IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0246481
(2011-09-27)
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등록번호 |
US-9518711
(2016-12-13)
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발명자
/ 주소 |
- Marley, Mike
- Stoi, Gregory Alan
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출원인 / 주소 |
|
대리인 / 주소 |
The Bilicki Law Firm, P.C.
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인용정보 |
피인용 횟수 :
0 인용 특허 :
19 |
초록
▼
A modular headlamp assembly includes a low beam headlamp module, a high beam headlamp module, and front turn/parking lamp module. The low beam headlamp module and the high beam headlamp module are supported by a reflector carrier. Each of the high and low beam headlamp modules includes a heat sink a
A modular headlamp assembly includes a low beam headlamp module, a high beam headlamp module, and front turn/parking lamp module. The low beam headlamp module and the high beam headlamp module are supported by a reflector carrier. Each of the high and low beam headlamp modules includes a heat sink and mounting assembly with a heat sink portion bisecting a reflector member. The reflector carrier is adjustably fastened to a housing to allow for adjustment of the high and low beam headlamp modules within the modular headlamp assembly.
대표청구항
▼
1. A modular high and low beam headlamp assembly with a housing, said headlamp assembly comprising: a low beam headlamp module including:a low beam heat sink and mounting assembly having a low beam heat sink portion with first and second sides and a low beam mounting portion having alignment feature
1. A modular high and low beam headlamp assembly with a housing, said headlamp assembly comprising: a low beam headlamp module including:a low beam heat sink and mounting assembly having a low beam heat sink portion with first and second sides and a low beam mounting portion having alignment features formed therein;at least one first low beam LED light source supported by said first side of the low beam heat sink portion;at least one second low beam LED light source supported by said second side of the low beam heat sink portion; anda low beam reflector member attached to the low beam heat sink and mounting assembly such that the low beam heat sink portion separates the low beam reflector member into first and second segments such that light emitted by said at least one first low beam LED light source is reflected by the first segment and light emitted by said at least one second low beam LED light source is reflected by the second segment, said low beam reflector member including mating features for engaging the alignment features formed on the low beam mounting portion to facilitate the alignment of the low beam reflector member to the low beam heat sink and mounting assembly;a high beam headlamp module positioned adjacent to the low beam headlamp module including:at least one high beam LED light source;a high beam heat sink and mounting assembly including a high beam heat sink portion having first and second sides, said first side supporting the at least one high beam LED light source and a high beam mounting portion, said high beam mounting portion having alignment features formed therein;a thermally conductive compound disposed between the high beam heat sink and the at least one high beam LED light source;a high beam reflector member including an upper reflective portion and a lower portion, which are separated by the high beam heat sink portion, said high beam reflector member including mating features engaging the alignment features formed on the high beam mounting portion to facilitate the alignment of the high beam reflector member with the high beam heat sink and mounting assembly; anda reflector carrier including:a first receiving pocket containing the low beam headlamp module, the first receiving pocket having recesses formed therein accepting mounting extensions of the low beam headlamp module such that low beam headlamp module is aligned within reflector carrier;a second receiving pocket containing the high beam headlamp module, the second receiving pocket having recesses formed therein for accepting mounting extensions of the high beam headlamp module such that high beam headlamp module is aligned within said reflector carrier; anda plurality of attachment features formed within a back side of the reflector carrier, wherein at least one of said plurality of attachment features facilitates adjustable attachment of the reflector carrier to the housing. 2. The headlamp assembly of claim 1 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are formed from a thermally conductive material. 3. The headlamp assembly of claim 2 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are formed from a material in the group consisting of aluminum, copper and magnesium. 4. The headlamp assembly of claim 2 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are treated with a thermally emissive coating to facilitate heat transfer through radiation. 5. The headlamp assembly of claim 4 wherein the thermally emissive coating is an E-coat, an anodized coating, or a powder coat. 6. The headlamp assembly claim 1 wherein the low beam heat sink portion is oriented vertically such that it bisects the low beam headlamp module vertically. 7. The headlamp assembly of claim 1 wherein the low beam heat sink portion is oriented horizontally such that it bisects low beam headlamp module horizontally. 8. The headlamp assembly of claim 1 wherein the low beam mounting structure portion includes a plurality of mounting extensions protruding therefrom to facilitate alignment of the low beam headlamp module within the first receiving pocket of the reflector carrier and the high beam mounting structure portion includes a plurality of mounting extensions protruding therefrom to facilitate alignment of the high beam headlamp module within the second receiving pocket of the reflector carrier. 9. The headlamp assembly of claim 1 wherein the high beam reflector member and the low beam reflector member are formed of a thermoplastic or thermoset vacuum metalized material. 10. The headlamp assembly of claim 1 wherein the low beam heat sink portion includes a light source receiving portion formed therein on at least one of said first and second sides for receiving the at least one low beam LED light source and the high beam heat sink portion includes a light source receiving portion formed within the first side for receiving the at least one high beam LED light source. 