Claims:WE CLAIM:
1. A headlamp assembly (100) comprising:
a housing (110) having a compartment (115);
a first light source (122) disposed inside the compartment (115);
a second light source (124) disposed inside the compartment (115) upwardly of the first light source (122); and
a third light source (126) disposed inside the compartment (115) forwardly of the first light source (122) and the second light source (124) in a vehicle rear-front direction (R-F).

2. The headlamp assembly (100) as claimed in claim 1, wherein the first light source (122) and the second light source (124) are disposed along a common vertical plane.

3. The headlamp assembly (100) as claimed in claim 1, wherein the third light source (126) is disposed substantially centrally in a width direction (W) of the headlamp assembly (100).

4. The headlamp assembly (100) as claimed in claim 3, wherein the third light source (126) forms a T shape when viewed in a vehicle front-rear direction (F-R).

5. The headlamp assembly (100) as claimed in claim 1, wherein the first light source (122) comprises one or more Light Emitting Diodes (LEDs) mounted on a first Printed Circuit Board (PCB), the second light source (124) comprises one or more LEDs mounted on a second PCB, and the third light source (126) comprises one or more LEDs mounted on a third PCB.

6. The headlamp assembly (100) as claimed in claim 1 comprising: a first heat sink (132) disposed in the compartment (115) and configured to dissipate heat from the first light source (122); a second heat sink (134) disposed in the compartment (115) and configured to dissipate heat from the second light source (124) and the third light source (126).

7. The headlamp assembly (100) as claimed in claim 6, wherein the first heat sink (132) is configured to dissipate heat from a lower portion of the third light source (126) and the second heat sink (134) is configured to dissipate heat from an upper portion of the third light source (126).

8. The headlamp assembly (100) as claimed in claim 6, wherein the first heat sink (132) is in thermal communication with the second heat sink (134) and configured to partially transfer heat to the second heat sink (134).

9. The headlamp assembly (100) as claimed in claim 1, wherein the first light source (122) is configured to be a high beam of a vehicle (10), the second light source (124) is configured to be a low beam of the vehicle (10) and the third light source (126) is configured to be a front positioning lamp of the vehicle (10).

10. The headlamp assembly (100) as claimed in claim 9 comprising a reflector unit (140) disposed in the compartment (115), the reflector unit (140) having: a first reflector (142) disposed downwardly of the first light source (122) and configured to direct light emitted from the first light source (122) to make the high beam of the vehicle (10); a second reflector (144) disposed downwardly of the second light source (124) and configured to direct light emitted from the second light source (124) to make the low beam of the vehicle (10); and a support member (146) disposed forwardly of the first reflector (142) and the second reflector (144), the support member (146) configured to mount the third light source (126).

11. The headlamp assembly (100) as claimed in claim 10, wherein the reflector unit (140) comprises a first seat member (141) disposed above the first reflector (142) and extending rearwardly from rear of the reflector unit (140) in a vehicle front rear direction, the first seat member (141) configured to receive the first light source (122).

12. The headlamp assembly (100) as claimed in claim 10, wherein the reflector unit (140) comprises a second seat member (143) disposed above the second reflector (144) and extending rearwardly from rear of the reflector unit (140) in a vehicle front rear direction, the second seat member (143) configured to receive the second light source (124).

13. The headlamp assembly (100) as claimed in claim 10, wherein the first reflector (142) and the second reflector (144) are disposed along a common vertical plane.

14. The headlamp assembly (100) as claimed in claim 1 comprising a primary lens (170) configured to engage with the housing (110) to define an anterior surface of the headlamp assembly (100), the primary lens (170) covering the compartment (115) from a vehicle front direction.

15. The headlamp assembly (100) as claimed in claims 10 and 14 comprising a bezel (160) disposed between the reflector unit (140) and the primary lens (170), the bezel (160) configured to receive a secondary lens (176) overlapping with the third light source (126).

16. The headlamp assembly (100) as claimed in claim 15, wherein the secondary lens (176) is disposed substantially centrally in the width direction (W) of the headlamp assembly (100).

17. The headlamp assembly (100) as claimed in claim 15, wherein the secondary lens (176) is en-moulded in the bezel (160).

18. The headlamp assembly (100) as claimed in claim 14 comprising a rim (172) surrounding a periphery of an interface between the primary lens (170) and the housing (110).

19. The headlamp assembly (100) as claimed in claim 1 comprising a driver unit (150) to control the first light source (122), the second light source (124) and the third light source (126), the driver unit (150) disposed in the compartment (115) at rear of the compartment (115).

