Apparatus and method for mounting and adjusting LED headlamps

An LED headlamp assembly comprising:

• a lamp housing;
• a carrier including a front side and a back side;
• a heat sink thermally coupled to the back side of the carrier, said heat sink including a plurality of fins;
• a plurality of LED units mounted to the front side of the carrier;
• a flexible bellows attached to the carrier and the housing to allow the carrier to move independent of the housing, said bellows being attached to a flange on the carrier by a clip device and a flange on the housing by a clip device;
• a frame structure mounted to the housing adjacent to the back side of the carrier, said frame structure including a series of cross-members;
• an outer lens mounted to the housing and defining a sealed enclosure in which the LED units are mounted;
• and
• at least one actuator and pivot rod mounted to the frame structure and coupled to the carrier, said actuator and pivot rod being operable to adjust the position of the carrier on the bellows.

A method for providing an LED headlamp assembly, said method comprising:

• providing a lamp housing;
• providing a carrier including a front side and a back side;
• thermally coupling a heat sink to the back side of the carrier;
• mounting a plurality of LED units to the front side of the carrier;
• attaching a flexible bellows to the carrier and the housing to allow the carrier to move independent of the housing;
• mounting a frame structure to the housing adjacent to the back side of the carrier;
• and
• coupling at least one actuator and pivot rod to the frame structure and the carrier for adjusting the position of the carrier on the bellows.