11. The headlamp assembly of claim 1 wherein the high beam mounting portion includes fins for heat dissipation which terminate at a base portion of the high beam mounting portion. 12. The headlamp assembly of claim 10 wherein the light shield blocks light from the at least one low beam LED light source in a 10 U-90 U range. 13. The headlamp assembly of claim 1 further comprising a socket and a pivot stud attached to at least one of said plurality of attachment features and a socket and adjuster pivot stud attached to another one of said plurality of attachment features, wherein adjuster pivot stud is adapted to facilitate movement of the reflector carrier with respect to the housing. 14. A modular high and low beam headlamp assembly comprising: a low beam headlamp module including:a low beam heat sink and mounting assembly having a low beam heat sink portion with first and second sides and a low beam mounting portion having alignment features formed therein;at least one first low beam LED light source supported by said first side of the low beam heat sink portion;at least one second low beam LED light source supported by said second side of the low beam heat sink portion;a light shield positioned adjacent to the at least one low beam LED light source for blocking a portion of the light in a low beam pattern; and a low beam reflector member attached to the low beam heat sink and mounting assembly such that the low beam heat sink portion separates the low beam reflector member into first and second segments such that light emitted by said at least one first low beam LED light source is reflected by the first segment and the light emitted by said least one second low beam LED light source is reflected by the second segment, said low beam reflector member including mating features for engaging the alignment features formed on the low beam mounting portion to facilitate the alignment of the low beam reflector member to the low beam heat sink and mounting assembly;a high beam headlamp module positioned adjacent to the low beam headlamp module including:at least one high beam LED light source;a high beam heat sink and mounting assembly including a high beam heat sink portion having first and second sides, said first side supporting the at least one high beam LED light source and a high beam mounting portion, said high beam mounting portion having alignment features formed therein;a high beam reflector member including an upper reflective portion and a lower portion, which are separated by the high beam heat sink portion, said high beam reflector member including mating features for engaging the alignment features formed on the high beam mounting portion to facilitate the alignment of the high beam reflector member with the high beam heat sink and mounting assembly; anda reflector carrier including:a first receiving pocket containing the low beam headlamp module, the first receiving pocket having recesses formed therein for accepting mounting extensions of the low beam headlamp module such that low beam headlamp module is aligned within said reflector carrier;a second receiving pocket containing the high beam headlamp module, the second receiving pocket having recesses formed therein for accepting mounting extensions of the high beam headlamp module such that high beam headlamp module is aligned within said reflector carrier; anda plurality of attachment features formed within a back side of the reflector carrier, wherein at least one of said plurality of attachment features facilitates adjustable attachment of the reflector carrier to a housing; anda housing including: an interior portion having a reflector carrier receiving portion defined therein, said reflector carrier receiving portion having attachment points through which at least one of the attachment features of the reflector carrier is adjustably fastened to the housing;a front turn/parking lamp reflector mounting area formed within the interior portion, said front turn/parking lamp reflector mounting area having attachment features through which the front turn/parking lamp reflector is attached to the housing;a cam feature formed within the front turn/parking lamp reflector mounting area for facilitating the attachment of a front turn/parking lamp socket assembly to the housing;an exterior portion having attachment points through which the housing is adapted to be mounted to a vehicle; anda circuit board module receiving opening formed within the interior portion of the housing for engaging a drive circuit housing. 15. The headlamp assembly of claim 14 further comprising a drive circuit module including a drive circuit housing with an interior portion adapted to contain a circuit board, a back portion having fins formed therein for heat dissipation and attachment tabs extending from drive circuit housing for attaching the drive circuit module to the headlamp housing at the circuit board module receiving opening. 16. The headlamp assembly of claim 14 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are formed from a thermally conductive material. 17. The headlamp assembly of claim 14 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are formed from a material in the group consisting of aluminum, copper and magnesium. 18. The headlamp assembly of claim 14 wherein the low beam heat sink and mounting assembly and the high beam heat sink and mounting assembly are treated with a thermally emissive coating to facilitate heat transfer through radiation and wherein the thermally emissive coating is an E-coat, an anodized coating, or a powder coat. 19. The headlamp assembly claim 14 wherein the low beam heat sink portion is oriented vertically such that it bisects the low beam headlamp module vertically. 20. The headlamp assembly of claim 14 wherein the low beam heat sink portion is oriented horizontally such that it bisects low beam headlamp module horizontally. 21. The headlamp assembly of claim 14 wherein the low beam mounting structure portion includes a plurality of mounting extensions protruding therefrom to facilitate alignment of the low beam headlamp module within the first receiving pocket of the reflector carrier and the high beam mounting structure portion includes a plurality of mounting extensions protruding therefrom to facilitate alignment of the high beam headlamp module within the second receiving pocket of the reflector carrier. 22. The headlamp assembly of claim 14 wherein the high beam reflector member and the low beam reflector member are formed of a thermoplastic or thermoset vacuum metalized material. 