Head lamp assembly and method of assembling
By using springs as the fixing mechanism, the risk of rotation or displacement of traditional fixtures in LED headlight assembly is solved, tool-free manual assembly and thermal expansion compensation are achieved, simplifying the assembly process.
Patent Information
- Application Number
- CN202380064289.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-08-03
- Filing Date
- 2023-08-02
- Publication Date
- 2025-04-15
AI Technical Summary
Traditional fixtures (such as screws, thermal stacking, etc.) have the risk of rotation or displacement in LED headlight assembly, and require special assembly equipment and steps, and the space occupies a large amount of time, making it difficult to implement in compact headlight assembly.
Using a spring as a fixing mechanism, by inserting the spring into the side wall opening of the LED module base, the end portion of the spring protrudes from the side wall and engages with the engagement groove in the bracket of the reflector carrier, and a deformation force is applied until the front edge of the reflector carrier crosses the top of the pin of the LED module base.
The manual assembly of LED headlights without using any tool is achieved, providing greater flexibility and adaptability, compensating for thermal expansion problems between the LED module and the reflector carrier, and simplifying the assembly process.
Smart Images
Figure CN119836543A_ABST
Abstract
Description
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 394,838, filed on August 3, 2022, the contents of which are incorporated herein by reference. Background Art
[0003] A motor vehicle headlamp typically includes: a lamp fixed to a lamp support structure; and a reflector configured to collect light from the lamp and make it available for forming a headlamp beam. Light emitting diodes (LEDs) are increasingly used as lamp components in motor vehicle headlamps. In LED headlamps, the LED emitter and the LED support component can be mounted on one or more printed circuit boards or on another structural component (such as a heat sink, etc.). The circuit board can be fixed to the support structure to form an integrated LED module. The reflector can be carried on a reflector carrier. The LED module can be assembled to the reflector carrier to provide an LED headlamp assembly. In known assembly methods, the reflector carrier and the LED module are fixed to each other using conventional fixing devices (such as screws, heat stacking, etc.). However, conventional fixing mechanisms have disadvantages when applied to the assembly of LED headlamps. Summary of the invention
[0004] A method of assembling a headlamp includes inserting a spring into a spring receiving opening in a side wall or other structure that protrudes vertically from opposite sides of a base of an LED module so that opposite end portions of the spring protrude from the side wall in opposite directions. Spring engagement grooves formed in brackets extending from opposite sides of a platform of a reflector carrier engage the opposite spring end portions. A deforming force is applied to the spring end portions via the spring engagement grooves until the front edge of the reflector carrier passes over the top of a pin that protrudes vertically from the base of the LED module. The vertical spacing between the front edges of the base of the LED module decreases until the front edge is below the top of the pin. BRIEF DESCRIPTION OF THE DRAWINGS
[0005] A more detailed understanding may be obtained from the following description, which is given by way of example in conjunction with the accompanying drawings, in which:
[0006] Figure 1A is a perspective view of a headlamp assembly showing one end of a securing mechanism coupling an LED module to a reflector carrier of the headlamp assembly;
[0007] Figure 1B yes Figure 1A A perspective view of the headlight assembly from one side showing Figure 1A The other end of the fixing mechanism shown in ;
[0008] Figure 2 is a perspective view of an example headlamp assembly;
[0009] Figure 3 Yes Figure 3 A flow chart of a method for assembling an LED module to a reflector carrier;
[0010] Figure 4 is a perspective view of the bottom of the LED module;
[0011] Figure 5 yes Figure 2 a perspective side view of a headlamp assembly shown in;
[0012] Figure 6 yes Figure 2 a perspective side view of a headlamp assembly shown in;
[0013] Figure 7 yes Figure 2 a bottom view of the headlamp assembly shown in ;
[0014] Figure 8 yes Figure 2 a side view of the headlamp assembly shown in ;
[0015] Fig. 9 Shows Figure 2 a side cross-sectional view of the headlamp assembly shown in ; and
[0016] Fig.10 yes Figure 2 A force diagram of a headlamp assembly is shown in FIG. DETAILED DESCRIPTION
[0017] Examples of different light illumination systems and / or light emitting diode ("LED") embodiments will be described more fully below with reference to the accompanying drawings. It will be understood that the drawings are not to scale. Some features may be enlarged in size relative to other features to facilitate description of various structural details in the illustrated examples. These examples are not mutually exclusive, and features found in one example may be combined with features found in one or more other examples to achieve additional embodiments. Therefore, it will be understood that the examples shown in the accompanying drawings are provided for illustrative purposes only, and they are not intended to limit the present disclosure in any way. Like numbers always refer to like elements.
