Description:FIELD OF THE INVENTION
[001] Present invention relates to a headlamp assembly. Embodiments of the present invention relate to the headlamp assembly for a saddle type vehicle.

BACKGROUND OF THE INVENTION
[002] Generally, in conventional saddle type vehicles, a headlamp assembly is provided. The headlamp assembly is a device which is embedded in front of the saddle type vehicle and enables the saddle type vehicle to provide illumination in front of the saddle type vehicle. Conventionally, the headlamp assembly are provided with high beam reflectors and low beam reflectors. The high beam reflectors are provided on a top portion of the headlamp assembly, while the low beam reflectors are provided on a bottom side of the headlamp assembly and positioned below the high beam reflectors. Each of the high beam reflectors on the top side and the low beam reflectors on the bottom side requires at least two Printed Circuit Boards (PCBs) for wiring and supporting the headlamp assembly. Further, the top side and the bottom side construction of the high beam reflectors and the low beam reflectors respectively have no uniformity in the distribution of light, resulting, in a non-uniform tolerance variation. Herein, the tolerance variance refers to an acceptable range of variation that still allows for the proper functioning of the headlamp assembly.
[003] Further, a Daytime Running Light (DRL) unit is disposed on the saddle type vehicle, and the DRL unit is used as an indication to inform an incoming vehicle or pedestrians regarding the saddle type vehicle. One or more PCBs are disposed behind the DRL unit in a horizontal alignment such that the DRL unit and the one or more PCBs share identical horizontal axis and identical horizontal plane for controlling illumination of the DRL unit. However, such a disposition of the one or more PCBs creates a direct visibility of hotspots on light source of the DRL unit. Further, the hotspots consequently create a non-uniform illumination on the DRL unit and make certain area of the DRL unit to be in focus as compared to other parts of the DRL unit. Therefore, the disposition of the one or more PCBs behind the DRL unit reduces overall homogeneity and intensity of the light source.
[004] Additionally, the headlamp assembly is also provided with a bezel to cover the one or more PCBs and a heat sink. Conventionally, the bezel of the headlamp assembly is small and is unable to cover the constructional details of the headlamp assembly that are bigger in size. Also, the bezel is unable to provide ingress protection for the parts of the headlamp assembly. To overcome the problems associated with the bezel, a larger-sized bezel can be mounted onto the headlamp assembly. However, manufacturing of the larger bezel is difficult as the larger bezel involves undercut and ejection of the larger bezel part from a mould is tedious. Therefore, a single bezel is unable to cover the internal parts of the headlamp assembly as the thickness of the single bezel is not sufficient for some parts of the headlamp assembly.
[005] Further, a mould is required to accommodate each of the high beam reflectors and the low beam reflectors of the headlamp assembly. Hence, the overall mechanical part count of the headlamp assembly increases leading to a costly headlamp assembly. Further, such structure also leads to a complicated and complex intrinsic construction of the headlamp assembly. Also, the complex construction of the headlamp assembly leads to the increased manufacturing defects due to different parts of the headlamp assembly.
[006] Further, in the saddle type vehicle, wherein the packaging space is limited, the packaging of the multiple high beam reflectors and the low beam reflectors on the headlamp assembly is difficult, leading to poor aesthetics of the headlamp assembly on the saddle type vehicle.
[007] Thus, there is a need in the art for a headlamp assembly for a saddle type vehicle, which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[008] In one aspect, the present invention is directed towards a headlamp assembly for a saddle type vehicle. The headlamp assembly has a housing adapted to be mounted onto a frame member. Further, a reflector is disposed within the housing and the reflector has one or more high beam reflectors and one or more low beam reflectors. The headlamp assembly has an inner bezel mounted to the housing and the inner bezel is adapted to cover one or more Daytime Running Light (DRL) units. The headlamp assembly further has an outer bezel disposed over the inner bezel and the outer bezel is adapted to cover the top side of the reflector in a front-rear direction of the saddle type vehicle.
[009] In an embodiment of the invention, the one or more high beam reflectors is disposed at a position lower than the one or more low beam reflector.
[010] In a further embodiment of the invention, a gap is provided between the one or more high beam reflectors and the one or more low beam reflectors.
[011] In a further embodiment of the invention, the headlamp assembly has at least one rib disposed in the gap and the at least one rib is adapted to connect the one or more high beam reflectors and the one or more low beam reflectors.
[012] In a further embodiment of the invention, the headlamp assembly has one or more Printed Circuit Boards (PCBs) connected to one or more light sources.
[013] In a further embodiment of the invention, the one or more PCBs are disposed downwardly of the one or more DRL units in a top-down direction of the saddle type vehicle.
[014] In a further embodiment of the invention, the one or more DRL units are positioned on a lower portion of the housing.
[015] In a further embodiment of the invention, the outer bezel is located on a top side of the reflector in the front-rear direction of the saddle type vehicle.
[016] In a further embodiment of the invention, the inner bezel is located on a lower portion of the housing.
[017] In a further embodiment of the invention, the inner bezel is provided to cover a left side of the housing, a bottom side of the housing and a right side of the housing.
[018] In a further embodiment of the invention, the shape of the reflector is a polygonal structure and the shape of the one or more DRL units is a honeycomb structure.