23. The headlamp assembly of claim 14 wherein the low beam heat sink portion includes a light source receiving portion formed therein on at least one of said first and second sides for receiving the at least one low beam LED light source and the high beam heat sink portion includes a light source receiving portion formed within the first side for receiving the at least one high beam LED light source. 24. The headlamp assembly of claim 14 wherein the high beam mounting portion includes fins for heat dissipation which terminate at a base portion of the high beam mounting portion. 25. The headlamp assembly of claim 23 wherein the light shield blocks light from the at least one low beam LED light source in a 10 U-90 U range. 26. The headlamp assembly of claim 23 wherein the reflector carrier further includes a carrier stabilizer feature extending from the reflector carrier to facilitate attachment of reflector carrier to the housing. 27. The headlamp assembly of claim 23 wherein the reflector carrier further includes: a receiving slot for a side reflex reflector;a slit formed in the receiving slot for accommodating a snap feature formed on said side reflex reflector; anda notch formed on an inner wall of reflector carrier adjacent to the slit for mating with the snap feature to secure a position of side reflex reflector within receiving slot. 28. The headlamp assembly of claim 23 wherein the reflector carrier further includes a socket and a pivot stud attached to at least one of said plurality of attachment features and a socket and adjuster pivot stud attached to another one of said plurality of attachment features, wherein adjuster pivot stud is adapted to facilitate movement of the reflector carrier with respect to the housing. 29. In a headlamp assembly with a housing including a high beam headlamp module with mounting extensions, a low beam headlamp module with mounting extensions, a reflector carrier comprising: a base;a first receiving pocket formed within the base containing the low beam headlamp module, the first receiving pocket having recesses formed therein for accepting mounting extensions of the low beam headlamp module such that low beam headlamp module fits within and is aligned within said reflector carrier;a second receiving pocket containing the high beam headlamp module, the second receiving pocket having a side wall extending forwardly from said base such that said second receiving pocket is positioned forwardly of said first receiving pocket, said second receiving pocket having recesses formed therein for accepting mounting extensions of the high beam headlamp module such that high beam headlamp module fits within and is aligned within said reflector carrier;wherein said high beam headlamp module is positioned adjacent to said low beam headlamp module; anda plurality of attachment features formed within a back side of the reflector carrier, wherein at least one of said plurality of attachment features facilitates adjustable attachment of the reflector carrier to the housing. 30. The reflector carrier of claim 29 further comprising a receiving slot for a side reflex reflector. 31. The reflector carrier of claim 30 wherein the reflector carrier further includes: a slit formed in the receiving slot for accommodating a snap feature formed on side reflex reflector anda notch formed on an inner wall of reflector carrier adjacent to the slit for mating with the snap feature to secure a position of side reflex reflector within receiving slot. 32. The reflector carrier of claim 29 further comprising a socket and a pivot stud attached to at least one of said plurality of attachment features and a socket and adjuster pivot stud attached to another one of said plurality of attachment features, wherein adjuster pivot stud is adapted to facilitate movement of the reflector carrier with respect to the housing. 33. The reflector carrier of claim 29 further comprising a carrier stabilizer feature extending from the reflector carrier to facilitate attachment of reflector carrier to the housing. 34. A modular high and low beam headlamp assembly with a housing, said headlamp assembly comprising: a low beam headlamp module including:a low beam heat sink and mounting assembly having a low beam heat sink portion with first and second sides and a low beam mounting portion having alignment features formed therein;a low beam reflector member coupled to the low beam heat sink and mounting assembly such that the low beam heat sink portion separates the low beam reflector member in to first and second segments;a first low beam LED light source positioned on said first side of the low beam heat sink portion for direction light towards said first segment of the low beam reflector;a second low beam LED light source positioned on said second side of the low beam heat sink portion for direction light towards said first segment of the low beam reflector;a high beam headlamp module positioned adjacent to the low beam headlamp module including:a high beam heat sink and mounting assembly including a high beam heat sink portion having first and second sides;a high beam reflector member including an upper reflective portion and a lower portion, which are separated by the high beam heat sink portion;at least one high beam LED light source positioned on a first side of the high beam heat sink portion; anda reflector carrier including:a first receiving pocket containing the low beam headlamp module;a second receiving pocket containing the high beam headlamp module; anda plurality of attachment features formed within a back side of the reflector carrier, wherein at least one of said plurality of attachment features facilitates adjustable attachment of the reflector carrier to the housing, wherein said reflector carrier is contained within the housing. 35. The modular high and low beam headlamp assembly of claim 34 wherein the low beam heat sink is oriented in a first plane and the high beam heat sink is oriented in a second plane that is perpendicular to the first plane. 36. The modular high and low beam headlamp assembly of claim 35 wherein the first low beam LED light source has a first optical axis and the second low beam LED light source has a second optical axis and the at least one high beam LED light source has a third optical axis that is perpendicular to the first optical axis and second optical axis. 37. The modular high and low beam headlamp assembly of claim 34 wherein the low beam reflector includes an outer rim and said low beam heat sink portion includes an edge portion protruding beyond said outer rim.
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