Description:PROJECTOR ASSEMBLY FOR A HEADLAMP

FIELD OF THE INVENTION

The present disclosure generally relates to a projector assembly, and more particularly, to a projector assembly for an automotive headlamp for low beam projections.

BACKGROUND

Headlamps are employed in a vehicle, such as two-wheelers to facilitate the illumination of region, such as ground/road, ahead of the vehicle. Headlamps typically include two modes of operation, one being a high beam and the other being a low beam. In the high beam, a long-distance high beam is visible, and the low beam is preferred in traffic conditions for focusing the light on the road. For the low beams, a reflector setup uses a lens to concentrate light from a light source. Conventional reflector setups are bulky owing to the use of lenses and associated parts. In addition, the assembly is also difficult for these kinds of headlamps and the lamination loss is high due to the multiple number of parts in the headlamp assembly. In addition, the headlamp assembly is prone to failure or breakdown due to multiple parts.

Therefore, a headlamp assembly is desired that facilitates the illumination in low beam conditions and is easy to assemble, has less number of parts, is cost-effective, and provides light of higher luminous intensity of the ground ahead of the vehicle.

SUMMARY
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify essential inventive concepts of the invention nor is it intended for determining the scope of the invention.

The present disclosure relates to a headlamp for a low-beam light distribution pattern is disclosed. The projector assembly comprises a light source, an optical element disposed in proximity to the light source and adapted to receive, collimate, and refract a plurality of light rays. The optical element comprises a first surface proximate to the light source, a plurality of serrations defining an angular projection on the first surface and adapted to collimate the light rays from the light source as a plurality of collimated light rays, a middle portion defined above the first surface and adapted to refract the collimated light rays as a plurality of first refracted light rays and a second surface disposed opposite to the first surface to further refract the first refracted light rays to project on a focus site.

The projector assembly comprises a light source adapted to generate a plurality of light rays, and an optical element disposed in proximity to the light source and adapted to receive, collimate and refract the plurality of light rays. The optical element comprises a first surface proximate to the light source, and a plurality of serrations defining an angular projection on the first surface. The plurality of serrations is adapted to receive the light rays from the light source and collimate an exit beam of the light rays. In addition, the optical element comprising a second surface disposed opposite to the first surface. The second surface of the optical element receives the exit beam of the light rays passing through the plurality of serrations and projects on a focus site.

In another embodiment, the present disclosure relates to a headlamp assembly. The headlamp assembly comprises a housing, and a projector assembly for a low-beam light distribution pattern and is adapted to rest inside the housing. The projector assembly comprises a printed circuit board, a light source electrically coupled on the printed circuit board and adapted to generate a plurality of light rays, and an optical element disposed in proximity to the light sources and adapted to receive, collimate, and refract the plurality of light rays. The optical element comprises a first surface proximate to the light source a plurality of serrations defining an angular projection on the first surface the plurality of serrations is adapted to receive the light rays from the light source to collimate an exit beam of the light rays. In addition, the optical element comprises a second surface opposite to the first surface. The second surface of the optical element receives the exit beam of the light rays passed through the plurality of serrations to project on a focus site, and an outer lens defining an outer configuration of the headlamp assembly.

In another embodiment, the present disclosure relates to an optical element of a projector assembly of a headlamp. The optical element comprises a first surface proximate to a light source of the headlamp, a plurality of serrations defining an angular projection on the first surface. The plurality of serrations is adapted to receive the light rays from the light source and collimate an exit beam of the light rays. In addition, the optical element includes a second surface opposite to the first surface. The second surface of the optical element receives the exit beam of the light rays passing through the plurality of serrations and projects the light rays on a focus site defining a low beam light distribution pattern.