BRIEF DESCRIPTION OF THE DRAWINGS
[019] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a left side view of a saddle type vehicle, in accordance with an embodiment of the present invention.
Figure 2 illustrates an exploded view of a headlamp assembly for the saddle type vehicle, in accordance with an embodiment of the present invention.
Figure 3 illustrates a perspective view of the headlamp assembly, in accordance with an embodiment of the present invention.
Figure 4 illustrates a front view of an outer bezel being mounted to a reflector of the headlamp assembly, in accordance with an embodiment of the present invention.
Figure 5 illustrates a sectional view of the headlamp assembly, in accordance with an embodiment of the present invention.
Figure 6 illustrates a sectional view of the headlamp assembly, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[020] The present invention relates to a headlamp assembly. Particularly, the present invention relates to the headlamp assembly for a saddle type vehicle. The headlamp assembly comprises a single piece reflector having one or more high beam reflectors and one or more low beam reflectors encased within a housing.
[021] Figure 1 illustrates an exemplary saddle type vehicle 10, in accordance with an embodiment of the invention. The saddle type vehicle 10 includes the headlamp assembly 100 arranged on an upper portion of a head pipe (not shown). The headlamp assembly 100 is disposed in front above a front wheel 12. Such a placement of the headlamp assembly 100 in the saddle type vehicle 10 ensures that a beam of light is directed in the front of the saddle type vehicle 10 in a front-rear direction, resulting in illumination of light in front of the saddle type vehicle 10. Consequently, improving visibility of a user of the saddle type vehicle 10.
[022] Referring to Figures 2 and 3 in conjunction with Figure 1, the headlamp assembly 100 is provided. The headlamp assembly 100 includes the housing 160 and a reflector 110. The housing 160 is configured to encase and protect the reflector 110 of the headlamp assembly 100. The reflector 110 is disposed within the housing 160 by means of conventionally known attachment provisions, such as fasteners, and the like. As further referenced in Figure 2, the reflector 110 is a unitary piece having one or more high beam reflectors 120a, 120b and one or more low beam reflectors 130a, 130b (as shown in Figure 4).
[023] The headlamp assembly 100 further has a heat sink 210 and a wiring harness 220. The heat sink 210 extends inwardly of the headlamp assembly 100 in a vehicle width direction. The heat sink 210 is configured to absorb the excessive heat or the unwanted heat from the one or more PCBs. The wiring harness 220 is configured to provide electric power to the headlamp assembly 100 for the illumination purposes.
[024] The headlamp assembly 100 further has one or more DRL units 200. The one or more DRL units 200 are configured to be switched ON automatically when an engine of the saddle type vehicle 10 is in running condition. Further, the headlamp assembly 100 comprises one or more Printed Circuit Boards (PCBs) 190 connected to one or more light sources. In an embodiment, the one or more Printed Circuit Boards (PCBs) 190 are connected to the one or more DRL units 200. The one or more PCBs 190 are configured to connect electronic components and the one or more light sources with each other in a controlled manner so as to control the illumination through the one or more DRL units 200. In an embodiment depicted in Figure 4, the one or more DRL units 200 are positioned on a lower portion of the housing 160. In an embodiment, the shape of the one or more DRL units 200 is a honeycomb structure. In the present embodiment, the term ‘lower portion’ pertains to a lower part of the housing 160 in a top-down direction of the saddle type vehicle 10. In an embodiment, the term ‘lower portion’ pertains to a lower or a bottom peripheral surface of the housing 160.
[025] Referring to Figures 5 and 6 in conjunction with Figure 2, the one or more PCBs 190 are disposed below the one or more DRL units 200. The one or more PCBs 190 acts as a basic part of the electronic system and at the same time for electrical connection of individual electronic components. The one or more PCBs 190 and the one or more DRL units 200 are welded together to assemble the one or more PCBs 190 below the one or more DRL units 200. The purpose of the one or more PCBs 190 are to activate the one or more DRL units 200 when the saddle type vehicle 10 is switched ON.
[026] The one or more PCBs 190 are disposed downwardly of the one or more DRL units 200 in a top-down direction of the saddle type vehicle 10. As shown, the one or more PCBs 190 are adapted to provide indirect illumination and also to provide the homogeneous light. The indirect illumination provided by the one or more PCBs 190 eliminates the visibility of the hotspots. Therefore, the one or more DRL units 200 eliminates the visibility of the vertical lines on the light guide. In an embodiment, six or more PCBs 190 are disposed below the one or more DRL units 200 on each side to confirm with the profile of the one or more DRL units 200.
[027] In an embodiment, as referenced in Figure 2, the headlamp assembly 100 includes the inner bezel 170. The inner bezel 170 is adapted to cover the one or more DRL units 200. Further, the headlamp assembly 100 comprises an outer bezel 180 disposed over the inner bezel 170. In an embodiment, the inner bezel 170 and the outer bezel 180 are adapted to cover the internal constructional details of the headlamp assembly 100. The inner bezel 170 and the outer bezel 180 are further configured to provide the ingress protection for the headlamp assembly 100.
[028] As further referenced in Figure 2, the headlamp assembly 100 has an outer lens 230. The outer lens 230 is configured to focus light on road. In an embodiment, the outer lens is produced by injection moulding. The components of the headlamp assembly 100 make for entire structure of the headlamp assembly 100 as shown in Figure 3.
[029] Referring to Figure 4 in conjunction with Figure 3, the headlamp assembly 100 is configured to be attached in front of the saddle type vehicle 10 for providing illumination. In the present embodiment, the headlamp assembly 100 is mounted on the saddle type vehicle 10 by means of one or more attachment provisions such as mounting provisions 240a, 240b, 240c, thereby mounting the headlamp assembly 100 on the front side of the saddle type vehicle 10. The left mounting provision 240a is configured to mount the left side of the headlamp assembly 100 to the saddle type vehicle 10. The middle mounting provisions 240b is configured to mount the middle side of the headlamp assembly 100 to the saddle type vehicle 10. The right mounting provision 240c is configured to mount the right side of the headlamp assembly 100 to the saddle type vehicle 10. Therefore, the mounting provisions 240a, 240b, 240c of the headlamp assembly 100 securely and safely attach the headlamp assembly 100 to the saddle type vehicle 10.
