Embodiment of the present invention relates to automotive lighting systems and more particularly to a class-C headlamp with single chip LEDs and projector lens.
BACKGROUND OF THE INVENTION
A well-designed headlamp is one of the important aspects of a vehicle. The headlamp of a vehicle provides safe and comfortable driving conditions at night or in dark places. The projector is one of the important parts of the headlamp. A projector is used for illuminating larger road surface area and at greater distances. Traditionally a projector uses multiple filament lamps and/or HIDs for a low beam and/or high beam. Such filament lamps consume more power and provide limited illumination. But with the introduction of LEDs, the traditional bulbs and/or HIDs as a light source are being replaced by the LEDs in the projector headlamps.
LEDs provide more illumination and consume less power than the previously used light sources. The vehicular LED lamps have two configurations i.e., low-beam and high beam. But for getting better focus LEDs are generally used as the light source. The light of the LEDs covers area up to only 1200. The area enclosed by this coverage causes wastage of light inside the headlamp. The LEDs use multiple electronic circuits. The use of multiple electronic circuits generates a large amount of heat as well as acquire a lot of space inside the headlamp. Thus, heat management as well as space management also become an issue.
In the prior art, the use of multiple chip LEDs, multiple electronic circuits and the requirement of additional heat management system led to space constraints, more power consumption and increase in design and development cost of the headlamp projector.
Therefore, there is a need in the art for a class-C LED headlamp with a single chip LED and projector lens that does not suffer from above-mentioned deficiencies and provide an effective and viable solution.
OBJECT OF THE INVENTION
The object of the proposed invention is to provide a class-C headlamp with single chip LEDs and projector lens.
Another object of the present invention is to provide a compact size headlamp with single chip LEDs and projector lens.
Yet another object of the present invention is to provide an energy efficient headlamp projector.
Yet another object of the present invention is to provide a headlamp projector to cover a wider area of light.
Yet another object of the present invention is to provide a single PCB containing single chip LEDs for projection of high beam and low beam.
SUMMARY OF THE INVENTION
Embodiments of the present invention aim to provide a class-C headlamp with a single chip LEDs and projector lens.
According to an aspect of the present invention the class-C headlamp with a single chip LED and projector lens, may comprise a housing, configured to house a projector unit. Further, the projector unit may comprise a first projector portion for the high beam configuration, a second projector portion for the low beam configuration. In addition, each of the first projector portion and the second projector portion may comprise one or more single chip Light-emitting diodes (LEDs) configured to produce light, and a printed circuit board (PCB) may be configured to operate both the first projector portion and the second projector portion. Furthermore, the one or more single chip LEDs may be embedded in the PCB. Moreover, the PCB may be configured to supply electrical power to the one or more single chip LEDs.
In accordance with an embodiment of the present invention, each of the first projector portion and second projector portion may comprise one or more inner lens and one or more projector lens.
In accordance with an embodiment of the present invention, the one or more inner lens may be adapted to cover the one or more single chip LEDs.
In accordance with an embodiment of the present invention, the one or more inner lens may have an inner concave surface and an outer convex surface.
In accordance with an embodiment of the present invention, the one or more inner lens may be covered by the one or more projector lens.
In accordance with an embodiment of the present invention, the headlamp may comprise a transparent lens adapted to cover the projector unit positioned therein and the housing.
In accordance with an embodiment of the present invention, the housing may comprise a plurality of grooves, configured to secure the projector unit.
In accordance with an embodiment of the present invention, the light from the one or more single chip LEDs passes through the inner concave surface and the outer convex surface of the one or more inner lens to diverge the light of the one or more single chip LEDs.
In accordance with an embodiment of the present invention, the diverged light may enter into the surface of the one or more projector lens to converge light.
In accordance with an embodiment of the present invention, the converged light may pass through the transparent lens.
In accordance with an embodiment of the present invention, the headlamp may comprise an extension, sandwiched between the transparent lens and the housing, configured to support the projector unit.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments.
