DESC:COWL INTEGRATED HEADLAMP UNIT
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202321090081 filed on 30/12/2023, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to a mounting mechanism of lighting equipment(s) on vehicles. Particularly, the present disclosure relates to the mounting mechanism of headlamp of vehicle(s).
BACKGROUND
The growing demand for more affordable and efficient vehicles, combined with consumer preferences for higher-performing lighting systems pushes automobile manufacturers to innovate to meet the consumer demands. Consequently, the automotive industry has continuously sought to optimize vehicle lighting systems for improved performance, reduced weight, and cost-efficiency.
Conventionally, a headlamp assembly includes a headlamp unit that is mounted to a headlamp crown using a metal stay or additional structural support. The metal stays are metal brackets or reinforcements that are used to secure the headlamp unit to the headlamp crown thereby, ensuring a stable, vibration-resistant connection. The headlamp unit after the assembly with the required lightening components is mounted to the headlamp crown using metal stays, which are fastened using welding, riveting, or screwing. Once the headlamp assembly is complete, it is integrated into the vehicle front-end structure.

However, there are certain underlining problems associated with the above-mentioned mounting mechanism of the headlamp of vehicles. For instance, the addition of multiple metal stays increases the weight and cost of the headlamp assembly. Further, each stay is an additional part requiring sourcing, fabrication, and assembling and therefore, contributing to the overall complexity and time involved in production. Furthermore, misalignment of the headlamp unit, crown, or stays leads to misdirection headlamp beam and vehicle aerodynamics.
Therefore, there exists a need for a mounting mechanism of headlamp of vehicles that is efficient, safe, and overcomes one or more problems as mentioned above.
SUMMARY
An object of the present disclosure is to provide a headlamp assembly for a vehicle.
Another object of the present disclosure is to provide a headlamp assembly for a vehicle with improved structural integrity.
In accordance with an aspect of the present disclosure, there is provided a headlamp assembly for a vehicle, the headlamp assembly comprising:
- a headlamp crown comprising a front end and a rear end and;
- a headlamp unit comprising at least one source of illumination,
wherein the headlamp unit is mounted on the rear end of the headlamp crown via a plurality of fasteners.
The headlamp assembly for a vehicle, as described in the present disclosure, is advantageous in terms of providing a headlamp assembly with enhanced stability and durability. The mounting of the headlamp unit directly onto a headlamp crown ensures that the headlamp unit remains firmly in place during the vehicle operation under vibrations or external impacts. Further, the mounting via fasteners reduces the risk of misalignment or shifting of the headlamp unit and therefore, ensures that the headlamp unit remains in the precise orientation and delivers consistent illumination to the rider.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figures 1, and 2 illustrate a detailed view of a headlamp assembly for a vehicle, in accordance with different embodiments of the present disclosure.
Figure 3 illustrates an exploded view of a headlamp crown of the head lamp assembly, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
As used herein, the term “headlamp assembly” and “assembly” are used interchangeably and refer to a complete unit of lighting apparatus installed at the front of a vehicle, designed for visibility in low-light conditions. The headlamp assembly consists of the headlight housing, lens, light source, reflectors, and electrical connectors. The assembly is mounted on the front of the vehicle and is positioned to provide an optimal beam pattern for forward visibility. The headlamp assembly may include, but not limited to, high and low beam settings, turn signals, and daytime running lights, all integrated into a single unit.
As used herein, the terms “headlamp crown” and “crown” are used interchangeably and refer to the surrounding or enclosing component that forms the outer structure or casing of the headlamp unit. The headlamp crown serves as a protective outer structure that houses the internal components of the headlamp. Further, the headlamp crown maintains the shape and integrity of the headlamp by providing mounting points for attaching the headlamp to the vehicle. Additionally, the headlamp crown also serves as an aesthetic function, contributing to the overall design and appearance of the vehicle.
As used herein, the term “headlamp unit” refers to the complete assembly of components designed to provide forward illumination for a vehicle. It typically includes lenses, light sources (such as bulbs or LEDs), reflectors, and electrical connections that work together to ensure proper illumination of the road ahead. Further, the headlamp unit provides different lighting functions, such as low beams, high beams, bi-functional, and Day-time Running Lights (DRLs). The design of the unit ensures that the light is distributed evenly to avoid glare for other drivers while providing optimal visibility for the driver. The headlamp unit may further include adaptive lighting systems that automatically adjust the direction or intensity of the light based on driving conditions, such as steering angle, vehicle speed, or road elevation.
