSEMBLY

TECHNICAL FIELD

[0001] The present subject matter relates to a headlamp assembly. More particularly, to an aiming mechanism of the headlamp assembly. BACKGROUND

[0002] Progress in development of light sources is making it technically possible to design powerful illumination concepts for advanced front lighting systems for vehicles. However, headlamps developed and produced in the last decade have become increasingly complex in design and functionality.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The detailed description is explained with reference to an embodiment of headlamp assembly with the accompanying figures. The same numbers are used throughout the drawings to reference like features and components. [0004] Figure 1 illustrates a localized front side view of a front cowl (101) configured to have twin headlamps (103) and an exploded view of a headlamp assembly (105) getting assembled to the front cowl (101) in accordance with one example implementation of the present subject matter, where few parts are omitted from the figures for brevity. [0005] Figure 2 illustrates an exploded view of a headlamp cover assembly (102) in accordance with one example implementation of the present subject matter.

[0006] Figure 3 illustrates an exploded view of a headlamp (103) getting attached with the headlamp cover assembly (102) in accordance with one example implementation of the present subject matter. [0007] Figure 4a illustrates a front side view of the front cowl (101) with an enlarged localized view showing receptacle (302A) of adjusting screw (302) in accordance with one example implementation of the present subject matter.

[0008] Figure 4b illustrates a side cut section view across A-A’ axis of a headlamp (103) assembled to the front cowl (101) and a localized perspective view of the headlamp assembly (105) where few parts are omitted from the figure in accordance with one example implementation of the present subject matter.

DETAILED DESCRIPTION

[0009] Various features and embodiments of the present subject matter here will be discernible from the following further description thereof, set out hereunder. According to an embodiment, non-circular headlamp assembly described here is configured to have headlamp adjustment mechanism. It is contemplated that the concepts of the present invention may be applied to application including marine application, and automotive industry. The detailed explanation of the constitution of parts other than the present subject matter which constitutes an essential part has been omitted at suitable places.

[00010] Progress in the development of automotive lighting technologies includes styling, packaging and functionality. The evolution of headlamps is dominated by basic design conflict between providing good visibility for a user and avoiding glare for oncoming vehicles. The headlamp encloses a light source, usually attached to the front of a vehicle, with the purpose of illuminating the road ahead during periods of low visibility, such as night or precipitation. A headlight preferably refers to the beam of the light produced and distributed by the headlamp. Taken to the extreme, good visibility for driver can be achieved by allowing the headlights emit the maximum possible amount of light, while the requirement of avoidance of glare is just the opposite of it implying no light from the headlight at all. Therefore, it is a challenge to find an optimal between two conflicting design goals.

[00011] The light distribution is represented in terms of luminous intensity and illumination patterns. There is a significant between the luminous intensity distribution of a new headlight and headlight on the vehicle that has been on the road for some time. Typically, headlights on the vehicle, when vehicle is driven on the road, may produce different luminous intensity, because of factors like the vehicle may not be level, or the headlight is incorrectly aimed etc. It is observed that incorrectly aimed lights tend to produce more glare than new headlights. The most dramatic change in headlights over the last decade has been the widespread adoption of the high intensity discharge light which if misaimed, owing to variations and other factors, makes things slightly worse in terms of glare.

[00012] The misaim occurs due to vibrations and/or other forces acting on the vehicle during its operations, or minor collisions without the knowledge of the vehicle user. In addition, some service centres may be unable to correctly calibrate the aim of the headlamps leading to incorrectly aimed headlamps even after vehicle servicing. Therefore, there is a need to have a solution to the above problems. It becomes necessary to provide an automatic or periodic adjustment to maintain the desired light beam direction over the service life of the vehicle. Therefore, the headlamp assemblies are provided with adjusting mechanisms to ensure the desired orientation adjustment in the light beam direction to be set by the user.

[00013] The known arts suffer from a number of drawbacks, but common disadvantage is multiplicity of parts including multiple adjusting screws, multiple gears, linkages which mutually cooperate to enable adjustment of few selected components of headlight assembly. This becomes more critical due to its conflict with available layout space at the front region of the vehicle as well as the small installation space in the vehicle.

