Claims:1. A headlamp assembly (100) for a vehicle, the headlamp assembly (100) comprising:
a housing member (202) having at least one inlet (402) and at least one outlet (404-1, 404-2), the at least one inlet (402) adapted to allow ingress of ambient air within the housing member (202) and the at least one outlet (404-1, 404-2) adapted to allow egress of the ambient air from the housing member (202);
a plurality of lighting modules (302) disposed in the housing member (202); and
a cooling module (304) disposed in the housing member (202) and adapted to conduct heat from the plurality of lighting modules (302), the cooling module (304) comprising:
a first heat sink (502) adapted to support at least one of the plurality of lighting modules (302) and adapted to conduct heat from the at least one of the plurality of lighting modules (302), wherein the first heat sink (502) includes a first set of fins (616-1, 616-2) exposed to the ambient air such that the heat from the first heat sink (502) is conducted to the ambient air; and
a second heat sink (504) coupled to the first heat sink (502), the second heat sink (504) adapted to support at least one of the plurality of lighting modules (302) and adapted to conduct heat from the at least one of the plurality of lighting modules (302), wherein the second heat sink (504) includes a second set of fins (706) exposed to the ambient air entering through the at least one inlet (402) such that the heat from the second heat sink (504) is conducted to the ambient air;
wherein the first heat sink (502) and the second heat sink (504) are adapted to conduct the heat from each other.

2. The headlamp assembly (100) as claimed in claim 1, further comprising a lens (204) adapted to be coupled with the housing member (202) to form an inner chamber (802), wherein the at least one inlet (402) and at least one outlet (404-1, 404-2) are adapted to allow ingress and egress of the ambient air in the inner chamber (802), respectively.

3. The headlamp assembly (100) as claimed in claim 1, wherein the plurality of lighting modules (302) includes a first lighting module (302-1), a second lighting module (302-2), and a third lighting module (302-3), the first lighting module (302-1) is supported on the first heat sink (502), each of the second lighting module (302-2) and the third lighting module (302-3) is supported on the second heat sink (504).

4. The headlamp assembly (100) as claimed in claim 3, wherein each of the first lighting module (302-1), the second lighting module (302-2), and the third lighting module (302-3) includes at least one light source and a reflector adapted to reflect light from the at least one light source.

5. The headlamp assembly (100) as claimed in claim 4, wherein the at least one light source is a Light Emitting Diode (LED).

6. The headlamp assembly (100) as claimed in claim 3, wherein the first lighting module (302-1), the second lighting module (302-2), and the third lighting module (302-3) include a Low Beam (LB) lighting module, a Day Light Running (DRL) lighting module, and a High Beam (HB) lighting module, respectively.

7. The headlamp assembly (100) as claimed in claim 3, wherein the first heat sink (502) includes a first horizontal portion (602) and a first longitudinal portion (604), the first horizontal portion (602) is adapted to support the first lighting module (302-1).

8. The headlamp assembly (100) as claimed in claim 3, wherein the second heat sink (504) includes a second horizontal portion (702) and a second longitudinal portion (704), the second horizontal portion (702) and the second longitudinal portion (704) are adapted to support the second lighting module (302-2).

9. The headlamp assembly (100) as claimed in claim 8, wherein the second horizontal portion (704) is adapted to support the third lighting module (302-3).

10. The headlamp assembly (100) as claimed in claim 1, wherein each of the first heat sink (502) and the second heat sink (504) is formed of Aluminium. , Description:FIELD OF THE INVENTION

The invention relates to automotive lighting and in particular, relates to a headlamp assembly for a vehicle.