[030] Referring to Figure 4, the headlamp assembly 100 includes the housing 160 adapted to be mounted onto the frame member. In an embodiment, the headlamp assembly 100 comprises the reflector 110. The reflector 110 is made of a glass material or a metallic material and is configured for reflecting the light in the required direction for providing the illumination on road. Herein, as referenced in Figure 4, the reflector 110 is a single piece reflector to be disposed within the housing 160. In an embodiment, the shape of the reflector 110 is a polygonal structure. Further, referring to Figure 4, the reflector 110 includes one or more high beam reflectors 120a, 120b and one or more low beam reflectors 130a, 130b. The one or more high beam reflectors 120a, 120b are configured to project a beam of light to illuminate the road ahead for a longer distance. The one or more low beam reflectors 130a, 130b are configured to project the beam of light to illuminate the road ahead for a shorter distance as compared to the one or more high beam reflectors 120a, 120b.
[031] Further, the one or more high beam reflectors 120a, 120b are disposed at a position lower than the one or more low beam reflectors 130a, 130b. The one or more high beam reflectors 120a, 120b are integrated with the one or more low beam reflectors 130a, 130b. As shown in Figure 4, a gap 140a, 140b is provided between the one or more high beam reflectors 120a, 120b and the one or more low beam reflectors 130a, 130b. Further, a left gap 140a is provided between the left high beam reflector 120a and the left low beam reflector 130a. A right gap 140b is provided between the right high beam reflector 120b and the right low beam reflector 130b. Such a disposition of the gap 140a, 140b allows for providing a floating feel appearance and therefore, the high beam reflectors 120a, 120b and the low beam reflectors 130a, 130b are perceived to be as different portions.
[032] Further, as shown in Figure 4, at least one connecting rib 150a, 150b is disposed in the gap 140a, 140b and is adapted to connect the one or more high beam reflectors 120a, 120b and the one or more low beam reflectors 130a, 130b. Further, a left connecting rib 150a is provided between the left high beam reflector 120a and the left low beam reflector 130a and a right connecting rib 150b is provided between the right high beam reflector 120b and the right low beam reflector 130b. Such a disposition of the connecting rib 150a, 150b allows for the manufacturing of the single reflector 110 with ease through injection moulding. Further, the flow of material is also provided with ease and hence, the overall manufacturing process is enhanced.
[033] In an embodiment, as referenced in Figure 4, the headlamp assembly 100 includes the inner bezel 170 mounted to the housing 160. The inner bezel 170 is adapted to cover the one or more DRL units 200. The inner bezel 170 is located on the lower portion of the housing 160. The lower portion of the housing 160 is configured to engage the inner bezel 170 by means of conventionally known attachment provisions. Further, the inner bezel 170 is provided to cover a left side of the housing 160, a bottom side of the housing 160 and a right side of the housing 160. In an embodiment, the inner bezel 170 and the outer bezel 180 conforms to contour of an outer cover of the headlamp assembly 100. Consequently, the inner bezel 170 and the outer bezel 180 cover the outer cover of the headlamp assembly 100, thereby providing ingress protection to the headlamp assembly 100.
[034] In a further embodiment depicted in Figure 4, the headlamp assembly 100 comprises the outer bezel 180 disposed over the inner bezel 170. The outer bezel 180 is adapted to cover the top side of the reflector 110 in the front-rear direction of the saddle type vehicle 10. Further, the outer bezel 180 is located on a top side of the reflector 110 in the front-rear direction of the saddle type vehicle 10. The outer bezel 180 is adapted to provide a chrome finish of the bezel. The reflector 110 on the top side is covered by the outer bezel 180 as the top side of the reflector 110 is left uncovered by the inner bezel 170 since the top side has less thickness. Therefore, the disposition of the inner bezel 170 and the outer bezel 180 provides for the entire covering of the headlamp assembly 100.
[035] The claimed invention as disclosed above is not routine, conventional or well understood in the art, as the claimed aspects enable the following solutions to the existing problems in conventional technologies. Specifically, the claimed aspect relates to providing a headlamp assembly for a saddle type vehicle which ensures proper illumination of road for safety of a user. Further, the headlamp assembly is located in the packaging space available on front side of the saddle type vehicle above a front wheel, such that the location of the headlamp assembly allows for better utilisation of available dead packaging space. The present invention allows for the prevention of visibility of the hotspots to the user since the one or more PCBs are disposed below the one or more DRL units. Also, the outer bezel covers the see through gaps and provides for uniform and homogeneous surface. Further, the headlamp assembly provides for a single piece reflector, wherein the high beam reflectors and the low beam reflectors are integrated with each other. This allows for better performance and durability of the headlamp assembly, which lowers the overall part count due to the integration of the high beam reflectors with the low beam reflectors.
[036] Further, conventionally since a lot of headlamp assembly components are required to be manufactured, the present invention has reduced the overall headlamp assembly components and thereby, reducing the overall manufacturing costs and part count. Further, the present invention makes more packaging space available in the saddle type vehicle for mounting of other vehicle components as well.
[037] Further, the location of the headlamp assembly in the present invention is easily accessible, thus making assembly easier and less sophisticated. In addition, such disposition and the construction of the headlamp assembly reduces the complexity of the assembly, thus lowering the length of cable required to connect the different components of the headlamp assembly, which prevents copper losses. This leads to cost saving not only in terms of length of cable, but also in terms of reduced copper losses, leading to better overall vehicle efficiency.
[038] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