[00014] In known arts, plurality of adjusting screws move the headlamp assembly in relation to a front cowl to correct headlight aim. The lateral or side to side adjustment is accomplished by turning the adjusting screw at the side of the headlamp. Vertical or up-and-down adjustment is accomplished by turning the adjusting screw at the top of the headlamp which requires precise skill therefore requires more time. Moreover, the adjustments are made after removing a headlamp bezel. Removing the headlamp bezel is also a time consuming task as it involves unscrewing plurality of headlamp bezel retaining screws. In addition to above, it is observed that rarely do vehicle’s users adjust or reset the headlamp to desired optimal orientation. This inhibition from users is often due to complex adjustment mechanism especially for commercial load carrying and passenger vehicle users and may continue to use the vehicle with poor illumination and safety. Further, due to day and night running of commercial load carrying and passenger vehicles on roads including unmetalled or rugged roads, the adjusting screws is subjected to severe road shocks leading to loosening or coming off of the adjustment means.

[00015] Further, to avoid fouling or interference between the headlamp bezel and adjusted or tilted headlamp an optimum working clearance should be maintained. However, the front cowl is the front portion of the vehicle wherein a cutout section is provided for packaging of headlamp. Therefore, entry of water into an inside region of the vehicle or the driver cabin through a gap between the headlamp bezel and headlamp during rain or water wash can lead to undesirable damage of systems e.g. corrosion in the front cowl, water entry into wiring harness connections etc. Furthermore, unattended damage e.g. corrosion in the front cowl can also affect a floor of the driver cabin, resulting in costly repairs that may involve replacement of a chassis itself. [00016] Due to above problem of multiplicity of separate components including adjusting screws, which increases the number of parts, entail a high cost and water ingression into driver cabin through the gap. This adversely affects the durability of the front cowl and its associated parts. The present subject matter aims to address the above drawbacks by providing an efficient and compact headlamp assembly overcoming all problems of known art.

[00017] Further, it is object of the invention is to provide a smooth and less time consuming headlamp adjustment operation which can be done by ordinary user without use of specialized tools.

[00018] It is another object of the invention is to provide a headlamp assembly which is simple in construction, has higher reliability, compact in design with reduced part count, less weight and is economical to manufacture.

[00019] It is yet another object of the present invention is to improving the reliability of headlamp adjustment mechanism by eliminating the loosening or falling out phenomenon of the adjusting means.

[00020] It is another object of the present invention is to provide a headlamp assembly which eliminates the water ingression into the inside regions or driver cabin. [00021] Therefore, according to the present subject matter to attain the above mentioned objectives, a first characteristic of the present invention is that a headlamp assembly is configured with one or more headlamp cover assembly; and one or more headlamp atached to said headlamp cover assembly, said headlamp includes one or more adjusting screw and having one end coupled to said headlamp cover assembly with a translational degree of freedom to enable headlight adjustment.

[00022] In addition to the first characteristic, a second characteristic of the present invention is the headlamp assembly, wherein said headlamp cover assembly is configured with at least one headlamp cover; and one or more mounting member; wherein one or more said mounting member is detachably atached to said headlamp cover.

[00023] In addition to the first characteristic and the second characteristic, a third characteristic of the present invention is the headlamp assembly, wherein one or more said mounting member is configured to have one or more openings adapted to receive one or more ball joint holder.

[00024] In addition to the first characteristic and the third characteristic, a fourth characteristic of the present invention is the headlamp assembly, wherein one or more said ball joint holder is configured to engage one end of one or more said adjusting screw.

[00025] In addition to the first characteristic, a fifth characteristic of the present invention is the headlamp assembly, wherein said head lamp includes plurality of peripherally spaced mounting lugs projecting outwardly from its periphery.

[00026] In addition to the first characteristic and the fifth characteristic, a sixth characteristic of the present invention is the headlamp assembly, wherein said plurality of periphery spaced mounting lugs include one or more opening adapted to receive one or more said ball nut.

[00027] In addition to the first characteristic and the sixth characteristic, a seventh characteristic of the present invention is the headlamp assembly, wherein one or more said ball nut includes an axial bore in which said threaded portion of one or more said adjusting screw is threadably coupled or engaged.

[00028] An eighth characteristic of the present invention is the headlamp assembly, comprising of one or more headlamp cover assembly; and one or more headlamp atached to one or more said headlamp cover assembly, one or more said headlamp includes one or more primary mounting lug, one or more said primary mounting lug configured to have opening adapted to receive one or more ball nut, one or more secondary mounting lug and tertiary mounting lug wherein one or more said secondary mounting lug and one or more said tertiary mounting lug is configured to have openings adapted to receive attachment means.