The headlamp assembly facilitates the low beam projection to facilitate the illumination of the road at higher luminous intensity. In addition, the headlamp assembly meets the AIS/ ECE R149 class-D homologation requirement. No additional parts such as a collimator not required to be mounted on the light sources thereby eliminating any lumen losses incurred by the collimator. The lesser no of parts facilitates an overall reduction of the cost, reduction of the weight, and reduction in the assembly time of the headlamp assembly thereby facilitating a compact arrangement with less not of parts in the headlamp assembly. The reduced number of parts in the headlamp assembly facilitates in easy replacement during any malfunctioning of the headlight assembly.

Further, the headlamp assembly achieves a higher luminous intensity with the same current drawn from the battery of the vehicle thereby preventing the draining of the battery and prolonging the battery life. Further, a clear vision is available to the rider/user at low beams with an aesthetically pleasing design of the headlamp assembly. In addition, the mounting of the projector assembly within the housing facilitates a sealed arrangement of the same thereby preventing any failure caused due to water or moisture thereby prolonging the life of the headlamp assembly.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates a front view of a headlamp assembly, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a side-sectional view of the headlamp assembly, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates an exploded view of the headlamp assembly, in accordance with an embodiment of the present disclosure;
Figure 4 illustrates an assembled view of a projector assembly, in accordance with an embodiment of the present disclosure;
Figure 5 illustrates an exploded view of the projector assembly, in accordance with an embodiment of the present disclosure;
Figure 6 illustrates a side-sectional view of the projector assembly, in accordance with an embodiment of the present disclosure;
Figure 7 illustrates a sectional view of an optical element with a light rays emitting from a light source illuminated, in accordance with another embodiment of the present disclosure;
Figure 8 illustrates a front-perspective view of the optical element, in accordance with another embodiment of the present disclosure;
Figure 9 illustrates a back-perspective view of the optical element, in accordance with another embodiment of the present disclosure; and
Figure 10 illustrates a bottom view of the optical element, in accordance with another embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

For example, the term “some” as used herein may be understood as “none” or “one” or “more than one” or “all.” Therefore, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would fall under the definition of “some.” It should be appreciated by a person skilled in the art that the terminology and structure employed herein is for describing, teaching, and illuminating some embodiments and their specific features and elements and therefore, should not be construed to limit, restrict, or reduce the spirit and scope of the present disclosure in any way.

For example, any terms used herein such as, “includes,” “comprises,” “has,” “consists,” and similar grammatical variants do not specify an exact limitation or restriction, and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated, for example, by using the limiting language including, but not limited to, “must comprise” or “needs to include.”

Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more…” or “one or more elements is required.”

Unless otherwise defined, all terms, and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by a person ordinarily skilled in the art.

Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

Referring to Figure 1 to Figure 3, a headlamp assembly 100 to facilitate the illumination of a front portion of a vehicle (not shown) is shown. Specifically, Figure 1 illustrates a front view of the headlamp assembly 100. Figure 2 illustrates a side-sectional view of the headlamp assembly 100. Figure 3 illustrates an exploded view of the headlamp assembly 100.

As shown in Figure 1 to Figure 3, the headlamp assembly 100 includes a housing 102, an outer lens 104 adapted to mechanically couple with the housing 102 and defining a transparent medium to facilitate the travel of the plurality of light rays, a bezel 106 adapted to extend between the outer lens 104 and the housing 102 to facilitate the coupling of the outer lens 104 with the housing 102 and provide an aesthetic presence to the headlight assembly 100. In addition, the headlight assembly 100 includes a driver printed circuit board 108 coupled with a battery (not shown) of the vehicle to enable an electrical connection in the headlight assembly 100. In an embodiment, the housing 102 and the outer lens 104 are coupled via a plurality of fasteners.

