Claims:WE CLAIM
1. A headlamp assembly (200) for a motor vehicle (100), the headlamp assembly (200) comprising:
a housing (300) having a compartment (350); and
a reflector (500) disposed inside the compartment (350) and detachably attached to the housing (300), the reflector (500) having a first region (520a), a second region (520b) and a third region (520c), each region configured to receive light from a light source and thereby reflect the light to illuminate an area in front of the motor vehicle (100).

2. The headlamp assembly (200) as claimed in claim 1, comprising a first printed circuit board (PCB) (400) detachably attached to a top surface (510) of the reflector (500), the first PCB (400) having a first light source (410a) conforming to the first region (520a), a second light source (410b) conforming to the second region (520b) and a third light source (410c) conforming to the third region (520c).

3. The headlamp assembly (200) as claimed in claim 2, wherein the first light source (410a), the second light source (410b) and the third light source (410c) comprise Light Emitting Diodes (LEDs).

4. The headlamp assembly (200) as claimed in claim 1, wherein the first region (520a) and the third region (520c) reflect light emitted from the first light source (410a) and the third light source (410c) to emit a low beam.

5. The headlamp assembly (200) as claimed in claim 1, wherein the second region (520b) reflects light emitted from the second light source (410b) to emit a high beam.

6. The headlamp assembly (200) as claimed in claim 1, wherein the first region (520a), the second region (520b) and the third region (520c) each comprising at least a bottom flat parabolic surface (522a, 522b, 522c) for reflecting more incident light.

7. The headlamp assembly (200) as claimed in claim 1, wherein the compartment (350) of the housing (300) comprises a position lamp (600) therewithin, the position lamp (600) being positioned below the reflector (500).

8. The headlamp assembly (200) as claimed in claim 7, wherein the position lamp (600) is detachably attached to the housing (300).

9. The headlamp assembly (200) as claimed in claim 7, wherein the position lamp (600) comprises a second printed circuit board (PCB) (650) having at least one light source.

10. The headlamp assembly (200) as claimed in claim 9, wherein the light source comprises a Light Emitting Diode (LED).

11. The headlamp assembly (200) as claimed in claim 1 or 7, wherein the headlamp assembly (200) comprises a masking member (700) received by the reflector (500) and the position lamp (600), and detachably attached to the housing (300) by fastening means.

12. The headlamp assembly (200) as claimed in claim 1, wherein the headlamp assembly (200) comprises a lens (800) detachably attached to the housing (300) and defining an anterior outer wall (810) of the headlamp assembly (200).

13. The headlamp assembly (200) as claimed in claim 12, wherein periphery of the housing (300) comprises plurality of locking loops (330a, 330b, 330c).

14. The headlamp assembly (200) as claimed in claim 12 or 13, wherein periphery of the lens (800) comprises plurality of locking loops corresponding to the plurality of the locking loops (330a, 330b, 330c) of the housing (300) for detachably attaching the lens (800) to the housing (300).
, Description:FIELD OF THE INVENTION
[001] The present invention relates to a headlamp assembly for a motor vehicle.