20. The headlamp assembly (100) as claimed in claim 19 comprising a third heat sink (152) disposed in the compartment (115) and configured to dissipate heat from the driver unit (150), the third heat sink (152) partially exposed to atmosphere outside the compartment (115) at rear of the housing (110).

21. The headlamp assembly (100) as claimed in claim 20, wherein the partially exposed portion of the third heat sink (152) comprises cooling fins (154) configured to dissipate heat from the third heat sink (152) to atmosphere.

22. The headlamp assembly (100) as claimed in claim 1 comprising one or more air vents (118) at rear of the housing (110).

23. The headlamp assembly (100) as claimed in claim 1 comprising: a pair of first brackets (112) disposed at rear of the housing (110) and configured to be mounted to a top bridge member (22) connecting a pair of front forks (20) of the vehicle (10); a pair of second brackets (114) disposed at the rear of the housing (110) downwardly of the pair of first brackets (112) and configured to be mounted to a lower bridge member (24) connecting the pair of front forks (20) of the vehicle (10).

24. The headlamp assembly (100) as claimed in claims 20, 22 and 23, wherein the housing (110) comprises a recess (116) at the rear of the housing (110) wherein the partially exposed portion of the third heat sink (152), the one or more air vents (118) and the pair of first brackets (112) being disposed in the recess (116).

25. The headlamp assembly (100) as claimed in claim 24, wherein the recess (116) forms a bowl shaped cut out configured to expose the partially exposed portion of the third heat sink (152) and the one or more air vents (118) to atmosphere.

26. The headlamp assembly (100) as claimed in claim 24, wherein the housing (110) and the recess (116) are configured to block direct sight of the partially exposed portion of the third heat sink (152), the one or more air vents (118) and the pair of first brackets (112) when viewed in the vehicle width direction (W).

Dated this 9th day of March 2022
TVS MOTOR COMPANY LIMITED
By their Agent & Attorney

(Nikhil Ranjan)
of Khaitan & Co
Reg No IN/PA-1471 , Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[Refer Section 10, Rule 13]

TITLE OF INVENTION
A Headlamp Assembly

APPLICANT
TVS MOTOR COMPANY LIMITED, an Indian company, having its address at “Chaitanya”, No.12 Khader Nawaz Khan Road, Nungambakkam, Chennai 600 006, Tamil Nadu, India.

PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed. 
FIELD OF THE INVENTION
[001] The present invention generally relates to a headlamp assembly and particularly relates to disposition of components of the headlamp assembly.