BACKGROUND

Generally, headlamp assemblies are employed in vehicles, such as two-wheeler vehicles, three-wheeler vehicles, and four-wheeler vehicles, for illuminating path in front of the vehicles. A headlamp assembly includes multiple light sources which may be operable to generate light beams for illuminating path in the front of a vehicle. However, during operation of the light sources, heat may be generated within the headlamp assembly from the light sources, which may lead to temperature fluctuations within the headlamp assembly. Owing to such temperature fluctuations, the headlamp assembly may be subjected to overheating which may further lead to failure of various sub-components, such as the light sources, of the headlamp assembly. This may also result in substantial reduction in overall service life of the headlamp assembly.

In existing headlamp assemblies, various mechanisms are employed in order to reduce the temperature fluctuations within the headlamp assembly. For instance, various heat exchangers may be employed for absorbing heat from the light sources of the headlamp assembly. However, employing such heat exchangers may substantially increase overall weight of the headlamp assembly. Also, the headlamp assembly may include various fluid sources, such as fan, in order to conduct heat from the heat exchangers through forced convection. Owing to deployment of such fluid sources, overall cost of the headlamp assembly may substantially increase, and also may increase complexity in servicing of the headlamp assembly.

Therefore, there is a need for an improved solution for protecting vehicles from unauthorized access.

SUMMARY

In an embodiment of the present disclosure, a headlamp assembly for a vehicle is disclosed. The headlamp assembly includes a housing member having at least one inlet and at least one outlet. The at least one inlet adapted to allow ingress of ambient air within the housing member and the at least one outlet adapted to allow egress of the ambient air from the housing member. The headlamp assembly includes a plurality of lighting modules disposed in the housing member. Further, the headlamp assembly includes a cooling module disposed in the housing member and adapted to conduct heat from the plurality of lighting modules. The cooling module includes a first heat sink adapted to support at least one of the plurality of lighting modules and adapted to conduct heat from the at least one of the plurality of lighting modules. The first heat sink includes a first set of fins exposed to the ambient air such that the heat from the first heat sink is conducted to the ambient air. Further, the cooling module includes a second heat sink coupled to the first heat sink. The second heat sink is adapted to support at least one of the plurality of lighting modules and adapted to conduct heat from the at least one of the plurality of lighting modules. The second heat sink includes a second set of fins exposed to the ambient entering through the at least one inlet such that the heat from the second heat sink is conducted to the ambient air. The first heat sink and the second heat sink are adapted to conduct the heat from each other.

To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates a perspective view of a headlamp assembly for a vehicle, according to an embodiment of the present disclosure;

Figure 2 illustrates an exploded view of the headlamp assembly, according to an embodiment of the present disclosure;

Figure 3 illustrates a front perspective view of the headlamp assembly, according to an embodiment of the present disclosure;

Figure 4 illustrates a rear perspective view of the headlamp assembly, according to an embodiment of the present disclosure;

Figure 5 illustrates a perspective view of a cooling module of the headlamp assembly, according to an embodiment of the present disclosure;

Figures 6a and 6b illustrate different perspective views of the first heat sink of the cooling module, according to an embodiment of the present disclosure;

Figure 6c illustrates a front view of the first heat sink, according to an embodiment of the present disclosure;

Figures 7a and 7b illustrate different perspective views of the second heat sink of the cooling module, according to an embodiment of the present disclosure;

Figure 7c illustrates a rear view of the second heat sink, according to an embodiment of the present disclosure;

Figures 8a, 8b, and 8c illustrate different sectional views of the headlamp assembly depicting a flow of an ambient air within the headlamp assembly, according to an embodiment of the present disclosure; and

Figure 9 illustrates perspective views depicting an exemplary sequence of assembling the headlamp assembly, according to an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

Figure 1 illustrates a perspective view of a headlamp assembly 100 for a vehicle, according to an embodiment of the present disclosure. In an embodiment, the headlamp assembly 100 may be mounted on the vehicle. The vehicle may include, but is not limited to, a two-wheeler vehicle, a three-wheeler vehicle, and a four-wheeler vehicle. In an embodiment, the headlamp assembly 100 may be mounted at a front end of the vehicle. The headlamp assembly 100 may be adapted to illuminate an area in front of the vehicle, thereby providing enhanced visibility to a driver of the vehicle. Constructional and operational details of the headlamp assembly 100 are explained in detail in the description of Figure 2, Figures 3a-3b, Figure 4, Figures 5a-5c, and Figure 6 of the present disclosure.

