Abstract: A bulb shield for use in an automotive headlamp assembly, and a method for making same. The bulb shield includes a cup portion and a portion which extends from the cup portion and is configured for mounting to a reflector of the automotive headlamp assembly or to another, proximate structure. When the bulb shield is mounted, the cup portion is generally horizontally aligned with a headlamp bulb in the automotive headlamp assembly, thereby eliminating a “hot spot” which would otherwise be viewable when looking into the headlamp beam. The bulb shield includes a part made of a glass and polymer blend, and at least a portion of the part includes a vacuum aluminized coating. Such a bulb shield is relatively inexpensive and easy to make, yet can withstand the high temperatures which are typically experienced in an automotive headlamp assembly. Additionally, the bulb shield may include a complex cup shape.

Abstract: A motorized headlamp adjuster which is operably connectable to a control circuit and which is engageable with a headlamp assembly. Specifically, the headlamp adjuster includes an adjuster output shaft which is engageable with a reflector of a headlamp assembly. The headlamp adjuster includes a housing, and the adjuster output shaft extends from the housing. The adjuster output shaft preferably has a sealing member thereon which seals with the housing. Preferably, an external surface of the housing also has a sealing member thereon for engaging and sealing with the housing of the headlamp assembly when the headlamp adjuster is installed. As such, the headlamp adjuster is sealed, and seals with a headlamp housing when installed. Preferably, the headlamp adjuster does not include several complex components and is relatively easy to assemble.

Abstract: A latch mechanism which includes two paddles that are engaged by a lock plate. The lock plate is configured to swivel into engagement with lock portions of the paddles, thereby generally locking the paddles in place. Preferably, the lock plate engages a substantial width of the lock portions to avoid creating an undesirable asymmetrical loading condition. As a result of engaging a substantial width of the lock portions of the paddles, the locking of the paddles is robust and reliable. Preferably, the lock portions on the paddles include a retention ramp that engages corresponding structure on the lock plate. The retention ramp renders the engagement between the lock plate and paddles generally more effective.

Abstract: A rear lighting backplate that includes a backplate lower which is engaged with a backplate upper. A lead frame is sandwiched between the backplate lower and backplate upper. The backplate lower includes a receptacle for receiving a wire harness, and the backplate upper includes one or more integral bulb sockets which are configured to receive bulbs. The lead frame conductively engages each bulb which is engaged with the backplate upper and conductively engages the wire harness which is engaged in the receptacle on the backplate lower. Preferably, the lead frame includes clips for conductively engaging and retaining the bulbs in the bulb sockets. The backplate is preferably configured for selective engagement and disengagement from a lamp housing. Preferably, the backplate provides a sealing surface around each bulb for sealing with the lamp housing when the backplate is engaged therewith.

Abstract: A headlamp adjuster which includes an adjuster output shaft which is engageable with a reflector of a headlamp assembly. The adjuster output shaft extends from a housing, and the headlamp adjuster is configured such that in an overload condition, the adjuster output shaft is prevented from translating substantially axially, thereby reducing the risk of damage resulting from over-travel of the adjustor output shaft.

Abstract: A headlamp adjuster which includes an adjuster output shaft which is engageable with a reflector of a headlamp assembly. The adjuster output shaft extends from a housing, and the headlamp adjuster is configured such that in an overload condition, the adjuster output shaft is prevented from translating substantially axially, thereby reducing the risk of damage resulting from over-travel of the adjustor output shaft.

Abstract: A bulb shield for use in an automotive headlamp assembly, and a method for making same. The bulb shield includes a cup portion and a portion which extends from the cup portion and is configured for mounting to a reflector of the automotive headlamp assembly or to another, proximate structure. When the bulb shield is mounted, the cup portion is preferably generally horizontally aligned with a headlamp bulb in the automotive headlamp assembly, thereby eliminating a “hot spot” which would otherwise be viewable when looking into the headlamp beam. Preferably, at least a portion of the cup portion of the bulb shield is electro-formed. Such a bulb shield is relatively inexpensive and easy to make, yet can withstand the high temperatures which are typically experienced in an automotive headlamp assembly. Additionally, such a bulb shield can be inexpensively provided, yet meet precision requirements.