BACKGROUND OF THE INVENTION
[002] Motor vehicles are generally provided with headlamps in front for illuminating a road or a path ahead of them, especially during night travel. A headlamp assembly typically has a light source and a reflector housed inside a housing. The light source is either filament headlamp or a Light Emitting Diode (LED) positioned within the housing and connected to a heat sink which is further electrically connected to a power source. The reflector is positioned inside the housing in such a manner that it reflects the light originating from the light source to a region in front of the motor vehicle. A bezel is affixed on the housing which receives a lens thereby enclosing the housing.
[003] However, the reflector along with the heat sink adds to total weight of the headlamp assembly. It must be noted that roads, especially in developing countries, are still bumpy and uneven. Continuous riding over uneven roads causes loosening of fasteners over a short period of time. This results in vibration and rattling of the entire headlamp assembly while riding. The problem aggravates when an important part like the reflector, also loosens and vibrates on its own. This unfavourably leads to an uneven light focus and eventually causes mishaps due to affected vision. Since reflectors are generally permanently affixed to the bezel or the housing or both, any damage caused to the reflector by mechanical wear or accidents, requires replacement of the entire headlamp assembly.
[004] Further, there are many instances whereby due to an upgrade, or advancement in technology, the individual parts of the headlamp assembly require replacement. It must be noted that the reflector being a vital part of the headlamp assembly undergoes maximum wear; is exposed to maximum physical damages; and given its nature of use in the assembly, several technological advancements happen around the reflector. However, as the reflector is permanently affixed to the bezel or the housing, as mentioned earlier, in case the reflector requires repair or replacement, the entire headlamp assembly needs to be changed.
[005] Thus, there is a need in the art for a headlamp assembly, which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[006] The present invention is directed to a headlamp assembly for a motor vehicle. The headlamp assembly has a housing having a compartment; and a reflector disposed inside the compartment and detachably attached to the housing, the reflector having a first region, a second region and a third region, each region configured to receive light from a light source and thereby reflect the light to illuminate an area in front of the motor vehicle.
[007] In an embodiment of the invention, the headlamp assembly has a first printed circuit board (PCB) detachably attached to a top surface of the reflector, the first PCB having a first light source conforming to the first region, a second light source conforming to the second region and a third light source conforming to the third region.
[008] In another embodiment of the invention, the first light source, the second light source and the third light source comprise Light Emitting Diodes (LEDs).
[009] In yet another embodiment of the invention, the first region and the third region reflect light emitted from the first light source and the third light source to emit a low beam.
[010] In a further embodiment of the invention, the second region reflects light emitted from the second light source to emit a high beam.
[011] In another embodiment of the invention, wherein the first region, the second region and the third region each have at least a bottom flat parabolic surface for reflecting more incident light.
[012] In an embodiment of the invention, the compartment of the housing comprises a position lamp therewithin, the position lamp being positioned below the reflector. In another embodiment, the position lamp is detachably attached to the housing.
[013] In another embodiment, the position lamp comprises a second printed circuit board (PCB) having at least one light source. In an embodiment, the light source comprises a Light Emitting Diode (LED).
[014] In another embodiment of the invention, the headlamp assembly has a masking member received by the reflector and the position lamp, and detachably attached to the housing by fastening means.
[015] In a further embodiment, the headlamp assembly has a lens detachably attached to the housing and defining an anterior outer wall of the headlamp assembly.
[016] In yet another embodiment, periphery of the housing comprises plurality of locking loops.
[017] In a further embodiment, periphery of the lens comprises plurality of locking loops corresponding to the plurality of the locking loops of the housing for detachably attaching the lens (800) to the housing.