[0018] It will be understood that although the terms first, second, third, etc. can be used to describe various elements in this article, these elements should not be limited by these terms. These terms can be used to distinguish an element from another element. For example, the first element can be referred to as the second element and the second element can be referred to as the first element without departing from the scope of the present invention. As used herein, the term "and / or" can include any and all combinations of one or more associated listed items.
[0019] It will be understood that when an element such as a layer, region, or substrate is referred to as being "on" or "extending to" another element, it may be directly on or directly extending to another element, or there may also be intermediate elements. In contrast, when an element is referred to as being "directly on" or "directly extending to" another element, there may be no presence of intermediate elements. It will also be understood that when an element is referred to as being "connected" or "coupled" to another element, it may be directly connected or coupled to another element and / or connected or coupled to another element via one or more intermediate elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there is no presence of intermediate elements between the element and the other element. It will be understood that these terms are intended to cover different orientations of elements in addition to any orientation depicted in the figures.
[0020] Relative terms such as "below," "above," "upper," "lower," "horizontal," or "vertical" may be used herein to describe the relationship of one element, layer, or region to another element, layer, or region illustrated in the figures. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.
[0021] In conventional headlamp assembly methods, a reflector carrier is coupled to an LED module using conventional fixing devices such as screws, heat stacks, etc. However, conventional fixing mechanisms have disadvantages in LED headlamps. For example, tightening the screws poses a risk of the reflector carrier rotating or shifting relative to the LED module due to the torque applied to the screw head. Installing the screws requires a separate step and also requires screw installation equipment such as a power screw driver, heat stack equipment, jigs, placement holders, etc. In addition, the screws require a screw dome to cover the tip, which takes up space on the module. Typical headlamp assemblies have space limitations, which presents accessibility challenges when assembly is performed using manual or automated tools. Conventional assembly methods require dedicated assembly steps.
[0022] The structures and assembly methods described herein can provide greater flexibility in designing the reflector carrier. In addition, the coupling methods described herein can compensate for thermal expansion, which can create structural problems in the interface between the LED module and the reflector carrier. According to the methods described herein, assembly can be done manually without the use of any tools.
[0023] Figure 1A1 is a perspective view of a headlamp assembly 100 including an LED module 150 and a reflector carrier 170 assembled using screws 128. The LED module 150 includes a planar base 102 having a bottom surface 104 and a top surface (not visible) on which one or more circuit boards (not visible) may be mounted. Opposing sidewalls 107a, 107b may extend from the planar base 102 perpendicular to the plane in which the planar base 103 lies.
[0024] The reflector carrier 170 includes a platform 120 that receives an optical component 340, which is supported in a frame 341. The bottom surface 101 of the platform 120 is secured to a top surface (not shown) of the LED module 150 by means of screws 128. In an assembly method using screws, the reflector carrier 170 is assembled to the LED module 150 by first contacting the bottom surface 101 of the platform 120 with the top surface (not shown) of the LED module 150. Contact is maintained when a torque applying device such as a screwdriver engages a screw head 129 at one end of the screw 128. Torque can then be applied to the screw head of the screw 128 to advance the screw 128 through the flat base 102 and through the platform 120 until the tip (not shown) of the screw 128 is removed from the top surface 99 (at the top) of the platform 120. Figure 1B best shown in FIG) prominently.
