DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
Title of invention:
A COMPACT AND SLEEK HEADLAMP ASSEMBLY IN TWO/THREE WHEELER AUTOMOBILES
APPLICANT:
Varroc Engineering Ltd.
An Indian entity having address as:
L-4, MIDC Waluj,
Aurangabad-431136,
Maharashtra, India

The following specification particularly describes the invention and the manner which is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present Application claims priority from an Indian Provisional Patent Application 202021019611 filed on 08th of June 2020, incorporated herein by reference.

TECHNICAL FIELD
The present disclosure relates to the field of headlamp assembly in automobiles, and more particularly to a compact and sleek headlamp assembly in Two/Three-wheeler automobiles.
BACKGROUND
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
In the conventional art, a Headlamp is mounted on a centre of a Handlebar Assembly in automobiles, especially in two-wheeler automobiles. Further, the Headlamp may comprise a plurality of light sources, a primary optical element, a secondary optical element, a printed circuit board for the plurality light sources, and a housing for the plurality of light sources.
In the conventional headlamp assembly described above, as the light sources and the optical elements are having large size and are bulkier in design, the cluster of Headlamp incorporating these components, in turn, is huge and bulkier thereby accumulating a large space in the handlebar of the two/three wheeler. Specifically, the functions like LB/HB projections in the conventional headlamp assembly are typically achieved using components like reflectors, collimators and projectors, etc. which results in overall increase in package size. Further, presence of a greater number of parts in the headlamp assembly results in a complex design thereby leading to overall increase in manufacturing cost.
Therefore, there is an utmost need of an improved headlamp assembly with a lesser number of parts and/or components thereby making the entire headlamp assembly simple to build yet with reduced cost and meeting the statutory requirements of light projection.
SUMMARY
This summary is provided to introduce concepts related to a compact and sleek headlamp assembly in motor vehicles and the concepts are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
The present disclosure relates to a headlamp assembly for a motor vehicle. The headlamp assembly may comprise a plurality of light sources, wherein the plurality of light sources may comprise a high beam light source and two or more low beam light sources. Further, the headlamp assembly may comprise a primary optic. Further, the primary optic may be secured with the plurality of light sources. Further, the headlamp assembly may comprise a plurality of daytime running lamp (DRL) collimators. Further, the daytime running lamp (DRL) collimators may be secured to the primary optic. Further, the headlamp assembly may comprise a plurality of printed circuit boards, wherein the plurality of printed circuit boards may comprise a printed circuit board for the plurality of light sources and a printed circuit board for the plurality of daytime running lamp (DRL) collimators. Further, the headlamp assembly may comprise a plurality of inner bezels, wherein the plurality of inner bezels may be configured to accommodate the primary optic equipped with the plurality of light sources. Further, the headlamp assembly may comprise a main bezel, wherein the main bezel may be configured to accommodate the plurality of inner bezels. Further, the headlamp assembly may comprise a main lens positioned in front of the optical element. Further, the headlamp assembly may comprise a casing, wherein the casing may accommodate the plurality of inner bezels, the main bezel, and the main lens. Further, the headlamp assembly utilized in the present disclosure has much more compact size and yet configured to project light from headlamps in accordance with the photometry regulations. In one embodiment, the headlamp assembly may be integrated to an Integrated Handlebar assembly of the motor vehicle, wherein the said Integrated Handlebar assembly integrates number of components/modules associated to the operation of the motor vehicle.
BRIEF DESCRIPTION OF DRAWINGS
The detailed description is described with reference to the accompanying Figures. In the Figures, the left-most digit(s) of a reference number identifies the Figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.