[00029] In addition to the first characteristic, sixth characteristic and eighth characteristic, a ninth characteristic of the present invention is the headlamp assembly, wherein one or more said openings is adapted to receive attachment means, said attachment means include one or more sleeve and one or more cushion member, in tandem with one or more fastener to mount one or more said headlamp to one or more said headlamp cover assembly.

[00030] In addition to the first characteristic and the seventh characteristic, a tenth characteristic of the present invention is the headlamp assembly, wherein a receptacle of adjusting screw is accessible through an opening in a front cover. Further, the adjusting screw is guided by the ball nut such that the adjusting screw will be stationary and the headlamp alone will have translational degree of freedom while rotating the adjusting screw by the external tool.

[00031] The foregoing disclosure is not intended to limit the present disclosure to the precise forms or particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure. Thus, the present disclosure is limited only by the claims.

[00032] In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosure . It is to be understood that the forms of disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, materials, processes or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as “including”, “comprising”, “incorporating”, “consisting of’, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

[00033] Further, various embodiments disclosed herein are to be taken in the illustrative and explanatory sense, and should in no way be construed as limiting of the present disclosure. All joinder references (e.g., attached, affixed, coupled, connected, etc.) are only used to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the systems and/or methods disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references do not necessarily infer that two elements are directly connected to each other.

[00034] Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “third”, “primary”, “secondary”, “main” or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification. [00035] It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application. Additionally, any signal hatches in the drawings/figures should be considered only as exemplary, and not limiting, unless otherwise specifically specified. [00036] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[00037] Reference is being made to figure 1 that illustrates a localized front side view of a front cowl (101) configured to have twin headlamps (103) and an exploded view of a headlamp assembly (105) getting assembled to the front cowl (101) in accordance with one example implementation of the present subject matter, where few parts are omitted from the figures for brevity. The front cowl (101) is configured to have one or more cutout section (101A) configured to receive a headlamp cover assembly (102). The head cover assembly (102) is detachably attached to a front cowl (101). The headlamp cover assembly (102) can be attached to the front cowl (101) by using conventional joining techniques like welding, fastening and other means which is known to the person skilled in the art. The headlamp (103) is adjustably attached to the headlamp cover assembly (102). Further, a headlamp bezel (104) is configured to enclose the headlamp (103) and is attached to the front cowl (101). The headlamp bezel (104) is critically designed to provide appealing aesthetic look to the headlamp (103). Further, an edge trim/beading (rubber or foam) (not shown) is provided in a gap between the headlamp bezel (104) and headlamp (103). It acts as cushioning member and seals the uneven gap if any while tilting the headlamp (103) due to its property of high deflection for compression and good resilience which ensures gap free fit and finish.

[00038] Reference is being made to figure 2 that illustrates an exploded view of the headlamp cover assembly (102) in accordance with one example implementation of the present subject matter. The headlamp cover assembly (102) comprises of a headlamp cover (102A) and plurality of mounting members (102B, 102C). The plurality of mounting members (102B, 102C) are attached to the head cover (102A). The plurality of mounting members (102B, 102C) includes a first mounting member (102B) and a second mounting member (102C). The first mounting member (102B) and second mounting member (102C) are configured to have one or more openings (102BA, 102BB, 102CA). A primary opening (102BA) in the first mounting member (102B) is adapted to receive a ball joint holder (201). A first weld nut (102BAA) is attached to a rear surface (not shown) of the first mounting member (102B) and is coaxial to a secondary opening (102BB) in the first mounting member (102B). Further, a second weld nut (102CAA) is attached to a rear surface (not shown) of the second mounting member (102C) and is coaxial to a tertiary opening (102CA) in the second mounting member (102C).