These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:
Fig. 1 illustrates a class-C headlamp with a single chip LED and projector lens, in accordance with an embodiment of the present invention;
Fig. 2 illustrates a projector unit of the class-C headlamp, in accordance with an embodiment of the present invention; and
Fig. 3 illustrates a front view of the class-C headlamp, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS
While the present invention is described herein by way of example using embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modification/s, equivalent/s and alternative/s falling within the scope of the present invention as defined by the appended claim. The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claim. As used throughout this description, the word "may" be used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must).
Further, the words "a" or "an" means "at least one” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including", "comprising", "having", "containing", or "involving" and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers, or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles, and the likes are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
In this disclosure, whenever an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element, or group of elements with transitional phrases “consisting of”, “consisting”, “selected from the group of consisting of”, “including”, or “is” preceding the recitation of the composition, element, or group of elements and vice versa.
This present invention described herein may be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.
In accordance with an embodiment of the present invention, a class-C headlamp (100) with single chip LEDs (106) and projector lens (112) is described. Figure 1 illustrates a class-C headlamp (100) with single chip LEDs (106) and projector lens (112), in accordance with an embodiment of the present invention. As shown in figure 1, the class-C headlamp (100) comprises a housing (102), a projector unit (104), and a transparent lens (114). The housing (102) is configured to house the projector unit (104). The housing (102) is envisaged to comprise a plurality of grooves (not shown). The plurality of grooves is used to fasten the projector unit (104) with the housing (102). The material for housing (102) maybe, but not limited to, polycarbonate, polypropylene, polybutylene terephthalate, nylon.
Further, as shown in figure 1, the projector unit (104) comprises a first projector portion (1044) and a second projector portion (1042). The first projector portion (1044) is designed for a high beam configuration. The high beam configuration is when the light from the headlamp (100) attains a high beam of light. The second projector portion (1042) is designed for a low beam configuration. The low beam configuration is when the light from the headlamp (100) attains a low beam of light.
Figure 2 illustrates a projector unit (104) of the class-C headlamp (100), in accordance with an embodiment of the present invention. As shown in figure 2, the projector unit (104) comprises a printed circuit board (PCB) (108). The PCB (108) is placed in a way to provide circuitry for both the first projector portion (1044) and the second projector portion (1042). Each of the first projector portion (1044) and second projector portion (1042) comprise one or more single chip Light-emitting diodes (LEDs) (106), one or more inner lens (110) and one or more projector lens (112) respectively.
Further, returning to figure 1, the one or more single chip LEDs (106) are embedded in the PCB (108). The PCB (108) may be, but not limited to, a single layer, double layer, multi-layer, Rigid-PCB (108), flexible, Rigid-Flex, High-frequency, Aluminium-backed. The PCB (108) is configured to supply electrical power to the one or more single chip LEDs (106). The one or more single chip LEDs (106) are covered by the one or more inner lens (110). The one or more inner lens (110) have an inner concave surface and outer convex surface.
The material for the one or more inner lens (110) may be, but not limited to, glass, polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS), Polypropylene (PP), Polymethyl Methacrylate (PMMA), and Polyethylene terephthalate (PET). The one or more inner lens (110) are covered by the one or more projector lens (112). The material for the one or more projector lens (112) may be, but not limited to, glass, polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS), Polypropylene (PP), Polymethyl Methacrylate (PMMA), and Polyethylene terephthalate (PET).
In accordance with an embodiment of the present invention, as shown in figure 1, the transparent lens (114) is used to cover the projector unit (104) positioned therein and the housing (102). The material for the transparent lens (114) may be made of a material having transparency and rigidity for ease of the passage of light. The material for the transparent lens (114) may be, but not limited to, glass, silicon, fiber glass, polypropylene, polybutylenes terephthalate, polycarbonate, or nylon.