In addition, the headlamp assembly 100 may include a reflector assembly 110 to facilitate a high beam requirement of the headlight assembly 100 and a projector assembly 112 to facilitate a low beam requirement of the headlight assembly 100. In an embodiment, the reflector assembly 110 and the projector assembly 112 have an independent electrical circuit parallelly coupled with the driver printed circuit board 108 to enable an electrical connection for the reflector assembly 110 and the projector assembly 112. In an embodiment, the reflector assembly 110 may include a first printed circuit board 114 electrically coupled with the driver printed circuit board 108 to enable an electrical connection between the first printed circuit board 114 and the driver printed circuit board 108. In addition, the reflector assembly 110 may include a one or more light sources (not shown) on the first printed circuit board 114, and a reflector housing 116 to facilitate the reflection of the light in a high beam pattern. In addition, the reflector housing 116 may include a plurality of holes (not shown) to facilitate the ventilation of the air for absorbing heat from the reflector housing 116. In another embodiment, the reflector assembly 110 and the projector assembly 112 have a common electrical circuit (not shown) coupled with the driver printed circuit board 108 to enable an electrical connection for the reflector assembly 110 and the projector assembly 112.

Referring to Figure 4 to Figure 8, the projector assembly 112 of the headlight assembly 100 is shown. Specifically, Figure 4 illustrates an assembled view of the projector assembly 112. Figure 5 illustrates an exploded view of the projector assembly 112. Figure 6 illustrates a side-sectional view of the projector assembly 112. The projector assembly 112 is adapted to project the low beam of light from the headlight assembly 100 and enable a low beam light distribution from the headlight assembly 100.

The projector assembly 112 may include a printed circuit board 120 adapted to electrically couple with the driver printed circuit board 108 to enable an electrical connection in the printed circuit board 120, a light source 122 adapted to generate a plurality of light rays, an optical element 124 having serrations 154 disposed in proximity to the light sources 122 and adapted to receive, collimate and refract the plurality of light rays from the light source 122. In addition, the projector assembly 112 includes a heat sink 126 coupled with the printed circuit board 120. As shown, the heat sink 126 includes a plurality of fins 128 to facilitate the dissipation of the heat generated from the illumination of the light sources 122.

The heat sink 126 of the projector assembly 112 is adapted to mechanically couple with the housing 102 along a first end 130 and facilitates the mounting of the printed circuit board 120 on the heat sink 126. In addition, the heat sink 126 includes a second end 132 disposed opposite to the first end 130 and adapted to couple with the optical element 124. In an example, the heat sink 126 is made of aluminum, aluminum alloy, an Aluminum Die-Casted ADC alloy, or a ADC12 alloy of the aluminum to facilitate the heat dissipation from the projector assembly 112. The dissipation of the heat from the projector assembly 112 facilitates in reducing an operating temperature of the projector assembly 112. In addition, one or more fasteners or an adhesive may be used to facilitate the secure arrangement of the heat sink 126 within the housing 102 of the headlamp assembly 100. In an embodiment, the heat sink 126 may include a plurality of holes to facilitate the ventilation of the heat from the projector assembly 112.

Further, the printed circuit board 120 is mounted on the heat sink 126 along the first end 130. The printed circuit board 120 is adapted to mount the light sources 122 and facilitates an electrical connectivity and electrical power to the light source 122 for illumination. In an embodiment, the printed circuit board 120 may facilitate the mounting of the plurality of light sources 122.

Furthermore, the light source 122 is adapted to be mounted on the printed circuit board 120. The light source 122 may be a single light source or a plurality of light sources mounted on the printed circuit board 120 in any circuitry arrangement. In an example, the light source 122 may include but is not limited to a light emitting diode (LED), a chip on board (Cob) LED, a surface mounted diode (SMD) LED, or a dual in-line package (DIP) LED.

