GB2027862A - Method of attaching a metal light-source holder to a plastics head-light reflector - Google Patents

Abstract

Plastics studs 6, moulded directly in one piece with a head-light reflector 1, are provided along the periphery of an aperture 2 for the passage of the light-source bulb, the studs corresponding in position and dimensions to openings 7 provided on a metal light-source holder 5, and the ends of the studs are deformed against the rear surface of the light-source holder 5 when the holder has been positioned on the studs, to attach the holder 5 to the reflector 1. <IMAGE>

Description

SPECIFICATION Method of attaching a metal light-source holder to a plastics head-light reflector This invention relates to a method of attaching a metal light-source holder to a plastics headlight reflector.

Metal light-source holders generally consist of a metal disc which is stamped and cut out so as to provide means for fixing a lightsource such as a bulb, and means for fixing the light-source holder along the periphery of an aperture provided on the base of a reflector, the aperture being provided for receiving the light-source.

However, the operation of the means for fixing the bulb is frequently hindered by the means for fixing the light-source holder on the reflector, owing to the height of the latter.

Furthermore, the means for fixing the lightsource holder on the reflector, usually consisting of screws, rivets or clamps, are of complex construction and/or involve a relatively long mounting time.

There is thus a need for an improved method of attaching a light-source holder to a head-light reflector.

Accordingly the present invention provides a method of attaching a metal light-source holder to a plastics head-light reflector having an aperture therein for receiving a light source, in which plastics studs, moulded directly in one piece with the reflector, provided along the periphery of the aperture, and corresponding in position and dimensions to openings provided on the light-source holder, are engaged in the light-source holder openings and the ends of the studs projecting through the openings are deformed against the rear surface of the light-source holder to attach the latter to the reflector.

For a better understanding of the present invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: Figure 1 is a partial perspective view of the rear surface of a reflector and light-source holder, not yet assembled, and Figure 2 is a partial view of the Fig. 1 reflector with the light-source holder attached to it according to the method of the invention.

The method of the invention provides a strong, rapid and simple method of attaching a metal light-source holder to a plastics headlight reflector. The attachment does not form any excessive protuberances that might hinder the positioning and operation of means for fixing a light-source such as a bulb on the light-source holder.

The accompanying drawings thus show a reflector 1 made of a plastics material with good heat resistance, such as polysulphones, polyethersulphones, polycarbonates, polyterephthalates, butylene, etc., in order to avoid unwanted deformation in use. The reflector has an aperture 2 at its base for the passage of the bulb of the head light, the aperture being bounded by a cylindrical or polygonal flange 3 formed at the end of an extension 4.

The flange, which forms the bearing surface for the metal light-source holder 5, is provided with generally cylindrical studs 6, made integrally with the reflector 1 during its manufacture.

The light-source holder 5 preferably is produced by stamping and cutting out a metal disc. In the example illustrated, the lightsource holder 5 has a central aperture 5 for the passage of the bulb, cavities 52 to lighten it, bent edges 53 in the lightening cavities for centering the holder 5 on the flange 3 of the reflector, and slots 54 for the passage of a pin for fixing the bulb, the pin being positioned on hooks 55 at the outer periphery of the holder 5 for this purpose.

The holder 5 also contains openings 7 dimensioned and located to receive the studs 6 during assembly.

All that is then required in order to assemble the components is to position the holder 5 on the studs 6 by means of its openings 7, to press the holder 5 against the flange 3, then to deform, preferably by hammering, the ends of the studs 6 projecting from the openings 7, either with heat or ultrasonic means, so as to crush the plastics material of the studs 6 against the holder 5 and form flattened, fun-.

nel shaped heads of the studs which will fix the holder 5 strongly and accurately to the reflector.

The ends of all the studs can be hammered simultaneously by using an instrument adapted to the relative position of the studs.

1. A method of attaching a metal lightsource to a plastics head-light reflector having an aperture therein for receiving a light source, in which plastics studs, moulded directly in one piece with the reflector, provided along the periphery of the aperture, and corresponding in position and dimensions to openings provided on the light-source holder, are engaged in the light-source holder openings and the ends of the studs projecting through the openings are deformed against the rear surface of the light-source holder to attach the latter to the reflector.

2. A method according to claim 1, in which the studs are provided on a flange surrounding the aperture.

3. A method according to claim 1 or claim 2, in which the ends of the studs projecting through the openings are deformed by crushing, with or without accompanying heat or ultrasonic aid.