[0025] Screws are simple attachment means that are widely used in the assembly of a wide variety of structures. However, there are disadvantages to using screws to couple the components of an LED headlamp assembly. For example, there is a risk that the torque applied to the rotating screw 128 will cause the base 102 of the LED module 150 to rotate relative to the platform 120 of the reflector carrier 340. In addition, the use of screws to assemble the structure may require special assembly equipment, such as electric screwdrivers, thermal stacking equipment, clamps, position holders, etc. The tightening process itself is a dedicated assembly step performed in addition to the assembly steps of contacting the platform 170 with the LED module 150 and fixing the contact. These preparatory steps must be performed before the tightening step can be performed.
[0026] Figure 1B yes Figure 1A 1. A perspective view of a headlamp assembly of FIG. 100. Dome 600 is shown enclosing the screw tip protruding from top surface 99 of platform 120 after screw 128 is inserted. As can be seen from the figure, dome 600 occupies a large portion of the top surface area of assembly 100.
[0027] Figure 2 According to Figure 31 is a perspective view of a headlamp assembly 1000 of a method of assembling as shown in a flowchart. The headlamp assembly 1000 includes a reflector carrier 300 and an LED module 200. It is noteworthy that the LED module 200 is shown coupled to the reflector carrier 300 without using screws that penetrate the reflector carrier 300 and the LED module 200.
[0028] The LED module 200 includes a base 202. The base 202 has a substantially rectangular flat top surface 203 that defines a first plane of the LED module 200. The base 202 has opposite side walls 207a, 207b. The side walls 207a, 207b extend from opposite sides of the base 202 in a direction substantially perpendicular to the first plane in which the flat top surface 203 is located. Figure 2 In the example of FIG. 2 , the side walls 207a, 207b define a second plane of the LED module 200. The second plane is substantially perpendicular to the first plane. The LED module 200 further includes pins 213a, 213b.
[0029] Pins 213a, 213b protrude from the top surface 203 of the base 202, perpendicular to the first plane, and opposite to the direction in which the side walls 207a, 207b extend. Pins 213a, 213b can be used as guides for aligning the reflector carrier 300 with the LED module 200, and can also be used to limit the movement of the reflector carrier 300, which will be explained below.
[0030] The LED package 215 may be disposed on the top surface 203 and may be located in a front end portion of the top surface 203. The LED package 215 may be mounted on a printed circuit board, and the printed circuit board may be disposed on the top surface 203. The connector 222 and other components may be disposed on the top surface 203 of the LED module 200. The base 202 may include a heat sink to dissipate heat generated by the LED package 215 and other components disposed on the base 202.
[0031] The headlamp assembly 1000 also includes a reflector carrier 300. The reflector carrier 300 includes a platform 303 supporting a reflector 340, which is supported by a reflector frame 341. Figure 2 In the example of FIG. 3 , the platform 303 has a substantially rectangular flat top surface 304 and a substantially rectangular flat bottom surface that defines a first plane of the reflector carrier 300. The brackets 307a, 307b extend from opposite sides 309a, 309b ( Figure 2 (not visible in the figure) extends in a direction substantially perpendicular to the first plane of the reflector carrier 300. Figure 2In the example of , the supports 307a, 307b define a second plane of the reflector carrier 300. The second plane of the reflector carrier 300 is substantially perpendicular to the first plane of the reflector carrier 300.
[0032] Each bracket 307a, 307b has a spring engagement slot 311a, 311b. The spring engagement slots 311a, 311b are configured to slidably engage opposite end portions of the spring 205 extending from an opening (not shown) in each of the opposite side walls 207a, 207b of the LED module 200. The reflector carrier 300 also includes a front edge 305 extending along the front side of the platform 303. The front edge 305 may have grooves 314a, 314b for accommodating the pins 213a, 213b.