BACKGROUND OF THE INVENTION
[002] Headlamps are used to illuminate road in front of a vehicle in situations with diminished ambient lighting. Over the years headlamp designs have evolved to become a key part of vehicle styling. Headlamps being prominently visible from a front of the vehicle have acquired signature designs that allow the vehicle to be distinguished from vehicles of competing brands. Conventionally, headlamps made use of miniaturised electric bulbs to illuminate the road. More recently, electric bulbs in headlamps are being replaced by one or more Light Emitting Diodes (LEDs). LEDs are being preferred due to their smaller construction, better efficiency, higher light output and longevity as compared to electric bulbs. However, it is important to effectively manage heat produced by LEDs in the headlamp. Left unmanaged, heat generated may cause the LEDs to fail or decrease their longevity putting the LEDs in regular want of replacement, thus increasing overall maintenance cost of a headlamp assembly.
[003] Consequently, heat generated by the LEDs are dissipated outside the headlamp assembly with the aid of heat sinks and air vents provided in a headlamp housing of the headlamp assembly. Generally, the headlamp housing is provided with multiple openings forming breathable air vents to effectively dissipate heat from the housing to atmosphere. However, provision of multiple openings in the headlamp housing may be aesthetically unappealing and may increase risk of tampering. Hence, several style panels are used to cover up the openings. This increases weight of the headlamp assembly, cost of manufacture and time of assembly.
[004] Additionally, headlamps employ reflectors to focus light emitted by the electric bulbs/LEDs on to road. The reflectors are disposed inside the headlamp housing. Conventional reflectors have a high beam reflector and a low beam reflector disposed in a stepped manner and integrated into one reflector unit and placed in a compartment of the headlamp assembly. The integrated arrangement of the reflector unit requires more area to ensure that light emitted has adequate throw and focus. Thus, the reflector unit becomes bulky and would require a bigger headlamp assembly to house it. It also increases complexity of assembly and reduces design flexibility.
[005] Furthermore, front positioning lamps (FPLs) are not accommodated in a headlamp compartment due to thermal constraints. A larger headlamp compartment would be required to accommodate the FPLs within the headlamp compartment since it would be difficult to manage heat build up in the headlamp assembly without increasing its size. It is not desirable to increase size of the headlamp assembly due to vehicle layout constraints and costs involved. A large headlamp assembly also protrudes outwardly towards front of the vehicle, increasing the front overhang mass. In two wheelers this causes the headlamp assembly to become distant from the front forks and away from centre of gravity of the vehicle. This detrimentally affects the vehicle’s handling. Therefore, it is desirable to have a compact headlamp assembly disposed as close to the front forks as possible in order to improve vehicle handling.
[006] Further, a driver unit that controls the LEDs is generally placed outside the headlamp compartment and hidden by style panels of the vehicle. Even though this reduces the complexity of the headlamp assembly, it increases the length of wiring required and may impair the quality of signal transmission to the LEDs. However, packaging multiple (Printed Circuit Boards) PCBs, lenses, heat sinks, LEDs and wiring harnesses within a compact package increases complexity of the headlamp and difficulty in assembling it.
[007] Thus, there is a need in the art for a headlamp assembly, which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[008] In one aspect, the present invention is directed to a headlamp assembly which includes a housing, a first light source, a second light source and a third light source. The housing has a compartment. The first light source is disposed inside the compartment. The second light source is disposed inside the compartment at a position upwardly of the first light source. The third light source is disposed inside the compartment at a position forwardly of the first light source and the second light source in a vehicle rear-front direction.
[009] In an embodiment, the first light source and the second light source are disposed along a common vertical plane. In another embodiment, the third light source is disposed substantially centrally in a width direction of the headlamp assembly. In yet another embodiment, the the third light source forms a T shape when viewed in a vehicle front-rear direction.
[010] In a further embodiment, the first light source includes one or more Light Emitting Diodes (LEDs) mounted on a first Printed Circuit Board (PCB), the second light source includes one or more LEDs mounted on a second PCB, and the third light source includes one or more LEDs mounted on a third PCB.