Figure 2 illustrates an exploded view of the headlamp assembly 100, according to an embodiment of the present disclosure. Figure 3 illustrates a front perspective view of the headlamp assembly 100, according to an embodiment of the present disclosure. Referring to Figure 1, Figure 2, and Figure 3, in an embodiment, the headlamp assembly 100 includes a housing member 202 and a cover member 204 adapted to be coupled with the housing member 202. Further, the headlamp assembly 100 may include a mask 206 adapted to cover specific portion within the headlamp assembly 100 to obstruct dispersion of light, and thereby facilitating creation of optical pattern in the headlamp assembly 100. In an example, the cover member 204 may be inserted moulded with the mask 206 of the headlamp assembly 100.

In an embodiment, the housing member 202 and the cover member 204 may be coupled together to form an inner chamber to accommodate various sub-components of the headlamp assembly 100. The cover member 204 may be formed of a transparent material to allow transmission of light from the headlamp assembly 100. In an embodiment, the cover member 204 may interchangeably be referred to as a lens 204, without departing from the scope of the present disclosure.

Referring to Figure 1 and Figure 3, the headlamp assembly 100 may include a plurality of lighting modules 302 and a cooling module 304. The plurality of lighting modules 302 may be disposed in the housing member 202. In an embodiment, the plurality of lighting modules 302 may interchangeably be referred to as the lighting modules 302, without departing from the scope of the present disclosure. Each of the lighting modules 302 may be adapted to emit a beam of light to illuminate the area in front of the headlamp assembly 100. Each of the lighting modules 302 may include at least one light source and a reflector adapted to reflect the light from the at least one source. The at least one light source may interchangeably be referred to as the light sources, without departing from the scope of the present disclosure. In an embodiment, each of the light sources may be embodied as a Light Emitting Diode (LED).

In the illustrated embodiment, the lighting modules 302 include a first lighting module 302-1, a second lighting module 302-2, and a third lighting module 302-3. Therefore, in an embodiment, the lighting modules 302 may interchangeably be referred to as the lighting modules 302-1, 302-2, 302-3, without departing from the scope of the present disclosure. In an embodiment, the first lighting module 302-1 may be embodied as a Low Beam (LB) lighting module adapted to emit a Low Beam of the light. The second lighting module 302-2 may be embodied as a Day Light Running (DRL) lighting module. The third lighting module 302-3 may be embodied as a High Beam (HB) lighting module adapted to emit a High Beam of the light.

In an embodiment, the first lighting module 302-1 may include the at least one light source, such as a first set of light sources 306-1 and the reflector, such as a first reflector 306-2. Further, the first lighting module 302-1 may include a first Printed Circuit Board (PCB) assembly 306-3 to support the first set of light sources 306-1. Similarly, the second lighting module 302-2 may include the at least one light source, such as a second set of light sources 308-1 and the reflector, such as a second reflector 308-2. Further, the second lighting module 302-2 may include a second PCB assembly 308-3 to support the second set of light sources 308-1. Similarly, the third lighting module 302-3 may include the at least one light source, such as the third set of light sources 310-1 and the reflector, such as a third reflector 310-2. Further, the third lighting module 302-3 may include a third PCB assembly 310-3 to support the third set of light sources 310-1.