Figure 1 illustrates an exploded view of the headlamp assembly (hereinafter referred to as Compact D-lens Headlamp Assembly(100) interchangeably), in accordance with an embodiment of the present subject matter.
Figure 2 illustrates an isometric view 200 of a plurality of low beam D-lens of the Compact D-lens Headlamp Assembly(100), in accordance with an embodiment of the present subject matter.
Figure 3 illustrates an isometric view 300 of a high beam D-lens of the Compact D-lens Headlamp Assembly(100), in accordance with an embodiment of the present subject matter.
Figure 4 illustrates an isometric view 400 of complete assembly of the Compact D-lens Headlamp Assembly(100), in accordance with an embodiment of the present subject matter.
Figure 5 illustrates an Integrated Handlebar Assembly (IHB) accommodating the Headlamp comprising the Compact D-lens Assembly, in accordance with an embodiment of the present subject matter.
Figure 6 illustrates a profile of light projections from the Compact D-lens Headlamp Assembly(100), in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
Now referring to Figure 1, an exploded view of the Compact D-lens Headlamp Assembly(100) is illustrated, in accordance with an embodiment of the present subject matter. As shown, the Compact D-lens Headlamp Assembly(100) may comprise a fastener (102), a nitto cap (104), a heat sink (106), a grommet (108), a high beam D-lens (110), a plurality of Daytime Running Lamp (hereinafter referred to as DRL) collimators (112(a), 112(b)), a plurality of low beam D-lens (114(a) 114(b)), a plurality of inner bezels (116(a), 116(b)), a main lens (118), a main bezel (120), a casing (122), a plurality of fasteners (124), a plurality of printed circuit boards comprising a high beam/low beam printed circuit board (126), a Daytime Running Lamp (DRL) printed circuit board (128), and an aiming bracket (130).
In one embodiment, the High beam D-leans (110) may be mounted at the center of the Compact D-lens Headlamp Assembly(100). Further, the plurality of low beam D-lens (114(a) and 114(b)) may be mounted adjacent to the High beam D-Lens (110). It must be noted herein that, the plurality of low beam D-lens (114(a), 114(b)), and the High beam D-Lens (110) may collectively constitute a primary optic of the Compact D-lens Headlamp Assembly(100). Further, the inner bezel (116(a)) may be configured to provide housing means to the low beam D-lens (114(a)) and the DRL collimator (112(a)), and the inner bezel (116(b)) may be configured to provide housing means to the low beam D-lens (114(b)) and to the DRL collimator (112(b)). Further, the plurality of low beam D-lens (114(a),114(b)) and the High Beam D-lens (110) may be equipped with a plurality of light sources, wherein the plurality of light sources may comprise two or more light source for low beam, wherein the two or more light source for low beam may be equipped with the plurality of low beam D-lens (114(a),114(b)). Further, the plurality of light sources may also comprise a light source for high beam, wherein the light source for high beam may be equipped with the High Beam D-lens (110). Further, the plurality of light sources may comprise semi-conductor light-emitting elements (not shown in figure).
Further, the plurality of low beam D-lens (114(a) , 114(b)) and the High Beam D-lens (110) may be connected to the high beam/low beam printed circuit board (126) and the DRL collimator (112(a) and 112(b)) may also be connected to the Daytime Running Lamp (DRL) printed circuit board (128). Further, the plurality of low beam D-lens (114(a), 114(b)) may be enabled with the plurality of DRL collimators (112(a), 112(b)). Further, the plurality of low beam D-lens (114(a), 114(b)), the High Beam D-lens (110), the plurality of DRL collimators (112(a) ,112(b)), the high beam/low beam printed circuit board (126), the Daytime Running Lamp (DRL) printed circuit board (128), and the plurality of inner bezels (116(a) and 116(b)) may be further assembled within the casing (122) using the fasteners (124). Further, the casing (122) may be closed by a main bezel (120), wherein the main bezel may be further engaged with the assembly within the casing (122), thereby forming a Compact D-lens Headlamp Assembly(100). .