BRIEF DESCRIPTION OF THE DRAWINGS
[018] 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 shows a side view of a motor vehicle in accordance with an embodiment of the invention.
Figure 2 shows an exploded view of a headlamp assembly in accordance with an embodiment of the invention.
Figure 3 shows a reflector and a printed circuit board in accordance with an embodiment of the invention.
Figure 4 shows a front view of the headlamp assembly in accordance with an embodiment of the invention.
Figure 5 is a schematic representation showing cross sectional view of the headlamp assembly in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[019] The present invention relates to a headlamp assembly for a motor vehicle.
[020] Figure 1 illustrates a right-side view of an exemplary motor vehicle 100, in accordance with an embodiment of the present subject matter. The vehicle 100 comprises a main frame 10 having a head tube 12. Towards front side, the motor vehicle 10 has one or more front suspensions 14 connected to a front wheel 16 which is further connected to a handlebar assembly 18, which forms a steering assembly of the motor vehicle 100. The steering assembly has a pair of rear view mirrors 36a, 36b. The steering assembly is rotatably disposed about the head tube 12. The main frame 10 extends rearwardly downward from the head tube 12 and has a bent portion thereafter extending substantially in a longitudinal direction.
[021] The motor vehicle 10 further has an internal combustion (IC) engine 20. In the present embodiment, the IC engine 20 is swingably connected to the main frame 10. Towards rear side, the motor vehicle 10 has a rear wheel 22 connected to one or more rear suspensions 24. The motor vehicle 10 also has an exhaust system 26 extending rearwards from the IC engine 20. In addition, the vehicle 10 has a rear fender 28 covering at least a portion of the rear wheel 22 and is positioned upwardly of the rear wheel 22.
[022] Further, the motor vehicle 10 has a seat assembly 32 supported by the main frame 10. The seat assembly 32 is hingedly openable. The motor vehicle 10 has a floorboard 34 wherein a rider can operate the vehicle 100 in a seated position by resting feet on the floorboard 34. Further, the floorboard 34 is capable of carrying loads.
[023] In addition, a utility box is disposed below the seat assembly 32 and is supported by the main frame 10. A fuel tank (not shown) is disposed adjacent to the utility box. Furthermore, the vehicle 100 comprises of plurality of electrical and electronic components including a headlight assembly 200, a taillight assembly 30, a transistor-controlled ignition (TCI) unit (not shown), an alternator (not shown), a starter motor (not shown). Further, the vehicle 10 includes an anti-lock braking system (ABS), a synchronous braking system (SBS), or a vehicle control system (VCS). The motor vehicle 100 is thus made to stay in a riding ready position over a center stand 40.
[024] Referring to Figure 2, the headlamp assembly 200 of the present invention has a housing 300. The housing 300 is an encasing structure which receives and accommodates various components of the headlamp assembly 200. The housing 300 has a posterior wall 310, a right-side wall 320a and a left-side wall 320b, which along with the entire headlamp assembly 200 is docked on to the vehicle 100. The posterior wall 310 together with the side walls 320a, 320b forms a compartment 350 of the housing 300. Accordingly, the compartment 350 receives and accommodates various components of the headlamp assembly 200.
[025] Referring to Figures 2, 3, 4 and 5, the headlamp assembly 200 has a reflector 500. The reflector 500 of the present invention is received inside the compartment 350 and is detachably attached to the housing 300. As seen in the Figures, the reflector 500 has a first region 520a, a second region 520b, and a third region 520c. The first region 520a, the second region 520b, and the third region 520c are configured to have apertures on a top surface 510 of the reflector 500. Thus, the first region 520a has an aperture 530a, the second region 520b has an aperture 530b, and the third region 520c has an aperture 530c. Accordingly, the first region 520a, the second region 520b and the third region 520c receive light from a light source and thereby reflect the light to illuminate an area in front of the motor vehicle 100. In an embodiment of the invention, and as shown in Figure 3, each of the regions 520a, 520b and 520c have at least a bottom flat parabolic surface 522a, 522b, and 522c for reflecting more incident light. In another embodiment of the invention the reflector 500 is detachably attached to the housing 300 using fixating means like screws, nuts, bolts etc.
[026] As shown in Figures 2 and 3, in an embodiment of the invention, the headlamp assembly 200 has a first printed circuit board (PCB) 400. The first PCB 400 has a top surface 420 and a bottom surface 430 and is attached on the top surface 510 of the reflector 500 using fixating holes 412a, 412b and 412c (shown in Figure 3). Accordingly, the top surface 510 of the reflector 500 also has corresponding fixating holes 542a, 542b and 542c. In an embodiment of the invention, the first PCB 400 is detachably attached to the top surface 510 of the reflector 500 using fixating means such as screws, nuts, bolts etc.