Furthermore, in accordance with an embodiment of the present invention, as shown in figure 1, an extension (116) is provided. The extension (116) is sandwiched between the transparent lens (114) and the housing (102). The extension (116) is configured to support the projector unit (104). The material for the extension (116) may be, but not limited to, foam, rubber, metal, polypropylene, polybutylenes terephthalate, polycarbonate, acrylonitrile butadiene styrene (ABS), or nylon.
In accordance with an embodiment of the present invention, the PCB (108) is controlled by a switch (not shown). The PCB (108), on actuation of the switch, supplies the electrical power to the one or more single chip LEDs (106). The one or more single chip LEDs (106) produce light. As shown in figure 2, the light from the one or more single chip LEDs (106) passes through the one or more inner lens (110). The one or more inner lens (110) are used to diverge low-intensity light of the one or more LEDs (106).
In an aspect, as shown in figure 2, the diverged light covers a wider angle of the light area for example around 1700 and produces more illumination. The diverged light enters into the surface of the one or more projector lens (112). The one or more projector lens (112) converges light. The converged light is concentrated. The concentrated converged light passes through the transparent lens (114). As shown in figure 2, the projector lens (112) provides the output light that covers a wider angle of the light area and has a high intensity of illumination.
Figure 3 illustrates a front view of the class-C headlamp (100), in accordance with an embodiment of the present invention. As shown in figure 3, the concentrated converged light passes through the transparent lens (114) from the first projector portion (1044) and/or the second projector portion (1042) based on the selection made by a user operating the headlamp (100). The switch is configured to switch between the first projector portion (1044) and/or the second projector portion (1042) on commands of the user. The switch may be placed in a place easily operable by the user. The switch may be placed may be, but not limited to, on a handlebar, on dashboard, on steering wheel, on the head lamp or anyplace of a vehicle effortlessly approachable to the user.
The present invention provides a number of advantages. Firstly, a class-C headlamp (100) of the present invention solves the problem of the prior art by using single chip LEDs (106) and projector lens (112). The present invention uses class-C headlamp (100) reduce the area requirement for the electronic circuit of the headlamp (100). The present invention uses single chip LEDs (106) as a light source, providing the better illumination and much lesser consumption of battery power. The single chip LEDs (106) generates less heat. Due to the lesser heat generation, no heat sink is required to manage the head production. The use of single PCB (108) for high beam of light and the low beam of light reduce the size and cost of design of the present invention. The compact size and less power consumption of the present invention make it a cost-effective solution to the problems of the prior art.
Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be provided broadest scope consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.

We claim:

1.A class-C headlamp (100) with a single chip LED and projector lens, the headlamp (100) comprising:
a housing (102), configured to house a projector unit (104);
wherein the projector unit (104) comprising:
a first projector portion (1044) for the high beam configuration;
a second projector portion (1042) for the low beam configuration;
wherein each of the first projector portion (1044) and the second projector portion (1042) comprising one or more single chip Light-emitting diodes (LEDs) (106) configured to produce light; and
a printed circuit board (PCB) (108) configured to operate both the first projector portion (1044) and the second projector portion (1042);
wherein the one or more single chip LEDs (106) are embedded in the PCB (108); and
wherein the PCB (108) is configured to supply electrical power to the one or more single chip LEDs (106).
2. The headlamp (100) as claimed in claim 1, wherein each of the first projector portion (1044) and second projector portion (1042) comprising one or more inner lens (110) and one or more projector lens (112).
3. The headlamp (100) as claimed in claim 2, wherein the one or more inner lens (110) are adapted to cover the one or more single chip LEDs (106).
4. The headlamp (100) as claimed in claim 2, wherein the one or more inner lens (110) have an inner concave surface and an outer convex surface.
5. The headlamp (100) as claimed in claim 2, wherein the one or more inner lens (110) are covered by the one or more projector lens (112).
6. The headlamp (100) as claimed in claim 1 comprising a transparent lens (114) adapted to cover the projector unit (104) positioned therein and the housing (102).