Now, referring to Figure 2, an isometric view 200 of a plurality of the low beam D-lens (114(a), 114(b)) is illustrated, in accordance with one embodiment of the present subject matter. Further, the plurality of D-lens (114(a) ,114(b) )may have a length ranging between 15-32 mm, a height ranging between 10-30 mm, and a width ranging between 12-20 mm. In one embodiment, the length, the height and the width of the low beam D-lens (114(a), 114(b)) may be 31 mm, 10 mm, and 22 mm, respectively. In one embodiment, the the plurality of D-lens (114(a) , 114(b)) may be equipped with a semi-conductor light-emitting elements (not shown in figure) as a light source. It is to be noted herein that the semi-conductor light-emitting elements may not be equipped with any secondary optical means. More specifically, the Compact D-lens Headlamp Assembly(100)of the present disclosure is enabled to acquire the function of switching from low beam projection to high beam projection and vice versa without using any secondary optical means such as reflectors. Therefore, the elimination of usage of secondary optics result in using lesser parts thereby resulting in ease of assembly and reduction in complexity in design and cost.
Further, in another embodiment, referring to Figure 3, an isometric view (300) of a high beam D-lens (110) is illustrated. The high beam D-lens (110) may have a length ranging between 28-32 mm, a height ranging between 20-25 mm, and a width ranging between 14-18 mm. In a preferred embodiment, the length, the height and the width of the High beam D-lens 110 may be 30 mm, 21 mm, and 16 mm respectively.
Now, referring to Figure 4, an isometric view (400) of complete assembly of the Compact D-lens Headlamp Assembly(100) is illustrated, in accordance an embodiment of the present subject matter. As depicted, the plurality of low beam D-lens 114(a) and 114(b) may be enclosed within the plurality of inner bezels (116(a), 116(b)), and wherein the plurality of inner bezels (116(a), 116(b)) may be accommodated in the main bezel (120), wherein the main bezel (120) may be further engaged with the main lens (118) to form a complete Compact D-lens Headlamp Assembly(100). Further, the casing (122) of the Compact D-lens Headlamp Assembly(100)may be provisioned with a heat sink (106) adapted to dissipate the heat accumulated within the Compact D-lens Headlamp Assembly(100) . In one embodiment, the compact and sleekly designed Compact D-lens Headlamp Assembly(100) may have a length ranging between 200-230 mm, a height ranging between 60-70 mm, and a width ranging between 100-105 mm. In a preferred embodiment, the length, height and width of the compact and sleekly designed Compact D-lens Headlamp Assembly(100)may be 219 mm, 66 mm, and 102 mm respectively.
Now, referring to Figure 5, an Integrated Handlebar Assembly (hereinafter referred to as IHB) (500) accommodating the Compact D-lens Headlamp Assembly(100) is illustrated, in accordance with an embodiment of the present subject matter. In one embodiment, the IHB may be configured to accommodate the Compact D-lens Headlamp Assembly(100). Further, the Compact D-lens Headlamp Assembly(100) may be mounted to the handlebar using the fastener (102). The fastener (102) may comprise a plurality of screws, wherein the fastener (102) may attach the Compact D-lens Headlamp Assembly(100) with the handlebar through the aiming bracket (130) attached to the heatsink.
In one embodiment, the IHB (500) may be utilized in the motor vehicle, wherein the motor vehicle may comprise two wheeler vehicles including, but are not limited to, motorbikes, scooters, mopeds, as well as three wheeler vehicles such as autorickshaws, and the like.
Figure 6 illustrates profile of light projections from the Compact D-lens Headlamp Assembly(100), in accordance with an embodiment of the present subject matter. It must be noted herein that although the aforementioned Compact D-lens Headlamp Assembly(100)is compact and sleek in design, however, the aforementioned Compact D-lens Headlamp Assembly(100)meets the Photometry requirements as per the regulations prescribed by at least ECE, FMVSS & CCC. It must be noted that in order to meet the Photometry requirements as per the regulations, the light projected from the D-lens may be provisioned to have a spread of ±25° in the horizontal direction, and up to -12° vertically downwards. Further, the Emax intensity spot may not be positioned downside vertically and may be maintained at -2.5° vertically. Further, the light projected at high beam may be provisioned to have a spread of 6° in vertical direction, and a spread of ±15° in the horizontal direction. Further, the Emax intensity spot may be maintained at 80 lx at 0.5° in vertically upwards direction. Further, the light projected at low beam may be provisioned to have a spread of -2.4° in horizontal direction, and a spread of -12° in vertical direction. Further, the Emax intensity spot may be maintained at 30.3 lx at 9° in vertically upwards direction.