As used herein, the term “source of illumination” refers to any device that emits light to provide visibility in dark or low-light environments. Specifically, in a vehicle, the source of illumination is the light bulb or LED within the headlamp or lighting unit for producing the light. The illumination source affects the brightness, colour temperature, energy efficiency, and lifespan of the lighting system. Further, advanced lighting technologies such as adaptive headlights adjust the illumination based on vehicle speed, steering angle, or elevation, improving road safety. As automotive lighting technology continues to evolve, sources of illumination are becoming more energy-efficient and capable of offering better control over light distribution, reducing energy consumption while maximizing performance and safety.
As used herein, the terms “fastener” and “at least one fastener” are used interchangeably and refer to a means that physically joins or affixes two or more objects together. Additionally, the fasteners are used to build non-permanent joints that can be separated or dismantled without damaging the joining components. The fasteners may include, but not limited to, screws, nuts and bolts, clips and retainers, push-to-connect fasteners, and adhesives.
As used herein, the term “trims” refers to the decorative and functional components that surround the main headlamp unit, providing both aesthetic appeal and additional protection to the light source. The trims are made from materials such as plastic, chrome, or aluminium and are designed to complement the vehicle overall exterior styling. Further, the usage of the trims may include directing airflow around the headlamp to improve aerodynamics, preventing debris from entering the housing, and providing a mounting point for other lighting elements, like turn signals or daytime running lights.
In accordance with an aspect of the present disclosure, there is provided a headlamp assembly for a vehicle, the headlamp assembly comprises:
- a headlamp crown comprising a front end and a rear end; and
- a headlamp unit comprising at least one source of illumination,
wherein the headlamp unit is mounted on the rear end of the headlamp crown via a plurality of fasteners.
Referring to figure 1, in accordance with an embodiment, there is described a headlamp assembly 100 for a vehicle. The headlamp assembly 100 comprises a headlamp crown 102 comprising a front end 102A and a rear end 102B, and a headlamp unit 104 comprising at least one source of illumination. Further, the headlamp unit 104 is mounted on the rear end 102B of the headlamp crown 102 via a plurality of fasteners 106. Furthermore, the headlamp crown 102 comprises a top-end 102C and a bottom-end 102D.
The mounting of the headlamp unit 104 onto the rear end 102B of the headlamp crown 102 via a plurality of fasteners 106 enhances the stability and durability of the headlamp unit 104, ensuring that remains firmly in place during the vehicle operation. Specifically, mounting via the plurality of fasteners 106 reduces the risk of misalignment or shifting of the headlamp unit 104 during the vehicle operation and therefore, ensures that the headlamp unit 104 remains in the correct orientation and delivers consistent illumination. Further, the plurality of the fasteners 106 allows for simpler disassembly during repairs or replacements of the headlamp assembly 100. Furthermore, the positioning of the headlamp unit 104 at the rear end 102B of the headlamp crown 102 allows for optimized space utilization, minimizing the overall size of the headlamp assembly 100. Therefore, the above-mentioned configuration improves the structural integrity of the headlamp assembly 100, contributing to longer service life and consistent performance.
Referring to figure 2, in accordance with an embodiment, there is described a headlamp assembly 100 for a vehicle. The headlamp assembly 100 comprises a headlamp crown 102 comprising a front end 102A and a rear end 102B, and a headlamp unit 104 comprising at least one source of illumination. Further, the headlamp unit 104 is mounted on the rear end 102B of the headlamp crown 102 via a plurality of fasteners 106. Furthermore, the headlamp crown 102 comprises a top-end 102C and a bottom-end 102D. Furthermore, the plurality of fasteners 106 comprises a pair of top-end fasteners 106A and a pair of bottom-end fasteners 106B.
In an embodiment, the plurality of fasteners 106 comprises a pair of top-end fasteners 106A and a pair of bottom-end fasteners 106B. The distribution of the fastening points across the top and bottom of the headlamp unit 104, the headlamp assembly attains an even and secure attachment to the headlamp crown 102. Further, the above-mentioned configuration reduces the risk of misalignment or shifting during the vehicle operation, ensuring that the headlamp unit 104 remains in the correct orientation and delivers consistent illumination. Additionally, the placement of fasteners 106 facilitates even distribution of mechanical loads, minimizing stress concentrations and contributing to a longer lifespan for both the fasteners 106 and the headlamp assembly 100. The dual-point fastening also facilitates modularity, enabling quick and easy replacement or upgrading of the headlamp unit 104 without disturbing the overall assembly.