[027] As mentioned hereinabove, the present invention has light sources which emit a desired amount of light to illuminate an area in front of the vehicle 100. In this regard, the first PCB 400 has a first light source 410a (not shown), a second light source 410b (not shown) and a third light source 410c (shown in Figure 5) mounted on the bottom surface 430 thereof. Thus, when the first PCB 400 is detachably attached on the top surface 510 of the reflector 500, the first light source 410a conforms to the aperture 530a of the first region 520a of the reflector 500. Similarly, the second light source 410b conforms to the aperture 530b of the second region 520b and the third light source 410c conforms to the aperture 530c of the third region 520c. In a further embodiment of the invention, the first light source 410a, the second light source 410b and the third light source 410c are Light Emitting Diodes (LEDs).
[028] In another embodiment of the invention, the first region 520a and the third region 520c are configured to reflect the light emitted from the first light source 410a and the third light source 410c respectively, to emit a low beam. Further, the second region 520b is thus configured to reflect the light emitted from the second light source 410b to emit a high beam. This configuration of the high beam and the low beam light emission ensures increased symmetricity in the reflection of the light.
[029] In an embodiment of the invention, the headlamp assembly 200 has a position lamp 600. The position lamp 600 is disposed inside the compartment 350 of the housing 300 and is positioned below the reflector 500. The position lamp 600 is also detachably attached to the housing 300 using fixating means like screws, nuts, bolts, etc. In another embodiment of the invention, and as shown in Figure 2, the position lamp 600 has a second PCB 650 detachably attached to posterior side of the position lamp 600. In an embodiment, the second PCB 650 is detachably attached using fixating means like screws, nuts, bolts, etc. Further, the second PCB 650 has at least one light source mounted thereon in order for the position lamp 600 to emit a desired amount of light. In an embodiment of the invention, the at least one light source is a Light Emitting Diode (LED).
[030] In a further embodiment of the present invention, and as shown in Figure 3, 4 and 5 the housing assembly 200 has a masking member 700. The masking member 700 is received by the reflector 500 and the position lamp 600 inside the compartment 350 of the housing 300 and is detachably attached to the housing 300 using fixating means such as screws, nuts, bolts etc.
[031] Referring now to Figure 5, in an embodiment of the present invention, the housing 200 engages with a lens 800 in order to form an airtight casing. The airtight casing arrangement prohibits permeation of dust, smoke, water, pollutants and other particulate matter from entering inside the casing. Accordingly, referring to Figures 4 and 5, the housing 300 has a plurality of locking loops 330a, 330b, 330c around its periphery. Further, the lens 800 has corresponding locking loops around its periphery. Thus, the lens 800 is detachably attached to the housing 300. Accordingly, the lens 800 defines an anterior outer wall 810 of the headlamp assembly 200.
[032] Advantageously, the present invention provides a reflector that is simple and modular in nature. Configuration of the reflector of the present invention being detachably attached with the bezel and the housing, provides flexibility of adapting the same reflector in any headlamp assembly without making any substantial modifications. Further, the present invention uses a single reflector that is common for both, high beam and low beam light emissions. This requires only a single PCB for supplying light for both high beam and low beam light emissions. Furthermore, since the present invention requires a single PCB for both high beam and low beam emissions, the need for having a separate heat sink is eliminated. Hence, the headlamp assembly becomes lighter in weight and does not heat up over long usage. Further still, presence of a high beam LED in the center and two low beam LEDs in the periphery ensures increased symmetricity in reflection of light. Additionally, modularity of the reflector reduces overall weight of the headlamp assembly. Further, less heavy and less bulky nature of the headlamp assembly of the present invention ensures that overall handling of the vehicle is improved, as the load of the headlamp assembly acting on the handlebar is reduced. The modularity of the reflector also reduces tooling complexity. The modularity of the reflector ensures that the position lamp LED can be made flexible and headlamp assemblies can be made with or without position lamps. Thus, when the position lamp has to be accessed, the lens is removed and then the masking member, while the reflector is not disturbed, since all components are independently detachably attached to the housing. The present invention also enables effective air circulation which causes effective heat transfer from the LED to the PCB, which in turn transfers to atmosphere.
[033] 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.