[0033] Figure 3 Yes Figure 2 and Figure 3 The LED module 200 shown in FIG. Figure 2 Flow chart of the method of the reflector carrier 300 shown in FIG. Figure 3-Figure 10 Describe the method.
[0034] The spring may be inserted into a spring receiving opening in a side wall vertically protruding from opposite sides of a base of the LED module such that opposite end portions of the spring protrude from the side wall in opposite directions (802). Figure 4 An example spring 205 is shown inserted into example spring receiving openings 211a, 211b formed in example opposite side walls 207a, 207b of the LED module 200. The spring receiving openings 211a, 211b may have different Figure 4 The shapes shown in . For example, the openings 211a, 211b can be holes in the opposite side walls 207a, 207b. Any kind of opening that allows the opposite end portions of a spring, rod or other elongated flexible member to pass through the side wall can be suitable for embodiments within the scope of the embodiments described herein.
[0035] When the spring 205 is located in the spring receiving openings 211a, 211b, the opposite middle portions 223a, 223b of the spring 205 can contact the corresponding portions of the opposite side walls 207a, 207b defining each of the openings 211a, 211b. The opposite end portions 221a, 221b of the spring 205 can extend outwardly in opposite directions from the opposite side walls 207a, 207b.
[0036] like Figure 4As shown in FIG. 1 , the spring 205 is at rest (e.g., in its equilibrium position). The opposite spring end portions 221a, 221b may deform. When this occurs, the middle portions 223a, 223b contacting the opposite side walls 207a, 207b at the openings 211a, 211b may apply a force to the LED module 200 in the direction of the applied deformation force (e.g., in the direction in which the spring end portions 221a, 221b are deformed).
[0037] Spring 205 can be a simple spring. However, spring 205 need not necessarily be a spring. For example, spring 205 can include a flexible rod made of a flexible alloy such as spring steel. In general, any elongated flexible member (such as a shaft, rod, bar, etc.) can be suitable as long as it can be deformed and also has sufficient strength to return to its original shape after deformation. In some examples, spring 205 can be substantially straight in its rest position, such as Figure 4 . Alternatively, the spring 205 may have a curved or bent shape in its rest position. The spring 205 may include various other features, for example to prevent the spring 205 from being lost or inaccessible during assembly or alignment. Regardless of the shape of the spring 205 in its equilibrium position, the spring 205 may be configured to apply a restoring force in a direction that returns the spring 205 to its equilibrium position in response to any deforming force that deforms the spring 205 from its equilibrium position.
[0038] Back to Figure 3 , and refer to Figure 5 , opposite spring end portions 221a, 221b of spring 205 extending from side walls 207a, 207b can be aligned with opposite spring engagement slots 311a, 311b formed in opposite brackets 307a and 307b (804). Alignment can be performed by positioning LED module 200 relative to reflector carrier 300 so that platform 303 is generally aligned with base 202 along longitudinal axis y, wherein transverse axis x is generally parallel, so that LED module 200 can be moved between opposite brackets 307a, 307b of reflector carrier 300.
[0039] In the aligned position, the bottom surface 203 of the LED module 200 may face the bottom surface 201 of the platform 303 (at Fig. 9 ). The base 202 of the LED module 200 can be separated from the platform 303 by a distance that is at least sufficient to allow the pins 213a, 213b of the LED module 200 to clear the bottom surface 201 of the platform 303 when the LED module 200 moves the spring 205 toward the spring engagement slots 311a, 311b of the reflector carrier 300. At this point in the method, the spring 205 is in its equilibrium or rest position.
[0040] Generally speaking, the LED module 200 and the reflector carrier 300 can be aligned by manipulating one or both so that they are relatively positioned horizontally and vertically so that the LED module can be moved toward the reflector carrier 300, or vice versa, so that the end portions 221a, 221b of the spring 205 engage with the grooves 311a, 311b.