[011] In an embodiment, the headlamp assembly includes a first heat sink and a second heat sink. The first heat sink is disposed in the compartment and is configured to dissipate heat from the first light source. The second heat sink is disposed in the compartment and is configured to dissipate heat from the second light source and the third light source. In another embodiment, the first heat sink is configured to dissipate heat from a lower portion of the third light source and the second heat sink is configured to dissipate heat from an upper portion of the third light source. In yet another embodiment, the first heat sink is in thermal communication with the second heat sink and is configured to partially transfer heat to the second heat sink.
[012] In a further embodiment, the first light source is configured to be a high beam of a vehicle, the second light source is configured to be a low beam of the vehicle and the third light source is configured to be a front positioning lamp of the vehicle.
[013] In an embodiment, the headlamp assembly includes a reflector unit disposed in the compartment. The reflector unit includes a first reflector, a second reflector and a support member. The first reflector is disposed downwardly of the first light source and is configured to direct light emitted from the first light source to make the high beam of the vehicle. The second reflector is disposed downwardly of the second light source and is configured to direct light emitted from the second light source to make the low beam of the vehicle. The support member is disposed forwardly of the first reflector and the second reflector. The support member is configured to mount the third light source.
[014] In another embodiment, the reflector unit includes a first seat member disposed above the first reflector. The first seat member extends rearwardly from rear of the reflector unit in a vehicle front rear direction and is configured to receive the first light source. In yet another embodiment, the reflector unit includes a second seat member disposed above the second reflector. The second seat member extends rearwardly from rear of the reflector unit in a vehicle front rear direction and is configured to receive the second light source.
[015] In yet another embodiment, the first reflector and the second reflector are disposed along a common vertical plane.
[016] In an embodiment, the headlamp assembly includes a primary lens configured to engage with the housing and cover the compartment from a vehicle front direction. The primary lens engages with the housing to define an anterior surface of the headlamp assembly.
[017] In a further embodiment, the headlamp assembly includes a bezel disposed between the reflector unit and the primary lens. The bezel is configured to receive a secondary lens which overlaps with the third light source. In an embodiment, the secondary lens is disposed substantially centrally in the width direction of the headlamp assembly. In another embodiment, the secondary lens is en-moulded in the bezel.
[018] In yet another embodiment, the headlamp assembly includes a rim surrounding a periphery of an interface between the primary lens and the housing.
[019] In a further embodiment, the headlamp assembly includes a driver unit disposed in the compartment at rear of the compartment. The driver unit is configured to control the first light source, the second light source and the third light source. In an embodiment, the headlamp assembly includes a third heat sink disposed in the compartment. The third heat sink is partially exposed to atmosphere outside the compartment at rear of the housing and is configured to dissipate heat from the driver unit. In another embodiment, the partially exposed portion of the third heat sink includes cooling fins configured to dissipate heat from the third heat sink to atmosphere.
[020] In yet another embodiment, the headlamp assembly includes one or more air vents at rear of the housing.
[021] In a further embodiment, the headlamp assembly includes a pair of first brackets and a pair of second brackets. The pair of first brackets is disposed at rear of the housing and is configured to be mounted to a top bridge member connecting a pair of front forks of the vehicle. The pair of second brackets is disposed at the rear of the housing downwardly of the pair of first brackets and is configured to be mounted to a lower bridge member connecting the pair of front forks of the vehicle.
[022] In another embodiment, the housing includes a recess at rear of the housing. The partially exposed portion of the third heat sink, the one or more air vents and the pair of first brackets are disposed in the recess. In yet another embodiment, the recess forms a bowl shaped cut out configured to expose the partially exposed portion of the third heat sink and the one or more air vents to atmosphere. In another embodiment, the housing and the recess are configured to block direct sight of the partially exposed portion of the third heat sink, the one or more air vents and the pair of first brackets when viewed in the vehicle width direction.