In addition, the optical element 124 of the projector assembly 112 is adapted to be mounted on the heat sink 126 such that the printed circuit board 120 is sandwiched between the optical element 124 and the heat sink 126. As shown in Figure 6, the optical element 124 includes a first end 134 adapted to couple with the heat sink 126 and a second end 136 disposed opposite to the first end 134 and adapted to face towards the outer lens 104 of the headlamp assembly 100. In addition, the optical element 124 includes a flange portion 138 disposed along the first end 134 to facilitate the coupling of the optical element 124 with the heat sink 126. Further, the optical element 124 includes at least one protruding portion 140 extending outwardly from the flange portion 138 towards the outer lens 104, In an example, the protruding portions 140 of the optical element 124 includes a first protruding portion 140a and a second protruding portion 140b coupled to the first protruding portion 140a via a bridge portion 142 to facilitate the secure arrangement of the optical element 124. In another embodiment, the optical element 124 may include a single protruding portion (not shown). In another embodiment, the optical element 124 may include a plurality of protruding portions (not shown). In an embodiment, the optical element 124 is made of a plastic molded components such as a polymethyl methacrylate to facilitate a transparent configuration to the optical element 124.

Referring to Figure 7 to Figure 10, the optical elements 124 are shown in various views and configurations. Specifically, Figure 7 illustrates a sectional view of the optical element 124 with the light source 122 illuminated. Figure 8 illustrates a front-perspective view of the optical element 124. Figure 9 illustrates a back-perspective view of the optical element 124. Figure 10 illustrates a bottom view of the optical element 124.

The first protruding portion 140a of the optical element 124 is explained. The structure, shape, and configuration of the first protruding portion 140a and the second protruding portion 140b are similar so for clarity and brevity only the first protruding portion 140a is explained. The first protruding portion 140a includes a first end 144 disposed proximate to the flange portion 138 and a second end 146 disposed opposite to the first end 144 and disposed proximate to the bridge portion 142. In addition, the first protruding portion 140a includes a central portion 148 projecting outwardly from the two ends 144, 146 such that the central portion 148 is disposed spaced apart from the light source 122. As shown, the central portion 148 of the first protruding portion 140a is adapted to receive the light rays from the light source 122.

In addition, the central portion 148 of the first protruding portion 140a includes a first surface 150 adapted to face towards the light source 122 and a second surface 152 disposed opposite to the first surface 150 and adapted to face towards the outer lens 104. In addition, the central portion 148 includes a middle portion 156 placed in between the first surface 150 and the second surface 152. In addition, the first surface 150 includes a plurality of serrations 154 defining an angular projections/bumps or a saw tooth shaped projections on the first surface 150, to receive the plurality of light rays from the light source 122. As shown in Figure 7, the plurality of serrations 154 on the first surface 150 of the central portion 148 of the first protruding portion 140a is adapted to receive the light rays from the light source 122 and collimate the light rays as a plurality of collimated light rays from the plurality of serrations 154. In an embodiment, the plurality of serrations 154 defines a grid shape configuration formed on the first surface 150 of the first protruding portion 140a of the optical element 124. In an embodiment, each of the plurality of serrations 154 is a type of a fish-eye lens extending along the first surface 150 in a grid pattern to collimate the light rays from the first surface 150. In an example, the angular projection of the plurality of serrations 154 has a radius in a range of 2 millimetres to 3 millimetres. In an exemplary embodiment, each of the plurality of serrations 154 spread about 2 millimetres to 4 millimetres horizontally and 2 millimetres to 4 millimetres vertically on the first surface 150. In an exemplary embodiment, the distance between the plurality of serrations 154 and the light source 122 is in the range of 10 millimetres to 15 millimetres.

As shown in Figure 7, the light source 122 generates a plurality of light rays 700a in all directions. The light rays 700a are incident on the plurality of serrations 154 of the first surface 150 of the optical element 124. The light rays 700a are collimated from the plurality of serrations 154. The collimated light rays are then refracted as a plurality of a first refracted light rays 700c via the middle portion 156 of the optical element 124. The first refracted light rays 700c are then again refracted as a plurality of exit light rays 700b after passing through the second surface 152 of the optical element 124. As shown, the exit light rays 700b from the optical element 124 are refracted light rays with very minimal deflection to facilitate the projection of the exit light rays 700b. Further, the middle portion 156 is adapted to receive the collimated light rays from the plurality of serrations 154 and refract the collimated light rays as a plurality of first refracted light rays 700c. In this manner, the exit light rays 700b are focused on a ground/road ahead of the vehicle.