[00039] Reference is being made to figure 3 that illustrates an exploded view of the headlamp (103) getting attached with the headlamp cover assembly (102) in accordance with one example implementation of the present subject matter. The head lamp (103) includes plurality of peripherally spaced mounting lugs (103A, 103B, 103C) projecting outwardly from its periphery. The plurality of periphery spaced mounting lugs (103A, 103B, 103C) includes one or more opening (103AA, 103BA, 103CA). The plurality of mounting lugs (103A, 103B, 103C) includes one or more primary mounting lug (103A), one or more secondary mounting lug (103B) and one or more tertiary mounting lug (103C). The primary mounting lug (103A) is configured to have opening (103AA) adapted to receive a ball nut (301). The ball nut (301) includes an axial bore in which a threaded portion of an adjusting screw (302) is threadably received such that its one end is attached to the ball holder (201). Further, the secondary mounting lug (103B) and tertiary mounting lug (103C) are configured to have openings (103BA, 103CA) adapted to receive attachment means (303). The attachment means (303) includes a sleeve (303A) and a cushion member (303B), which is in tandem with a fastener (303C) to mount the headlamp (103) to the headlamp cover assembly (102). The external surface features of the sleeve (303A) can have a size and shape to allow to engage the internal surface features of the cushion member (303B). Additionally, the internal surface features of the sleeve (303A) can receive the threaded fastener (303C) such that the receptacle of the threaded fastener (303C) rests on the sleeve (303A).

[00040] Reference is being made to figure 4a that illustrates an front side view of the front cowl (101) with an enlarged localized view showing receptacle (302A) of adjusting screw (302) and figure 4b illustrates a side cut section view of headlamp (103) assembled to front cowl (101) across A-A’ axis and a localized perspective view of the headlamp assembly (105) where few parts are omitted from the figure in accordance with one implementation of the present subject matter. For sake of brevity, figure 4a and figure 4b will be discussed together. To adjust the headlamp (103) the user can engage tightening tool (such as “flat head” or “phillips” screwdriver or an “alien” wrench) into the receptacle (302A) of the adjusting screw (302) and can rotate it in clockwise or anti-clock wise direction to adjust the light beam. The receptacle (302A) of adjusting screw (302) is accessible through an opening (401A) in a front cover (401). The adjusting screw (302) is guided by the ball nut (301) such that the adjusting screw (302) will be stationary and the headlamp (103) alone will have translational motion i.e. translational degree of freedom while rotating the adjusting screw (302) by the external tool. At the same time, the cushion member (303B) due to resilient properties allows predetermined translational motion of headlamp (103). As described, the adjusting screw (302) can be rotated with an ease in order to have a desired adjustment. The overall adjustment of the headlamp (103) is achieved by inserting and rotating the external tool through the adjusting screw (302). One will appreciate in light of the disclosure herein that the cushion member (303B) can be formed from rubber, nylon, or other suitable material that is light weight, durable, and that can provide a resilient barrier between the harder component like the headlamp (103) and fastener (303C) so as to allow predetermined movement of the headlamp (103) while adjusting it through adjusting screw (302). Further, the ability of the cushion member (303B) to expand and contract in tandem with the headlamp (103) can help prevent creating stresses that can lead to headlamp (103) damage.

[00041] According to one implementation of the present invention, the headlamp is non-circular in shape but headlamp assembly can include headlamp of any size and shape like circular shape.

[00042] According to above architecture, the primary efficacy of the present invention is that, a smooth and less time consuming headlamp adjustment operation can be done by ordinary user without use of specialized tools because it does not require precise skills and specialized tools for adjustment.

[00043] According to above architecture, the primary efficacy of the present invention is that, the headlamp assembly is configured to have a simple construction, characterized by a compact design with reduced part count. This further leads to less weight and is economical to manufacture since assembly time will be less which reduces the man-hours on the floor.

[00044] According to above architecture, the primary efficacy of the present invention is that, the adjustment screw, the ball nut and the ball holder are mounted at an optimum location and disposed diagonally such that both horizontal and vertical aiming can be done using single adjustment screw. More specifically, said adjusting screw having one end connected to said ball holder is guided by the ball nut such that the adjusting screw will be stationary and the headlamp alone will have translational degree of freedom while rotating the adjusting screw by the external tool. [00045] According to above architecture, the primary efficacy of the present invention is that, the headlamp assembly reliability is improved due to lesser number of parts and falling out of adjusting screws is eliminated due use of single adjusting screw for adjustment and whose one end is attached to ball holder and is guided by ball nut. [00046] According to above architecture, the primary efficacy of the present invention is that, to achieve the desired sealing of any leakage of moisture or water to enhance the life of the front cowl and chassis frame structure, because the cutout in the front cowl is sealed with the headlamp cover. This prevents the water ingression into driver cabin. As an additional protection, the access opening may be closed by a snap- fit plug which the user can remove whenever the headlamp unit is to be adjusted. This will ensure the opening is plugged and thereby avoid any chance of water and mud entry into the inside region. While the solution proposed is suitable for a multi-track vehicle, it can be implemented in single track vehicles like saddle type two wheeled vehicles as well. [00047] While the present invention has been shown and described with reference to the foregoing preferred embodiments, it will be apparent to those skilled in the art that changes in form, connection, and detail may be made therein without departing from the spirit and scope of the invention.