BRIEF DESCRIPTION OF THE DRAWINGS
[023] 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 schematic side elevation view of an exemplary vehicle, in accordance with an embodiment of the present invention.
Figure 2 illustrates a front elevation view of an exemplary vehicle, in accordance with an embodiment of the present invention.
Figure 3 illustrates an exploded view of an exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 4 illustrates a cross sectional side view of the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 5 illustrates a cross sectional side view of the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 6 illustrates a cross sectional rear view of the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 7 illustrates a cross sectional front view of the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 8 illustrates a front elevation view of the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 9 illustrates a rear elevation view of the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 10 illustrates a top plan view of the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 11 illustrates a side elevation view of the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 12 illustrates a front perspective view of the exemplary vehicle with the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 13 illustrates a front perspective view of the exemplary vehicle with the exemplary headlamp assembly, in accordance with an embodiment of the present invention.
Figure 14 illustrates a front perspective view of the exemplary headlamp assembly with exemplary mounting components, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[024] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.
[025] The present invention generally relates to a headlamp assembly and particularly relates to disposition of components of the headlamp assembly. In the ensuing exemplary embodiments, the vehicle 10 is a two-wheeled vehicle. However, it is contemplated that the disclosure in the present invention may be applied to any automobile like a three-wheeled or four-wheeled vehicle capable of accommodating the present subject matter without defeating the scope of the present invention.
[026] Figure 1 illustrates a schematic side elevation view of an exemplary vehicle 10, in accordance with an embodiment of the present subject matter. Figure 2 illustrates a front elevation view of another exemplary vehicle 10, in accordance with an embodiment of the present subject matter. The vehicle 10 comprises a front wheel 36, a rear wheel 38, a frame member (not shown) and a seat 44. The frame member includes a head pipe 18, a main tube (not shown), a down tube (not shown), and seat rails (not shown). The head pipe 18 supports a steering shaft (not shown) and a front suspension 20 attached to the steering shaft. In the illustrated embodiment, the front suspension 20 is a fork type suspension. Further, a headlamp assembly 100 and an instrument cluster (not shown) are arranged on an upper portion of the head pipe 18.
[027] The vehicle 10 includes a prime mover 12 that is adapted to provide motive force for movement of the vehicle 10. In an embodiment, the prime mover 12 is an internal combustion engine and a fuel tank 42 is mounted on the main tube. In another embodiment, the prime mover 12 is an electric motor. The front suspension 20 supports the front wheel 36. The upper portion of the front wheel 36 is covered by a front fender 46 mounted to the lower portion of the front suspension 20 at a distal end of the steering shaft. A handlebar 32 is operatively coupled to the steering shaft and can rotate to and fro about the steering shaft for steering the vehicle 10. The down tube positioned in front of the prime mover 12 extends slantingly downward from the head pipe 18. The main tube of the frame member is located above the prime mover 12 and extends rearward from the head pipe 18.
[028] Seat rails are joined to the main tube and extend rearward to support the seat 44. A rear swing arm (not shown) is connected to the frame member to swing vertically, and a rear wheel 38 is connected to rear end of the rear swing arm. The rear swing arm is supported by a rear suspension 50. A taillight unit 54 is disposed at a rear of the seat assembly 44. A grab rail 52 is also provided to the seat rails. The rear wheel 38 arranged below the seat 44 rotates by the motive force generated by the prime mover 12 transmitted through a transmission (not shown). A rear fender 48 is disposed above the rear wheel 38. An exhaust pipe (not shown) extends vertically downward from the prime mover 12 and then extends below the prime mover 12, longitudinally along length of the vehicle 10 before terminating in a muffler (not shown).
[029] Figure 3 illustrates an exploded view of an exemplary headlamp assembly 100, in accordance with an embodiment of the present subject matter. The headlamp assembly 100 includes a housing 110. In the illustrated embodiment, the housing 100 has a circular periphery. However, the periphery of the housing 110 may take any shape depending on design requirements. A compartment 115 is defined in the housing 110. A first light source 122, a second light source 124 and a third light source 126 are disposed inside the compartment 115. As illustrated in Figure 4, the second light source 124 is disposed inside the compartment 115 at a position upwardly of the first light source 122. The third light source 126 is disposed inside the compartment 115 at a position forwardly of the first light source 122 and the second light source 124 in a vehicle rear-front (R-F) direction. Further, a driver unit 150, a reflector unit 140, a bezel 160 and heat sinks 132, 134, 152 are disposed inside the compartment 115.