The second surface 152 of the central portion 148 of the first protruding portion 140a of the optical element 124 may receive the first refracted rays 700c and is projected on a focus that may be a ground/surface or a road in front of the vehicle. In an embodiment, the second surface 152 of the central portion 148 of the first protruding portion 140a of the optical element 124 defines a plano-convex lens to project the exit beam of light rays. In an example, the maximum distance between the second surface 152 and the plurality of serrations 154 is in the range of 13 millimetres to 18 millimetres. In an exemplary embodiment, the second surface 152 is spread horizontally in the range of 30 millimetres to 40 millimetres and the vertical spread is in the range of 25 millimetres to 35 millimetres. In an exemplary embodiment, the second surface 152 is having a radius in the range of 10 millimetres to 40 millimetres.

The second protruding portion 140b is similar to the first protruding portion 140a and facilitates the receiving light rays from the light source 122 and refracts the exit light rays 700b from the second protruding portion 140b thereby facilitating a projection of the light rays on a ground/base ahead of the vehicle. The together focusing of the light rays from the first protruding portion 140a and the second protruding portion 140b of the optical element 124 defines the low beam of the headlamp assembly 100.

The advantages of the headlamp assembly 100 are now explained. The headlamp assembly 100 facilitates the low beam projection to facilitate the illumination of the road at higher luminous intensity. In addition, the headlamp assembly 100 meets the AIS/ ECE R149 class-D homologation requirement. No additional parts such as a collimator is not required to be mounted on the light sources 122 thereby eliminating any lumen losses incurred by the collimator. The lesser no of parts facilitates an overall reduction of the cost, reduction of the weight, reduction in the assembly time of the headlamp assembly 100 thereby facilitating a compact arrangement with less not of parts in the headlamp assembly 100. The reduced number of parts in the headlamp assembly 100 facilitates in easy replacement during any malfunctioning of the headlight assembly 100.

Further, the headlamp assembly 100 achieves a higher luminous intensity with the same current drawn from the battery of the vehicle thereby preventing the draining of the battery and prolonging the battery life. Further, a clear vision is available to the rider/user at low beams with an aesthetically pleasing design of the headlamp assembly 100. In addition, the mounting of the projector assembly 112 within the housing 102 facilitates a sealed arrangement of the same thereby preventing any failure caused due to water or moisture thereby prolonging the life of the headlamp assembly 100.

While specific language has been used to describe the present disclosure, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.
, Claims:We claim:

1. A projector assembly (112) of a headlamp assembly (100) for a low beam light distribution pattern, the projector assembly (112) comprising:
a light source (122) adapted to generate a plurality of light rays (700a); and
an optical element (124) disposed in proximity to the light source (122) and adapted to receive, collimate, and refract the plurality of light rays, the optical element (124) comprising:
a first surface (150) proximate to the light source (122);
a plurality of serrations (154) defining an angular projection on the first surface (150), wherein the plurality of serrations (154) is adapted to receive the plurality of light rays (700a) from the light source (122) and collimate the light rays as a plurality of collimated light rays;
a middle portion (156) formed above the first surface (150), wherein the middle portion (156) is adapted to receive the collimated light rays from the plurality of serrations (154) and refract the collimated light rays as a plurality of first refracted light rays (700c); and
a second surface (152) disposed opposite to the first surface (150) and disposed above the middle portion (156), wherein the second surface (152) of the optical element (124) receives the first refracted light rays (700c) from the middle portion (156) and refract the first refracted light rays (700c) as a plurality of exit light rays (700b) to project on a focus site.

2. The projector assembly (112) as claimed in claim 1, wherein the plurality of serrations (154) defines a grid formed on the first surface (150) of the optical element (124).