[0041] To bring the end portions 221a, 221b of the spring 205 into contact with the slots 311a, 311b, the LED module 200 can be aligned on the vertical axis so that the front edge 305 of the platform 303 is above the top of the pins 213a, 213b, as shown in FIG. Figure 6 as shown in . Figure 6 The LED module 200 is shown in a position where the end portions 221a, 221b of the spring 205 are initially in contact with the slot guides 440a, 440b (one visible) in the brackets 307a, 307b of the reflector carrier 300. The platform 303 and the base 202 are shown to be vertically aligned with the front edge 305 of the platform 303 separated by a distance from the base 202 of the LED module 200. This distance will be at least greater than the height of the pins 213a, 213b from the base 202 of the LED module 200. This distance will define an angle 7 between the platform 303 of the reflector carrier 300 and the base 202 of the LED module 200.
[0042] Angle 7 can be wide enough to ensure that the front edge 305 of the platform 303 is above the top of the pins 213a, 213b, thereby allowing the front edge 305 to pass over the pins 213a, 213b when the opposite end portions 221a, 221b of the spring 205 are engaging with the spring engagement grooves 311a, 311b via the guide portions 440a, 440b. At the first contact point between the end portions 221a, 221b of the spring 205 and the guide portions 440a, 440b, the spring 205 is in a balanced position.
[0043] Back to Figure 3 ,refer to Figure 6 , the reflector carrier 300 can be moved relative to the LED module 200 so that the opposite end portions 221a, 221b of the spring 205 apply force (806) along the guide portions 440a, 440b to the end portions 301a, 301b (not visible) of the spring engagement slots 311a, 311b. In an example embodiment, the end portions of the spring engagement slots 311a, 311b can be equipped with bearings (not shown) to accommodate the spring 205 when the spring 205 moves into the end portions 301a, 301b (not visible).
[0044] The LED module 200 and the reflector carrier 300 can move relative to each other so that the spring end portions 221a, 221b slide and engage in the groove. When this occurs, the inclined guide portions 440a, 440b can apply a deformation force to the end portions 221a, 221b in the vertical (+z) direction and in the direction of the longitudinal axis (+y) of the base 202 of the LED module 200. Therefore, when the end portions 221a, 221b of the spring 205 move along the guide portions 440a, 440b, the spring 205 can begin to deform along the resultant force of the deformation forces in the +z and +y directions, thereby bending the spring end portions in the resultant force direction R.
[0045] Figure 7 Yes Figure 6 2 is a bottom view of a portion of an LED module 200 and a reflector holder 400 shown in FIG. The opposing middle spring portions 221a, 221b may contact the base 202 via the openings 211a, 211b in the LED module 200. The spring end portions 221a, 221b are shown to bend in response to movement of the guide portions 440a, 440b along the slots 311a, 311b of the brackets 307a, 307b.
[0046] When the LED module 200 moves in the -y direction, the spring end portions 221a, 221b tend to bend in the +y direction toward the rear portion 41 of the base 202 and in the +z direction toward the platform 303 of the reflector holder 300 so as to move in the combined direction +R (in Fig.10 ). At the same time, the spring ends will exert an opposing restoring force on the guide portion in the -R direction. And at the same time, the intermediate spring portions 221a, 221b, which are in contact with the base 202 via the openings 211a, 211b, will exert a force on the base 202 in the +y direction, thereby opposing the movement of the base 202 in the -y direction.
[0047] It will be understood that all movements described herein are relative. In some embodiments, both the LED module 200 and the reflector carrier 300 can be manipulated relative to each other to achieve a combined movement. In other embodiments, either the LED module 200 or the reflector carrier 300 can be stationary, while the other can move. At any time during the execution of the method, the stationary can become mobile, and vice versa. For example, in one embodiment, the reflector carrier 300 can remain stationary, while the LED module 200 can move toward the reflector carrier 300, with the front end 40 of the LED module 200 leading.