[030] The headlamp assembly 100 includes a primary lens 170 configured to engage with the housing 110 to define an anterior surface of the headlamp assembly 100 (shown in Figure 14). The primary lens 170 covers the compartment 115 from a vehicle front direction such that all components inside the compartment 115 are placed within an enclosure defined by the housing 110 and the primary lens 170. The primary lens 170 has a transparent lens structure and a frame structure surrounding the transparent lens structure. The frame structure acts as a carrier for the lens structure and increases its sturdiness. The frame structure is adapted to be received in the housing 110, whereby it can be attached onto an exterior of the housing 110. The transparent lens structure aids in focusing light emitted from the headlamp assembly 100 on to road for better visibility. In an embodiment, the headlamp assembly 100 includes a rim 172 surrounding a periphery of an interface between the primary lens 170 and the housing 110. The rim 172 improves the sturdiness of the headlamp assembly 100 and covers the interface made by attaching the housing 110 with the primary lens 170. In an embodiment, the rim 172 aids in preventing dust and water entry into the housing 110 via the interface and enhances the aesthetic appeal of the headlamp assembly 100.
[031] In an embodiment, the first light source 122 includes one or more Light Emitting Diodes (LEDs) mounted on a first Printed Circuit Board (PCB), the second light source 124 includes one or more LEDs mounted on a second PCB, and the third light source 126 includes one or more LEDs mounted on a third PCB. The PCB acts as a base on which the LEDs can be affixed to and supports circuitry associated with the LEDs. The LEDs and their associated circuitry can be affixed/embedded on the respective PCBs using any method known in the art. In another embodiment, the first light source 122 is adapted to be a high beam of the vehicle 10, the second light source 124 is adapted to be a low beam of the vehicle 10 and the third light source 126 is adapted to be a front positioning lamp (FPL) of the vehicle 10.
[032] Figure 5 illustrates a cross sectional side view of the exemplary headlamp assembly 100, in accordance with an embodiment of the present subject matter. Referring to Figures 3 and 5, the reflector unit 140 includes a first reflector 142 and a second reflector 144 to focus light generated in the headlamp assembly 100 and ensure sufficient throw of light on road. The first reflector 142 is disposed downwardly of the first light source 122 and is adapted to direct light emitted from the first light source 122 to make the high beam of the vehicle 10. The second reflector 144 is disposed downwardly of the second light source 124 and adapted to direct light emitted from the second light source 124 to make the low beam of the vehicle 10. In the illustrated embodiment, the first reflector 142 which makes the high beam is provided below the second reflector 144 which makes the low beam. Instead of providing a reflector unit with high beam reflector and low beam reflector integrated into one reflector body adapted to focus light emitted from one single focal point, the headlamp assembly 100 envisages two different reflectors 142, 144 adapted to focus light from two different focal points to make the high beam and the low beam respectively. Thereby the size of the reflector unit 140 can be reduced.
[033] In an embodiment, the reflector unit 140 includes a first seat member 141 (shown in Figure 3) and a second seat member 143 (shown in Figure 3). The first seat member 141 is disposed above the first reflector 142 and extends rearwardly from rear of the reflector unit 140 in a vehicle front rear (F-R) direction. The first seat member 141 is adapted to receive the first light source 122. The second seat member 143 is disposed above the second reflector 144 and extends rearwardly from rear of the reflector unit 140 in a vehicle front rear (F-R) direction. The second seat member 143 is adapted to receive the second light source 124. In the illustrated embodiment, the first seat member 141 is disposed downwardly of the second seat member 143. In an embodiment, first seat member 141 and the second seat member 143 are adapted to receive the respective PCBs with LEDs mounted thereon. As illustrated in figure 3, the reflector unit 140 further includes a support member 146 disposed forwardly of the first reflector 142 and the second reflector 144. The support member 146 is adapted to mount the third light source 126.
[034] In an embodiment, the first light source 122 and the second light source 124 are disposed along a common vertical plane. In another embodiment, the first reflector 142 and the second reflector 144 are disposed along another common vertical plane to match the disposition of the first light source 122 and the second light source 124 along the first common vertical plane. In yet another embodiment, the third light source 126 is disposed substantially centrally in a width direction W (shown in Figure 2) of the headlamp assembly 100. Accordingly, the support member 146 of the reflector unit 140 which mounts the third light source 126 is also disposed substantially centrally of the housing 110 in the vehicle width direction W (shown in Figure 7). The symmetric arrangement of the first light source 122, the second light source 124 and the third light source 126 with respect to each other and the housing 110 enhances the aesthetic appeal of the headlamp assembly 100. In yet another embodiment, the third light source 126 forms a T shape when viewed in a vehicle front-rear (F-R) direction (shown in Figure 8). The third light source 126 which acts as the FPL is a signature element of the vehicle 10 and can be used to indicate the brand of the vehicle 10 and/or distinguish it from vehicles of other brands. Hence, the third light source 126 can be formed in any shape to suit manufacturer’s requirements.
[035] Referring to Figure 6, the headlamp assembly 100 includes a first heat sink 132 and a second heat sink 134. The first heat sink 132 is disposed in the compartment 115 and is in thermal communication with the first light source 122. The second heat sink 134 is disposed in the compartment 115 and is in thermal communication with the second light source 124 and the third light source 126. The first heat sink 132 is adapted to dissipate heat away from the first light source 122 and the second heat sink 134 is adapted to dissipate heat away from both the second light source 124 and the third light source 126. In an embodiment, the first heat sink 132 and the second heat sink 134 are adapted to dissipate heat transferred to them to the housing 110 and the compartment 115.