3. The projector assembly (112) as claimed in claim 1 comprising:
a printed circuit board (120) having a plurality of circuits to facilitate an illumination of the light source (122); and
a heat sink (126) coupled with the printed circuit board (120), and includes a plurality of fins (128) to facilitate the dissipation of the heat generated from the illumination of the light source (122).

4. The projector assembly (112) as claimed in claim 1, wherein the optical element (124) comprising a flange portion (138) adapted to couple the optical element (124) with the printed circuit board (120).

5. The projector assembly (112) as claimed in claim 1, wherein each of the plurality of serrations (154) defines a fish-eye lens configuration to collimate the light rays out from the first surface (150).

6. The projector assembly (112) as claimed in claim 1, wherein the second surface (152) of the optical element (124) defines a plano convex lens to project the exit light rays (700b) on the focus area.

7. A headlamp assembly (100), comprising:
a housing (102);
a projector assembly (112) for a low beam light distribution pattern and adapted to rest inside the housing (102), the projector assembly (112) comprising:
a printed circuit board (120);
a light source (122) electrically coupled on the printed circuit board (120) and adapted to generate a plurality of light rays (700a); and
an optical element (124) disposed in proximity to the light sources (122) and adapted to receive, collimate, and refract the plurality of light rays (700a), the optical element (124) comprising:
a first surface (150) proximate to the light source (122);
a plurality of serrations (154) defining an angular projection on the first surface (150), wherein the plurality of serrations (154) is adapted to receive the plurality of light rays (700a) from the light source (122) and collimate the light rays as a plurality of collimated rays;
a middle portion (156) formed above the first surface (150), wherein the middle portion (156) is adapted to receive the collimated light rays from the plurality of serrations (154) and refract the collimated light rays as a plurality of first refracted light rays (700c); and
a second surface (152) disposed opposite to the first surface (150) and disposed above the middle portion (156), wherein the second surface (152) of the optical element (124) receives the first refracted light rays (700c) from the middle portion (156) and refract the first refracted light rays (700c) as a plurality of exit light rays (700b) to project on a focus site; and
an outer lens (104) defining an outer configuration of the headlamp assembly (100).

8. The headlamp assembly (100) as claimed in claim 7, wherein the projector assembly (112) comprising:
a heat sink (126) coupled with a printed circuit board (120), and includes a plurality of fins (128) to facilitate the dissipation of the heat generated from the illumination of the light source (122).

9. The headlamp assembly (100) as claimed in claim 8, wherein each of the plurality of serrations (154) defines a fish eye lens configuration to collimate the light rays from the first surface (150), and the second surface (152) of the optical element (124) defines a plane convex lens to project the exit light rays (700b) on the focus area.

10. An optical element (124) of a projector assembly (112) of a headlamp assembly (100), the optical element (124) comprising:
a first surface (150) proximate to a light source (122) of the headlamp assembly (100);
a plurality of serrations (154) defining an angular projection on the first surface (150), wherein the plurality of serrations (154) is adapted to receive the plurality of light rays (700a) from the light source (122) and collimate the light rays as a plurality of collimated rays;
a middle portion (156) formed above the first surface (150), wherein the middle portion (156) is adapted to receive the collimated light rays from the plurality of serrations (154) and refract the collimated light rays as a plurality of first refracted light rays (700c); and
a second surface (152) disposed opposite to the first surface (150) and disposed above the middle portion (156), wherein the second surface (152) of the optical element (124) receives the first refracted light rays (700c) from the middle portion (156) and refract the first refracted light rays (700c) as a plurality of exit light rays (700b) to project on a focus site.

11. The optical element (124) as claimed in claim 10, wherein each of the plurality of serrations (154) defines a fish-eye lens configuration to collimate the light rays from the first surface (150), and the second surface (152) of the optical element (124) defines a plano-convex lens to project the exit light rays (700b) on the focus area.