[0048] return Figure 3, the relative movement between the reflector carrier 300 and the LED module 200 can be maintained (808) by moving the LED module 200 in the -y direction, thereby applying a deforming force to the end portions 221a, 221b of the spring 205. This can continue at least until the front edge 305 of the reflector carrier 300 passes over the pins 213a, 213b protruding from the base 202 of the LED module 200.
[0049] After the leading edge 305 leaves the top of the pins 213a, 213b, the angle 7 can be reduced (in Figure 6 ), so that the vertical spacing between the front edge 305 and the base 202 is reduced, thereby lowering the front platform 303 toward the base 202 behind the pins 213a, 213b (810). Figure 8 The front edge 305 of the reflector carrier 300 is shown after passing through the pins 213a, 213b and after reducing the vertical spacing. In this position, the front edge 305 is positioned close to the base 202 and presses against the pins 213a, 213b, and the spring end portions 221a, 221b are located in the grooves 311a, 311b.
[0050] Fig. 9 8 is a side section showing the relative structural positions of the LED module 200 and the reflector carrier 300 as a result of performing the action at 808. The base 202 can be substantially parallel to the platform 303 and extend beyond the front edge 305 of the reflector carrier 300 at the front end 40. The rear edge 503 of the platform 303 can be proximate to the connector 222. The front edge 305 can press against the pins 213a, 213b.
[0051] After performing 808, any force applied from the outside to the LED module and the reflector carrier to move them to perform the method can be removed. The LED module and the reflector carrier can now be firmly coupled without applying any external force.
[0052] Fig.10 3 is a force diagram showing the forces that maintain the coupling of the LED module 200 and the reflector carrier 300 after performing the method and removing any external forces. The groove 311a can exert a deformation force on the end portion of the spring 205 in the -y and -z directions, wherein the resultant force is in the -R direction, so that the spring end portion bends in the -R direction. The restoring force of the spring 205 can act in the +R direction, which tends to move the platform 303 (including the edge 305) in the +y direction, which will restore the spring 205 to balance. However, this movement can be blocked by the pins 213a, 213b of the LED module, thereby preventing the front edge 205 of the platform 303 from moving to allow the spring 205 to return to its resting position.
[0053] At the same time, the bending of the end portion of the spring 205 can exert a force in the +y direction on the base 202 of the LED module 200 via contact with the openings 211a, 211b in the side walls 207a, 207b. The restoring force will tend to move the base 202 in the -y direction. However, the pins 213a, 213b extending from the base 202 may encounter the front edge 305 of the platform 303 in the -y direction, which may prevent the base 202 from moving in the -y direction. The same combination of the deformation force and the restoring force on the spring 205 can act on the LED module 200 and the reflector carrier 300 in the +z and -z directions to prevent relative movement in the +z and -z directions.
[0054] exist Fig.10 In the position shown in , the forces are in balance and applied in a manner that can firmly couple the LED module 200 to the reflector carrier 300. Nevertheless, the flexibility of the spring 205 will still allow some small relative movement to accommodate relatively small forces due to environmental factors (such as thermal expansion of components).
[0055] Having described the embodiments in detail, those skilled in the art will appreciate that, given this description, modifications may be made to the embodiments described herein without departing from the spirit of the inventive concept. Therefore, it is intended that the scope of the invention not be limited to the specific embodiments illustrated and described.
Claims
1. A method of coupling an LED module to a reflector carrier in a headlamp assembly, comprising: inserting a spring into a spring receiving opening in a side wall vertically protruding from opposite sides of a base of the LED module so that opposite end portions of the spring protrude from the side wall in opposite directions; aligning opposed spring end portions with spring engagement slots formed in brackets extending from opposed sides of a platform of the reflector carrier; applying a deforming force to the spring end portion by moving the LED module to slide the spring end portion into the spring engagement slot until the front edge of the reflector carrier passes over the top of the pin protruding vertically from the base of the LED module; and The vertical spacing between the front edge and the base of the LED module is reduced until the front edge is below the tops of the pins.