Abstract: A window lift bracket for attachment to a mounting edge of a movable window and which is connectable to a window lifting mechanism. The window lift bracket includes a base which is attachable to the window lifting mechanism and spaced apart portions extending from the base being positionable on either side of the movable window. The spaced apart portions define a channel therebetween. The window lift bracket includes at least one member, such as a flexible beam member, which is disposed generally in the channel for engaging the window when the window is disposed therein. Preferably, the engagement between the member and the window provides a reduced stress area at the bottom of the channel. Opposing surfaces of the spaced apart portions may provide convoluted surfaces, such as protrusions and depressions, which effectively increase the surface area to which the adhesive adheres, thereby improving the adhesion of the adhesive to the window bracket and the window.

Abstract: A device for adjusting the position of a headlamp reflector of a headlamp assembly. The device includes a housing and a directing member, such as an adjustor screw, which generally extends from the housing. The directing member has an end which is engageable with the headlamp reflector of the headlamp assembly, and an opposite end which is configured to receive a driver generally coaxial with a longitudinal axis of the directing member. The directing member provides that rotation of the driver about an axis which is generally coaxial with the longitudinal axis of the directing member causes the directing member to translate relative to the housing thereby causing adjustment of the position of the headlamp reflector which is engaged with the first end of the directing member.

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.

Abstract: A device for adjusting an automotive headlamp reflector to a desired position and indicating a variance in the actual position of the headlamp reflector from the desired zero position. The device includes a directing member which can be operatively engaged with the reflector. An input shaft is provided in operative communication with the directing member, and the shaft, when rotated, can move the directing member in order to move the reflector to the desired position. A rotatable platform is disposed about the shaft. A planetary gear arrangement is provided which engages a gear on the shaft and includes an outer ring gear. Indicia is provided for indicating a position of the ring gear with relation to a position of the platform in order to indicate variance in the actual position of the headlamp reflector from the desired position.

Abstract: Apparatus for providing a visual indication of the horizontal and vertical orientation of a movable component of a headlamp assembly wherein said headlamp assembly is of the general type including a stationary housing and a movable reflector component, said movable component being pivoted to the stationary housing for movement in the vertical and horizontal plane by means of a stationary universal pivot and a vertical adjust mechanism vertically spaced from said stationary pivot and including a universal pivotal mounting to said movable component, and a horizontal adjust mechanism horizontally spaced from said stationary pivot and including a universal pivot effecting operative connection to said movable reflector component. The stationary universal pivot and said horizontal pivot define the vertical pivot axis for said component. Further said stationary universal pivot and the horizontal adjust pivot in effect defining a vertical pivot axis about which said movable component is pivoted in the vertical plane.

Abstract: A non-handed headlamp position indicator device is used to denote the proper aiming or "zero position" of a movable reflector component mounted in a stationary component of a headlamp arrangement so that a vehicle mechanic can easily return the headlamp in the moveable reflector component to the zero position. The non-handed indicator device of the present invention utilizes one component that can be used for right-hand and left-hand applications. The indicator device includes a bracket mounted on the reflector beneath an opening in the stationary housing which includes a U-shaped track portion. An arrow member is mounted on the U-shaped track portion and is slidable around the track portion. A scale, which includes a zero indicia, is provided on the stationary housing proximate to the opening.

Abstract: A self-drilling/self-tapping fastener which is suitable for attaching a sprinkler system to a metal supporting structure has a driving head and an integral shank with a threaded portion. Process-hardening and threading of the shank harden the shank to a degree of hardness that retains sufficient ductility for resisting vibration loads. The drill tip at the end of the shank and the lead threads adjacent the drill tip are locally hardened to a relatively high degree of hardness for drilling and tapping the metal support members. A graduated transition zone separates the high-hardness zone from the lower-hardness zone, which allows for a single fastener to exhibit two distinctly different material properties in one fastener. The fastener through this dual process also exhibits two distinct load-carrying capabilities.

Abstract: The indicating device is adapted to be installed on a platform on a headlamp frame with a slip fit and, once installed, is automatically locked into place. The indicating device includes a bubble level having a vial which is molded integrally with a base adapted to be assembled with a spring metal retaining bracket with a slip fit. The retaining bracket includes cantilevered legs with free end portions which resiliently engage the upper side of the base to enable an adjusting screw to tilt the vial upwardly and downwardly to various positions relative to horizontal.