In an embodiment, the top-end fasteners 106A are located at the top-end 102C of the headlamp crown 102. Beneficially, the positioning of the top-end fasteners 106A at the top-end 102 of the headlamp crown 102 provides improved structural integrity through the natural distribution of forces during operation. Further, the top-end 102C of the headlamp crown 102 is less prone to impact and mechanical stress compared to the bottom-end 102D and thereby provides a stable connection to keeping the headlamp unit 104 accurately aligned and prevents excessive movement or misalignment, even under conditions such as vibration or thermal expansion. Consequently, the above-mentioned positioning maintains consistent light projection and optical performance over the lifespan of the headlamp assembly 100. Additionally, the location of the top-end fasteners 106A at the upper portion of the headlamp crown 102 offers practical advantages for assembly and serviceability. During the initial installation, the top-end fasteners 106A are accessed easily, ensuring straightforward mounting of the headlamp unit 104 onto the crown. Similarly, during maintenance or replacement, the top-end fasteners 106A quickly loosen up to remove the headlamp unit 104, facilitating efficient disassembly without the need to disturb other components. This ease of access reduces the time and complexity of both initial installation and future repairs or upgrades, making the headlamp assembly more user-friendly and cost-effective to maintain.
In an embodiment, the bottom-end fasteners 106B are located at the bottom-end 102D of the headlamp crown 102. Advantageously, positioning the bottom-end fasteners 106B at the bottom-end 102D of the headlamp crown 102 helps to enhance the overall stability and rigidity of the headlamp assembly 100. The bottom-end 102D is subjected to more mechanical forces, such as vibrations and impacts from road surfaces, and thereby the fastener at the bottom ensures that the headlamp unit 104 is firmly held in place, reducing the risk of shifting or loosening over time. Further, the placement of fasteners 106 facilitates proper alignment, ensuring the headlamp unit 104 performs optimally by providing consistent and focused illumination. Furthermore, the bottom location allows for easy access to the plurality of fasteners 106 during disassembly (replacing or upgrading the headlamp unit). Consequently, the repair process is simplified, as the bottom-end fasteners 106B are quickly removed without disturbing the other components or the alignment of the top-end fasteners 106A.
Referring to figure 3, in accordance with an embodiment, there is described a headlamp crown 102 of the head lamp assembly 100. The headlamp crown 102 comprises a front end 102A, a rear-end 102B, a top-end 102C and a bottom-end 102D. Furthermore, the plurality of fasteners 106 comprises a pair of top-end fasteners 106A and a pair of bottom-end fasteners 106B. Furthermore, the headlamp assembly 100 comprises a plurality of trims 108. Furthermore, the plurality of trims 108 comprises a top trim 108A, a right trim 108B, and a left trim 108C Advantageously, the plurality of trims 108 protects the sensitive components of the headlamp unit 104, such as the lens or illumination source, from external damage debris, impacts, or environmental factors. The trims 108 act as a shield against dirt, moisture, and minor physical impacts, preserving the integrity of the headlamp unit 104 and extends the lifespan. Additionally, the trims 108 help to provide a finished, seamless look to the headlamp assembly 100, enhancing the overall design by masking any exposed edges, thus contributing to a more refined and professional appearance. Moreover, trims 108 assist with aerodynamics by reducing drag or optimizing airflow around the headlamp assembly 100, improving the vehicle overall efficiency and performance.
In an embodiment, the plurality of trims 108 are removably attached to the headlamp crown 102. Advantageously, the removable attachment of the plurality of trims 108 to the headlamp crown 102 allows for easy removal, replacements, and servicing without disassembling the headlamp unit 104. Additionally, the removable trims 108 allow for simplified access to internal components of the headlamp assembly 100, facilitating easier cleaning, inspections, or upgrades to the illumination system without disrupting the overall structure of the headlamp crown 102.
In an embodiment, the plurality of trims 108 comprises a top trim 108A, a right trim 108B, and a left trim 108C. The inclusion of a top trim 108A, a right trim 108B, and a left trim 108C in the headlamp assembly 100 allows for precise and comprehensive protection of the headlamp assembly 100. Moreover, the trims 108 assist with aerodynamics by reducing drag or optimizing airflow around the headlamp assembly 100, improving the vehicle overall efficiency and performance. By designing the trims 108 to cover different sections of the headlamp crown 102, the above-mentioned configuration ensures that all exposed areas are adequately shielded from environmental factors such as dirt, moisture, and impacts. Further, the separation of the trims 108 into distinct sections, manufacturers or vehicle owners to easily select or change individual pieces to suit aesthetic preferences or specific vehicle designs.
Based on the above-mentioned embodiments, the present disclosure provides significant advantages such as (but not limited to) enhanced stability and durability of the headlamp unit, reduced misalignment of lamp, focused beam of illumination, ease of disassembly, and thereby, the headlamp assembly is more user-friendly and cost-effective
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combinations of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, and “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A headlamp assembly (100) for a vehicle, the headlamp assembly (100) comprising:
- a headlamp crown (102) comprising a front end (102A) and a rear end (102B);
- a headlamp unit (104) comprising at least one source of illumination,
wherein the headlamp unit (104) is mounted on the rear end (102B) of the headlamp crown (102) via a plurality of fasteners (106)