4. A method of attaching a metal lightsource holder to a plastics head-light reflector,

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (5)

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Method of attaching a metal light-source holder to a plastics head-light reflector This invention relates to a method of attaching a metal light-source holder to a plastics headlight reflector. Metal light-source holders generally consist of a metal disc which is stamped and cut out so as to provide means for fixing a lightsource such as a bulb, and means for fixing the light-source holder along the periphery of an aperture provided on the base of a reflector, the aperture being provided for receiving the light-source. However, the operation of the means for fixing the bulb is frequently hindered by the means for fixing the light-source holder on the reflector, owing to the height of the latter. Furthermore, the means for fixing the lightsource holder on the reflector, usually consisting of screws, rivets or clamps, are of complex construction and/or involve a relatively long mounting time. There is thus a need for an improved method of attaching a light-source holder to a head-light reflector. Accordingly the present invention provides a method of attaching a metal light-source holder to a plastics head-light reflector having an aperture therein for receiving a light source, in which plastics studs, moulded directly in one piece with the reflector, provided along the periphery of the aperture, and corresponding in position and dimensions to openings provided on the light-source holder, are engaged in the light-source holder openings and the ends of the studs projecting through the openings are deformed against the rear surface of the light-source holder to attach the latter to the reflector. For a better understanding of the present invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: Figure 1 is a partial perspective view of the rear surface of a reflector and light-source holder, not yet assembled, and Figure 2 is a partial view of the Fig. 1 reflector with the light-source holder attached to it according to the method of the invention. The method of the invention provides a strong, rapid and simple method of attaching a metal light-source holder to a plastics headlight reflector. The attachment does not form any excessive protuberances that might hinder the positioning and operation of means for fixing a light-source such as a bulb on the light-source holder. The accompanying drawings thus show a reflector 1 made of a plastics material with good heat resistance, such as polysulphones, polyethersulphones, polycarbonates, polyterephthalates, butylene, etc., in order to avoid unwanted deformation in use. The reflector has an aperture 2 at its base for the passage of the bulb of the head light, the aperture being bounded by a cylindrical or polygonal flange 3 formed at the end of an extension 4. The flange, which forms the bearing surface for the metal light-source holder 5, is provided with generally cylindrical studs 6, made integrally with the reflector 1 during its manufacture. The light-source holder 5 preferably is produced by stamping and cutting out a metal disc. In the example illustrated, the lightsource holder 5 has a central aperture 5 for the passage of the bulb, cavities 52 to lighten it, bent edges 53 in the lightening cavities for centering the holder 5 on the flange 3 of the reflector, and slots 54 for the passage of a pin for fixing the bulb, the pin being positioned on hooks 55 at the outer periphery of the holder 5 for this purpose. The holder 5 also contains openings 7 dimensioned and located to receive the studs 6 during assembly. All that is then required in order to assemble the components is to position the holder 5 on the studs 6 by means of its openings 7, to press the holder 5 against the flange 3, then to deform, preferably by hammering, the ends of the studs 6 projecting from the openings 7, either with heat or ultrasonic means, so as to crush the plastics material of the studs 6 against the holder 5 and form flattened, fun-. nel shaped heads of the studs which will fix the holder 5 strongly and accurately to the reflector. The ends of all the studs can be hammered simultaneously by using an instrument adapted to the relative position of the studs. CLAIMS

1. A method of attaching a metal lightsource to a plastics head-light reflector having an aperture therein for receiving a light source, in which plastics studs, moulded directly in one piece with the reflector, provided along the periphery of the aperture, and corresponding in position and dimensions to openings provided on the light-source holder, are engaged in the light-source holder openings and the ends of the studs projecting through the openings are deformed against the rear surface of the light-source holder to attach the latter to the reflector.

2. A method according to claim 1, in which the studs are provided on a flange surrounding the aperture.

3. A method according to claim 1 or claim 2, in which the ends of the studs projecting through the openings are deformed by crushing, with or without accompanying heat or ultrasonic aid.

4. A method of attaching a metal lightsource holder to a plastics head-light reflector, substantiaily as hereinbefore described, with reference to the accompanying drawings.

5. A combined metal light-source holder and plastics head-light reflector attached together by the method according to any one of claims 1 to 4.