2. The method of claim 1, wherein the aligning comprises: The LED module is positioned relative to the reflector carrier so that the spring end portion contacts the inclined guide portion of the spring engagement slot and the platform of the reflector carrier forms an angle relative to the base of the LED module sufficient to position the front edge of the platform above the top of the pin.
3. The method of claim 2, wherein applying a deforming force further comprises: The LED module is moved relative to the reflector carrier so that when the end portion of the spring is slidingly engaged with the inclined guide portion of the spring engagement groove, the inclined guide portion deforms the end portion in a first direction.
4. The method according to claim 3 further includes moving the LED module relative to the reflector carrier so that the spring end portion moves from the inclined guide portion to a groove formed at the end of the spring accommodating groove under the action of a spring restoring force at the spring end portion.
5. The method according to claim 1, further comprising: After lowering the front edge below the top of the pins, any forces applied from the outside to the LED module and the reflector carrier are released to perform the method.
6. The method of claim 5, further comprising, after the external force is released, maintaining a deforming force on the end portion of the spring by the pin, thereby preventing the leading edge from moving to a position that causes the spring to fully return to its rest position.
7. The method according to claim 6, wherein the LED module is held firmly engaged with the reflector carrier by a restoring force of a spring middle portion at a base of the LED module opposing the spring engagement groove.
8. The method of claim 1, wherein a groove is formed in the front edge, and the method includes aligning the pin with the groove.
9. The method of claim 1, wherein the reflector carrier is securely coupled to the LED module without performing any step of screwing the LED module to the reflector carrier.
10. The method of claim 2, wherein each of the spring engagement slots includes a bearing at an end of the slot, and wherein the method includes continuing to move the LED module relative to the reflector carrier after the spring ends contact the bearings.
11. The method of claim 1 , wherein the LED module coupled to the reflector carrier forms a headlamp assembly, and the method further comprises positioning the headlamp assembly in a vehicle.
12. The method of claim 1, wherein the method is performed manually by a person without applying torque to the LED module or the reflector carrier.
13. The method of claim 1, wherein the method is automatically performed by a machine.
14. A headlamp assembly comprising: An LED module including a base and opposing side walls extending vertically from opposing sides of the base, each opposing side wall having a spring receiving opening formed therein; and A reflector carrier includes a platform including a front edge portion and opposed brackets extending from opposite sides of the platform, each opposed bracket having a spring engagement slot formed therein.
15. The headlamp assembly of claim 13, further comprising a pin protruding vertically from a base of the LED module in a direction opposite to a direction in which opposing side walls extend from the base.
16. The headlamp assembly of claim 13, further comprising a spring guide bearing disposed in each spring receiving opening.
17. The headlamp assembly of claim 13, further comprising a spring disposed in the base such that opposing spring end portions extend from opposing side walls via spring receiving openings formed in each side wall.
18. The headlamp assembly of claim 14, wherein the opposed spring end portions are disposed in opposed spring engagement slots formed in each of the opposed brackets of the reflector carrier.
19. The headlamp assembly of claim 14, further comprising a groove formed in a front edge of the reflector carrier, wherein the pin is disposed within the groove.
20. A method of assembling a headlamp, comprising: inserting a spring into a spring receiving opening in a side wall vertically protruding from opposite sides of a base of the LED module so that opposite end portions of the spring protrude from the side wall in opposite directions; engaging opposite spring end portions with spring engagement slots formed in brackets extending from opposite sides of the platform of the reflector carrier; applying a deforming force to the spring end portion via the spring engagement slot until the front edge of the reflector carrier passes over the top of a pin protruding vertically from the base of the LED module; and The vertical spacing between the front edge and the base of the LED module is reduced until the front edge is below the tops of the pins.