List of Reference Numerals and Characters
10 Saddle Type Vehicle
12 Front Wheel
100 Headlamp Assembly
110 Reflector
120a, 120b High Beam Reflectors
120a Left High Beam Reflector
120b Right High Beam Reflector
130a, 130b Low Beam Reflectors
130a Left Low Beam Reflector
130b Right Low Beam Reflector
140a, 140b Gaps
140a Left Gap
140b Right Gap
150a, 150b Ribs
150a Left Rib
150b Right Rib
160 Housing
170 Inner Bezel
180 Outer Bezel
190 Printed Circuit Boards (PCBs)
200 Daytime Running Light (DRL) units
210 Heat Sink
220 Wiring Harness
230 Outer Lens
240a, 240b, 240c Mounting Points
240a Left Mounting Point
240b Middle Mounting Points
240c Right Mounting Point
, Claims:WE CLAIM:
1. A headlamp assembly (100) for a saddle type vehicle (10), the headlamp assembly (100) comprising:
a housing (160) adapted to be mounted onto a frame member;
a reflector (110) disposed within the housing (160), the reflector (110) including one or more high beam reflectors (120a, 120b) and one or more low beam reflectors (130a, 130b);
an inner bezel (170) mounted to the housing (160), the inner bezel (170) being adapted to cover one or more Daytime Running Light (DRL) units (200); and
an outer bezel (180) disposed over the inner bezel (170), the outer bezel (180) being adapted to cover the top side of the reflector (110) in a front-rear direction of the saddle type vehicle (10).

