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US 9,518,711 B2Granted
Modular headlamp assembly
AssigneeTruck-Lite Co., LLC
InventorsMike Marley, Gregory Alan Stoi
Life of this patent
Estimating the term…
Abstract
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.
Claims37
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;
- 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 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;
- and
- a 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;
- and
- a 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.
14 more elements
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;
- and
- a 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;
- and
- a 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;
- and
- a 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;
- and
- a circuit board module receiving opening formed within the interior portion of the housing for engaging a drive circuit housing.
22 more elements
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;
- and
- a 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.
3 more elements
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;
- and
- a reflector carrier including:
- a first receiving pocket containing the low beam headlamp module;
- a second receiving pocket containing the high beam headlamp module;
- and
- a 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.
12 more elements
Dependencies are inferred from the claim text.