Clutching Adjuster Helical Thread Segments Axial Resistance
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Solution Overview
Problem
Existing vehicle lamp adjusters lack effective end of travel clutching regardless of resistance and length of travel clutching, leading to potential damage from undue axial force and varying clutching force, which can affect the aim and durability of lamp components.
Innovation Solution
The adjuster incorporates helical thread segments in the housing that expand to clutch the ball stud when significant resistance is met, combined with annular travel barriers for end of travel clutching, ensuring consistent axial movement and preventing damage by engaging throughout the length of travel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the adjuster length of travel exceeds the reflectors' range of motion, then the adjuster can accommodate different lamp designs, but it may collide with other lamp components and build resistance force causing damage
Solution Approach 1:
The patent incorporates clutching mechanisms that engage before undue resistance can cause damage. The clutching feature allows the adjuster to slip or disengage when encountering resistance beyond a predetermined threshold, preventing damage to lamp components while maintaining the ability to accommodate different lamp designs through standardized travel length
2Reliability
If the adjuster provides end of travel clutching regardless of resistance, then it prevents adjuster disengagement and component damage, but it requires additional complexity in the clutching mechanism
Solution Approach 1:
The patent combines end-of-travel clutching and length-of-travel clutching into a single integrated mechanism. The clutching feature is implemented once in the adjuster structure, and it automatically provides protection at both the ends of travel and throughout the length of travel when resistance is encountered, eliminating the need for separate clutching mechanisms for each function
3Object-affected harmful factors
If the clutching force varies too high along the length of travel, then it can prevent damage from undue resistance, but it can also prevent achieving the desired aim positioning
Solution Approach 1:
The patent designs the clutching mechanism with specific parameters (such as clutching force threshold, engagement point, and slip characteristics) that allow it to engage only when resistance exceeds a predetermined level. This ensures that normal adjustment forces throughout the length of travel do not trigger clutching, maintaining positioning accuracy, while still providing protection when undue resistance is encountered
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides consistent clutching force along the length of travel and at the end of travel, preventing damage to lamp components and ensuring accurate positioning, while minimizing the risk of adjuster disengagement.
Implementation Method 1
The adjuster includes a housing with at least one helical thread segment molded into the nose of the housing. A threaded portion of the ball stud is engaged to the helical thread segment. If the ball stud meets a significant force resistance, the helical thread segment will expand outward over a ball stud thread outer portion to clutch and prevent damage
Implementation Method 2
End of travel clutching is provided using annular travel barriers on the ball stud... When the threaded portion of the ball stud is rotated so that the engagement point with the helical thread segment reaches the outbound annular travel barrier wall or the inbound annular travel barrier wall and the ball stud continues to rotate, the helical thread segments expand and attempt to jump over the barrier. However, one of the helical thread segments does not jump and provides a retaining force that prevents disengagement
Data Source
Figure 1~1A
Figure 2~2A
Figure 2AA~2AAA
AI summary
A clutching adjuster (20) having a housing (30) with a nose (40), the nose (40) including a plurality of discrete helically-shaped thread segments (42), a ball stud (50) journaled by a ball stud bore (34) for axial movement therethrough and passing through the nose (40) of the housing (30), the ball stud (50) having a threaded portion (52), an unthreaded portion (56), a ball (51), and a drive spline portion (57), an outbound annular travel barrier (53) and an inbound annular travel barrier (54), wherein, in length of travel clutching operation and end of travel clutching operation where the ball stud (50) is axially rotated through the ball stud bore (34), the receipt of an undue axial force of resistance on the ball stud (50) results in outward deflection of engaged thread segments (42), thereby allowing the threaded engagement between the threaded portion (52) of the ball stud (50) and the thread segments (42) to clutch.