Now, the aforementioned illustrated embodiments offer the following advantages over the conventional Headlamp Assembly, which may include but are not limited to:
• The present disclosure provides a Headlamp package including a pair of D lenses left and right, for LB function, a pair of DRL collimators and a single D lens for HB function in the middle within the stipulated area provisioned for the headlamp in the automobile.
• The present headlamp assembly employs semi-conductor light-emitting element behind each D-lens without any reflector to form a low beam & high Beam base with near field spread, comfort light and maximum range.
• The present headlamp assembly is compact in size and sleek in design with minimal number of parts thereby resulting in overall reduction in complexity in design, manufacturing cost and assembly time and further meets the photometry standards prescribed globally.
The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

The foregoing description shall be interpreted as illustrative and not in any limiting sense. A person of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. The embodiments, examples and alternatives of the preceding paragraphs or the description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.

Although implementations of the headlamp assembly for a motor vehicle have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as examples of implementations of the headlamp assembly for a motor vehicle.
,CLAIMS:WE CLAIM:
1. A headlamp assembly for a motor vehicle, comprising:
a plurality of light sources comprising a high beam light source and two or more low beam light sources;
a primary optic, wherein the primary optic is secured with the plurality of light sources;
a plurality of daytime running lamp (DRL) collimators (112(a), 112(b)) secured to the a primary optic;
a plurality of printed circuit boards comprising a printed circuit board (126) of the plurality of light sources, and a printed circuit board (128) for the DRL collimators(112(a), 112(b)), and wherein the plurality of printed circuit boards are positioned rearwards to the plurality of light source and the plurality DRL collimators (112(a), 112(b)), and accommodate the plurality of light source and the plurality DRL collimators (112(a), 112(b);
a plurality of inner bezels (116(a), 116(b)), wherein the plurality of inner bezels (116(a), 116(b)) are configured to accommodate the a primary optic equipped with the plurality of light sources;
a main bezel (120), wherein the main bezel (120) is configured to accommodate the plurality of inner bezels (116(a), 116(b)); and
a main lens (118), wherein the main lens (118) is positioned in front of the primary optic and is secured to the main bezel (120).

2. The headlamp assembly as claimed in claim 1, wherein the headlamp assembly further comprises a casing (122), wherein the casing (122) accommodates the plurality of inner bezels (116(a), 116(b)), the main bezel (118), and the main lens (118), and wherein the casing (122) is equipped with a heat sink (106).

3. The headlamp assembly as claimed in claim 1, wherein the primary optic comprises a plurality of D-lens, wherein plurality of D-lens comprises two or more low beam D-lens (114(a), 114(b)) and a high beam D-lens (110).

4. The headlamp assembly as claimed in claim 1 and 3, wherein the high beam light source is equipped with the high beam D-lens (110) and the two or more low beam light sources are equipped with the two or more low beam D-lens 114(a), 114(b).

5. The headlamp assembly as claimed in claim 4, wherein the High beam D-lens (110) is mounted at the center of the headlamp assembly, and wherein the plurality of low beam D-lens (114(a), 114(b)) are positioned adjacent to the High beam D-lens (110).

6. The headlamp assembly as claimed in claim 1 and 3, wherein the plurality of daytime running lamp (DRL) collimators (112(a), 112(b)) are secured to the plurality of low beam D-lens (114(a), 114(b)).

7. The headlamp assembly as claimed in claim 3, wherein the low beam D-lens (114(a), 114(b)) is having a length ranging between 15-32 mm, a height ranging between 10-30 mm, 15 and a width ranging between 12-20 mm.

8. The headlamp assembly as claimed in claim 3, wherein the high beam D-lens (110) is having a length ranging between 28-32 mm, a height ranging between 20-25 mm, and a width ranging between 14-18 mm.

9. The headlamp assembly as claimed in claim 2, wherein the casing (122) is having a length ranging between 200-230 mm, a height ranging between 60-70 mm, and a width ranging between 100-105 mm.

10. The headlamp assembly as claimed in claim 1, wherein the headlamp assembly is incorporated in an Integrated handlebar assembly (500) of the motor vehicle, wherein the headlamp assembly is positioned centrally on the Integrated handlebar assembly (500), and configured to emit light to the front region of the motor vehicle.

Dated this 08th day of June 2020

Priyank Gupta
Agent for the Applicant
IN/PA-1454