7. The headlamp (100) as claimed in claim 1, wherein the housing (102) comprises a plurality of grooves configured to secure the projector unit (104).
8. The headlamp (100) as claimed in claim 2, wherein the light from the one or more single chip LEDs (106) passes through the inner concave surface and the outer convex surface of the one or more inner lens (110) to diverge the light of the one or more single chip LEDs (106).
9. The headlamp (100) as claimed in claim 8, wherein the diverged light enters into the surface of the one or more projector lens (112) to converge light.
10. The headlamp (100) as claimed in claim 9, wherein the converged light passes through the transparent lens (114).
11. The headlamp (100) as claimed in claim 6, comprising an extension (116), sandwiched between the transparent lens (114) and the housing (102), configured to support the projector unit (104).
Dated this the 4th day of February 2021.
[VIVEK DAHIYA]
AGENT FOR THE APPLICANT – IN/PA 1491.

ABSTRACT
A CLASS-C HEADLAMP WITH A SINGLE CHIP LED AND PROJECTOR LENS
A class-C headlamp (100) with a single chip LED and projector lens IS PROVIDED. The headlamp (100) comprising a housing (102), configured to house a projector unit (104). The projector unit (104) comprising a first projector portion (1044) for the high beam configuration, a second projector portion (1042) for the low beam configuration. Each of the first projector portion (1044) and the second projector portion (1042) comprising one or more single chip Light-emitting diodes (LEDs) (106) configured to produce light, and a printed circuit board (PCB) (108) configured to operate both the first projector portion (1044) and the second projector portion (1042). The one or more single chip LEDs (106) are embedded in the PCB (108). The PCB (108) is configured to supply electrical power to the one or more single chip LEDs (106).

We claim:
1. A class-C headlamp (100) with a single chip LED and projector lens, the headlamp (100) comprising:
a housing (102), configured to house a projector unit (104);
wherein the projector unit (104) comprising:
a first projector portion (1044) for the high beam configuration;
a second projector portion (1042) for the low beam configuration;
wherein each of the first projector portion (1044) and the second projector portion (1042) comprising one or more single chip Light-emitting diodes (LEDs) (106) configured to produce light; and
a printed circuit board (PCB) (108) configured to operate both the first projector portion (1044) and the second projector portion (1042);
wherein the one or more single chip LEDs (106) are embedded in the PCB (108); and
wherein the PCB (108) is configured to supply electrical power to the one or more single chip LEDs (106).
2. The headlamp (100) as claimed in claim 1, wherein each of the first projector portion (1044) and second projector portion (1042) comprising one or more inner lens (110) and one or more projector lens (112).
3. The headlamp (100) as claimed in claim 2, wherein the one or more inner lens (110) are adapted to cover the one or more single chip LEDs (106).
4. The headlamp (100) as claimed in claim 2, wherein the one or more inner lens (110) have an inner concave surface and an outer convex surface.
5. The headlamp (100) as claimed in claim 2, wherein the one or more inner lens (110) are covered by the one or more projector lens (112).
6. The headlamp (100) as claimed in claim 1 comprising a transparent lens (114) adapted to cover the projector unit (104) positioned therein and the housing (102).
7. The headlamp (100) as claimed in claim 1, wherein the housing (102) comprises a plurality of grooves configured to secure the projector unit (104).
8. The headlamp (100) as claimed in claim 2, wherein the light from the one or more single chip LEDs (106) passes through the inner concave surface and the outer convex surface of the one or more inner lens (110) to diverge the light of the one or more single chip LEDs (106).
9. The headlamp (100) as claimed in claim 8, wherein the diverged light enters into the surface of the one or more projector lens (112) to converge light.
10. The headlamp (100) as claimed in claim 9, wherein the converged light passes through the transparent lens (114).
11. The headlamp (100) as claimed in claim 6, comprising an extension (116), sandwiched between the transparent lens (114) and the housing (102), configured to support the projector unit (104).