2. The headlamp assembly (100) as claimed in claim 1, wherein the headlamp crown (102) comprises a top-end (102C) and a bottom-end (102D).

3. The headlamp assembly (100) as claimed in claim 1, wherein the plurality of fasteners (106) comprises a pair of top-end fasteners (106A) and a pair of bottom-end fasteners (106B).

4. The headlamp assembly (100) as claimed in claim 1, wherein the top-end fasteners (106A) are located at the top-end (102C) of the headlamp crown (102).

5. The headlamp assembly (100) as claimed in claim 1, wherein the bottom-end fasteners (106B) are located at the bottom-end (102D) of the headlamp crown (102).

6. The headlamp assembly (100) as claimed in claim 1, wherein the headlamp assembly (100) comprises a plurality of trims (108).

7. The headlamp assembly (100) as claimed in claim 1, wherein the plurality of trims (108) are removably attached to the headlamp crown (102).

8. The transmission unit (100) as claimed in claim 7, wherein the gear transmission drive (112) comprises a plurality of driving gears (126) mounted on the input shaft (106) and a plurality of driven gears (128) mounted on the output shaft (122).

9. The headlamp assembly (100) as claimed in claim 1, wherein the plurality of trims (108) comprises a top trim (108A), a right trim (108B), and a left trim (108C).