[036] In another embodiment, the first heat sink 132 is disposed substantially centrally of the compartment 115 and the second heat sink 134 is disposed upwardly of the first heat sink 132. In another embodiment, the first heat sink 132 is disposed on the first seat member 141 along with the first light source 122 (shown in Figure 3). And the second heat sink 134 is disposed on the second seat member 143 along with the second light source 124. Use of separate heat sinks for high beam and low beam light sources ensures efficient cooling and enhances the thermal performance of the headlamp assembly 100. In an embodiment, the first heat sink 132 and the second heat sink 134 are of the same size.
[037] In an embodiment, the low beam and the FPL are switched ON when the vehicle 10 is in ON condition. Thus, in vehicle ON condition the second light source 124 and the third light source 126 emit light and hence generate heat. Heat generated by the second light source 124 and the third light source 126 is transferred to the second heat sink 134. In another embodiment, the third light source 126, which acts as the FPL, is in thermal communication with both the first heat sink 132 and the second heat sink 134. Therefore, in vehicle ON condition the third light source 126 transfers heat from its top portion to the second heat sink 134 and from its bottom portion to the first heat sink 132 allowing for faster heat dissipation from the third light source 126.
[038] In yet another embodiment, the low beam and the FPL remain switched ON when the headlamp assembly 100 is in high beam mode. Therefore, in high beam mode the first light source 122, the second light source 124 and the third light source 126 are switched ON. Generally, the high beam has a greater intensity than the low beam. Hence, the first light source 122 which acts as the high beam will generate more heat and require a higher rate of heat dissipation. In high beam mode, heat generated in the second light source 124 and the third light source 132 is transferred to the second heat sink 134 and dissipated therefrom. Additionally, the heat generated in the first light source 122 is transferred to the first heat sink 132. In a further embodiment, the first heat sink 132 and the second heat sink 134 are in thermal communication with each other causing heat transferred to the first heat sink 132 from the first light source 122 to be partially dissipated to the second heat sink 134 in high beam mode. Since the low beam and the FPL generate low intensity heat, the second heat sink 134 has the buffer to receive and dissipate excess heat from the first heat sink 132 which is generated by the high beam. In yet another embodiment, heat transferred to the second heat sink 134 from the second light source 124 and the third light source 126 is partially dissipated to the first heat sink 132 in low beam mode. Thereby, thermal balance can be achieved during various modes of operation of the headlamp assembly 100.
[039] Referring to Figure 3, a bezel 160 is disposed inside the compartment 115. The bezel 160 is disposed between the reflector unit 140 and the primary lens 170. The bezel 160 enhances aesthetic appeal of the headlamp assembly 100 by blocking from direct sight certain internal components of the headlamp assembly 100 including PCBs and their associated circuitry, interfaces between joints of different components disposed in the compartment 115, etc. In an embodiment, the bezel 160 is adapted to receive a secondary lens 176 overlapping with the third light source 126. The secondary lens 176 is of the same shape as that of the third light source 126. The secondary lens 176 aids in focusing light emitted from the third light source 126. The secondary lens 176 is disposed substantially centrally in the width direction W of the headlamp assembly 100 in order to overlap with the third light source 126 which is disposed substantially centrally in a width direction W of the headlamp assembly 100. In an embodiment, the secondary lens 176 is en-moulded in the bezel 160. En-moulding may be achieved through any method known in the art. In another embodiment, the bezel 160 is provided with a holder bracket (not shown) to receive the secondary lens 176. The holder bracket has a cut out matching the shape of the secondary lens 176 in which the secondary lens 176 is mounted. The external boundary of the holder bracket is adapted to block the periphery of the PCB mounting the third light source 126 from direct view when seen from a front of the vehicle 10.
[040] As illustrated in Figures 3 and 5, the driver unit 150 is disposed in the compartment 115 at rear of the compartment 115. The driver unit 150 controls the operation of the first light source 122, the second light source 124 and the third light source 126. In an embodiment, the driver unit 150 switches ON the third light source 126 when the vehicle 10 is in an ignition ON condition. The driver unit 150 switches ON the second light source 124 also along with the third light source 126 when the prime mover 12 of the vehicle 10 is in an ON condition. When the headlamp assembly 100 is in high beam mode, the first light source 122, the second light source 124 and the third light source 126 are all switched ON by the driver unit 150. A third heat sink 152 is disposed inside the compartment 115 to a rear of the driver unit 150. The third heat sink 152 is adapted to dissipate heat from the driver unit 150. In an embodiment, the third heat sink 152 is partially exposed to the atmosphere at a rear of the housing 110 to aid in dissipation of heat to atmosphere. In another embodiment, cooling fins 154 adapted to dissipate heat from the third heat sink 152 to atmosphere is provided at the partially exposed portion of the third heat sink 152 for effective cooling (shown in Figures 4 and 9).
[041] Figure 9 illustrates a rear elevation view of the exemplary headlamp assembly 100, in accordance with an embodiment of the present subject matter. The housing 110 has one or more air vents 118 provided at its rear. The air vents 118 aid in regulating temperature within the compartment 115. In an embodiment, heated air inside the compartment 115 is exhausted through the top air vents 118 and cooler air from environment replaces the hot air via the bottom air vents 118. In another embodiment, travelling air may be taken into the headlamp assembly 100 through inlets and exhausted out through the air vents 118 for accelerated cooling.