2. The headlamp assembly (100) as claimed in claim 1, wherein the one or more high beam reflectors (120a, 120b) being disposed at a position lower than the one or more low beam reflectors (130a, 130b).

3. The headlamp assembly (100) as claimed in claim 1, wherein a gap (140a, 140b) is provided between the one or more high beam reflectors (120a, 120b) and the one or more low beam reflectors (130a, 130b).

4. The headlamp assembly (100) as claimed in claim 3, comprising at least one rib (150a, 150b) disposed in the gap (140a, 140b), the at least one rib (150a, 150b) being adapted to connect the one or more high beam reflectors (120a, 120b) and the one or more low beam reflectors (130a, 130b).

5. The headlamp assembly (100) as claimed in claim 1, comprising one or more Printed Circuit Boards (PCBs) (190) connected to one or more light sources.

6. The headlamp assembly (100) as claimed in claim 5, wherein the one or more PCBs (190) being disposed downwardly of the one or more DRL units (200) in a top-down direction of the saddle type vehicle (10).

7. The headlamp assembly (100) as claimed in claim 1, wherein the one or more DRL units (200) are positioned on a lower portion of the housing (160).

8. The headlamp assembly (100) as claimed in claim 1, wherein the outer bezel (180) being located on a top side of the reflector (110) in the front-rear direction of the saddle type vehicle (10).

9. The headlamp assembly (100) as claimed in claim 1, wherein the inner bezel (170) being located on a lower portion of the housing (160).

10. The headlamp assembly (100) as claimed in claim 1, wherein the inner bezel (170) being provided to cover a left side of the housing (160), a bottom side of the housing (160) and a right side of the housing (160).

11. The headlamp assembly (100) as claimed in claim 1, wherein the shape of the reflector (110) is a polygonal structure and the shape of the one or more DRL units (200) is a honeycomb structure.

Dated this 07 day of July 2023

TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471