List of reference R - Right direction L - Left direction 101 - Front cowl 103C - Tertiary mounting lug lOlA-Cutout section in Front cowl 20 103CA - Opening in tertiary mounting lug

102 - Headlamp cover assembly

104 - Headlamp bezel

102A - Headlamp cover

105 - Headlamp assembly 102B - First mounting member 201 - Ball joint holder

102BA - Primary opening

25 301 - Ball nut 102BB - Secondary opening

302 - Adjusting screw 102BAA - First weld nut

302A - Receptacle of Adjusting 102C - Second mounting member screw 102CA - Tertiary opening

303 - Attachment means 102CAA - Second weld nut

30 303A - Sleeve

103 - Headlamp

303B - Cushion member

103 A - Primary mounting lug

303C - Fastener

103AA - Opening in primary

401 - Front cover mounting lug

401 A - Opening in front cover

103B - Secondary mounting lug

103BA - Opening in secondary mounting lug

Claims

We Claim:

1. A headlamp assembly (105) comprising of one or more headlamp cover assembly (102) for a vehicle; and one or more headlamp (103) atached to said headlamp cover assembly (102), said headlamp includes (103) one or more adjusting screw (302) and said headlamp (103) has one end coupled to said headlamp cover assembly (102) with a translational degree of freedom to enable headlight (103) adjustment.

2. The headlamp assembly (105) as claimed in claim 1, wherein said headlamp cover assembly (102) includes at least one headlamp cover (102A); and one or more mounting members (102B, 102C); wherein one or more said mounting members (102B, 102C) is detachably atached to said headlamp cover (102A).

3. The headlamp assembly (105) as claimed in claim 2, wherein one or more said mounting members (102B, 102C) is configured to have one or more openings (102BA, 102BB, 102CA), one or more said openings (102BA, 102BB, 102CA) adapted to receive one or more ball joint holder (201).

4. The headlamp assembly (105) as claimed in claim 3, wherein one or more said ball joint holder (201) is configured to receive one end of one or more said adjusting screw (302).

5. The headlamp assembly (105) as claimed in claim 1, wherein said head lamp (103) includes plurality of peripherally spaced mounting lugs (103A, 103B, 103C) projecting outwardly from its periphery.

6. The headlamp assembly (105) as claimed in claim 5, wherein said plurality of periphery spaced mounting lugs (103A, 103B, 103C) includes one or more opening (103 AA, 103BA, 103CA) adapted to receive one or more said ball nut (301).

7. The headlamp assembly (105) as claimed in claim 6, wherein one or more said ball nut (301) includes an axial bore in which said threaded portion of one or more said adjusting screw (302) is threadably engaged.

8. A headlamp assembly (105) for a motor vehicle comprising of

One or more headlamp cover assembly (102); and One or more headlamp (103) attached to said headlamp cover assembly (102), said headlamp (103) includes one or more primary mounting lug (103A), said primary mounting lug (103A) configured to have opening (103AA) adapted to receive one or more ball nut (301), said ball nut (301) includes an axial bore in which said threaded portion of one or more adjusting screw (302) is threadably engaged, one or more secondary mounting lug (103B), and one or more tertiary mounting lug (103C); wherein one or more said secondary mounting lug (103B) and one or more said tertiary mounting lug (103C) are configured to have one or more openings (103BA, 103CA) adapted to receive attachment means (303).

9. The headlamp assembly (105) as claimed in claim 6 or claim 8, wherein one or more said openings (103AA, 103BA, 103CA) is adapted to receive said attachment means (303), said attachment means (303) include one or more sleeve (303A) and one or more cushion member (303B), in tandem with one or more fastener (303C) to mount one or more said headlamp (103) to one or more said headlamp cover assembly (102).

10. The headlamp assembly (105) as claimed in claim 1 or claim 7, wherein a receptacle (302A) of the adjusting screw (302) is accessible through an opening (401A) in a front cover (401), said adjusting screw (302) is guided by the ball nut (301) such that the adjusting screw (302) will be stationary and the headlamp (103) alone will have translational degree of freedom while rotating the adjusting screw (302) by an external tool.