[042] In an embodiment, a recess 116 is provided at rear of the housing 110. The recess 116 forms a bowl shaped cut out at rear of the housing 110. Figure 10 illustrates a top plan view of the exemplary headlamp assembly 100, in accordance with an embodiment of the present subject matter. The recess 116 forms a U shape in the housing 110, with the open part of the U shape facing a vehicle rearward direction and the U shape being aligned centrally of the housing 110 in a vehicle width direction W. In an embodiment, the housing 110 does not cover a top and a bottom of the recess 116. This allows for passage of air along the recess 116 in a vertical direction which can aid in cooling the exposed heat sink 152. The housing 110 however, extends rearwardly along a left side and a right side of the recess 116. As illustrated in Figure 11, the left and right extensions in the housing 110 prevents rear exterior surface of the recess 116 from being visible from a left or a right side of the vehicle 10. In an embodiment, the air vents 118 and the third heat sink 152 are disposed in the recess 116.
[043] In an embodiment, the headlamp assembly 100 is mounted to a front of the vehicle 10 with the aid of brackets and fasteners. Referring to Figure 9, a pair of first brackets 112 are disposed at rear of the housing 110. In an embodiment, the pair of first brackets 112 are disposed in the recess 116 towards a top of the housing 110. A pair of second brackets 114 is disposed at rear of the housing 110 at a location downwardly of the pair of first brackets 112. In an embodiment, the pair of second brackets 114 is disposed inside the recess 116. In another embodiment the pair of second brackets 114 is disposed outside the recess 116 on an external surface of the housing 110.
[044] In a further embodiment, an opening (not shown) to route a cable 119 into the compartment 115 is provided in the recess 116. Electric power to power the first light source 122, the second light source 124, the third light source 126 and the driver unit 150 disposed in the compartment 115 is provided from a battery by the cable 119. The cable 119 is also adapted to transmit signals to and from the driver unit 150 in order to control the operation and detect the state of the first light source 122, the second light source 124 and the third light source 126 from outside the housing 110. In another embodiment, the openings provided in the exterior of the housing 110 and the interfaces between components of the headlamp assembly 100 which are exposed to atmosphere are lined with O-rings/gaskets to prevent water and dust entry into the headlamp assembly 100.
[045] In yet another embodiment, the the left and right extensions in the housing 110 and the recess 116 are adapted to block direct sight of the partially exposed portion of the opening to route the cable 119, the third heat sink 152, the one or more air vents 118 and the pair of first brackets 112 when viewed in the vehicle width direction W. Thus, need for style panels to cover side portions of the headlamp assembly 100 is eliminated.
[046] Figures 12 and 13 illustrate a front perspective view of the exemplary vehicle 10 with the exemplary headlamp assembly 100, in accordance with an embodiment of the present subject matter. As illustrated, the pair of first brackets 112 is adapted to be mounted to a top bridge member 22 which connects a pair of front forks of the front suspension 20 of the vehicle 10. The pair of second brackets 114 is configured to be mounted to a lower bridge member 24 connecting the pair of front forks of the front suspension 20 of the vehicle 10. Figure 14 illustrates a front perspective view of the exemplary headlamp assembly 100 with exemplary mounting components 23, 25, in accordance with an embodiment of the present subject matter. In an embodiment, a headlamp upper bracket 23 detachably attached to the front forks of the front suspension 20 of the vehicle 10 is provided. The headlamp upper bracket 23 is detachably attached at its one end to the top bridge member 22 and at its other end to the pair of first brackets 112 (shown in Figure 10). In another embodiment, a headlamp lower bracket 25 is detachably attached to the lower bridge member 24. The pair of second brackets 114 are detachably attached to the distal end of the headlamp lower bracket 25 on the opposite end of the lower bridge member 24. Hence the headlamp assembly 100 is supported at its top portion by the headlamp upper bracket 23 and at its bottom portion by the headlamp lower bracket 25 on the vehicle 10.
[047] Advantageously, the present invention provides a headlamp assembly 100 and disposition of components of the headlamp assembly 100. The headlamp assembly 100 described hereinabove allows for a compact package of components making the headlamp assembly 100 considerably smaller and lighter in comparison to the known art. The disposition of the low beam, the high beam and the FPL in the same compartment 115 without increasing size of the compartment 115 permits to achieve a compact package. The clean design envisaged with the exposed components hidden away inside the recess 116 eliminates the need to use style panels to cover the sides of the headlamp assembly 100. The absence of style panels and the compact design shifts the centre of mass of the headlamp assembly 100 closer to the centre of gravity of the vehicle 10, thereby improving the vehicle’s handling. The placement of the driver unit 150 inside the headlamp housing 100 ensures that signals to control the light sources 122, 124, 126 are transmitted without delay and loss of data allowing for uninterrupted operation of the light sources 122, 124, 126. Further, provision of dedicated heat sinks 132, 134, 152 for the light sources 122, 124, 126 and the driver unit 150 guarantee thermal stability of the headlamp assembly 100 thereby increasing the longevity of the LEDs used. The possibility of thermal communication between the heat sinks 132, 134 for the light sources 122, 124, 126 allows for better heat dissipation. By achieving a compact design without the need for extra style panels the cost of the headlamp assembly 100 is made lower.
[048] 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 modifications may be made without departing from the scope of the invention as defined in the following claims.