For sake of brevity, the first set of light sources 306-1, the second set of light sources 308-1, and the third set of light sources 310-1 may interchangeably be referred to as the light sources 306-1, 308-1, 310-1, without departing from the scope of the present disclosure. Similarly, the first reflector 306-2, the second reflector 308-2, and the third reflector 310-2 may interchangeably be referred to as the reflectors 306-2, 308-2, 310-2. Further, the first PCB assembly 306-3, the second PCB assembly 308-3, and the third PCB assembly 310-3 may interchangeably be referred to as the PCB assemblies 306-3, 308-3, 310-3, without departing from the scope of the present disclosure.

As explained earlier, the headlamp assembly 100 may include the cooling module 304 disposed in the housing member 202. In an embodiment, the cooling module 304 may be adapted to support the lighting modules 302-1, 302-2, 302-3. Further, the cooling module 304 may be adapted to conduct heat from the lighting modules 302-1, 302-2, 302-3. For instance, the cooling module 304 may conduct the heat generated during operation of the lighting modules 302-1, 302-2, 302-3 of the headlamp assembly 100. Construction and operational details of the cooling module 304 of the headlamp assembly 100 are explained in detail in the description of the Figures 4a-4b and Figures 5a-5c of the present disclosure.

Figure 4 illustrates a rear perspective view of the headlamp assembly 100, according to an embodiment of the present disclosure. Referring to Figure 4, the housing member 202 of the headlamp assembly 100 includes at least one inlet 402 and at least one outlet 404. The at least one inlet 402 may be adapted to allow ingress of ambient air within the housing member 202. Further, the at least one outlet 404 may be adapted to allow egress of the ambient air from the housing member 202. The at least one inlet 402 and the at least one outlet 404 may be provided in the housing member 202 to allow a flow of the ambient air within the housing member 202, thereby conducting heat from the cooling module 304 disposed within the housing member 202 through natural convection.

In the illustrated embodiment, the housing member 202 may include the at least one inlet 402, such as the inlet 402 adapted to allow ingress of the ambient air. Further, the housing member 202 may include the at least one outlet 404, such as a first outlet 404-1 and a second outlet 404-2 adapted to allow egress of the ambient air entered in the housing member 202 through the inlet 402. In an embodiment, the first outlet 404-1 and the second outlet 404-2 may collectively be referred to as the outlets 404-1, 404-2, without departing from the scope of the present disclosure.

As shown in Figure 4, each of the first outlet 404-1 and the second outlet 404-2 may be located at an upper portion 406 of the housing member 202. Further, the inlet 402 may be located at a lower portion 408 of the housing member 202 to allow ingress of the ambient air. In an embodiment, the ambient air entering in the housing member 202 through the inlet 402 may come in contact with the cooling module 304 arranged within the housing member 202, and thereby conducting the heat from the cooling module 304, which is explained in detail in description of Figure 6a, Figure 6b, and Figure 6c of the present disclosure.

In the illustrated embodiment, as shown in Figure 4, the headlamp assembly 100 includes a pair of outlets, i.e., the first outlet 404-1 and the second outlet 404-2, and one inlet, i.e., the inlet 402. However, it should be appreciated by a person skilled in the art that it should not be construed as limiting, and the headlamp assembly 100 may include multiple inlets and multiple outlets for allowing ingress and egress of the ambient air, without departing from the scope of the present disclosure.

Figure 5 illustrates a perspective view of the cooling module 304 of the headlamp assembly 100, according to an embodiment of the present disclosure. The cooling module 304 may include a first heat sink 502 and a second heat sink 504 which is removably coupled to the first heat sink 502. The first heat sink 502 and the second heat sink 504 may be adapted to conduct the heat from each other. In an embodiment, the first heat sink 502 and the second heat sink 504 may collectively be referred to as the heat sinks 502, 504, without departing from the scope of the present disclosure.

In an embodiment, each of the heat sinks 502, 504 may be adapted to support at least one of the lighting modules 302-1, 302-2, 302-3. Further, each of the heat sinks 502, 504 may be adapted to conduct heat from the at least one of the lighting modules 302-1, 302-2, 302-3. Each of the heat sinks 502, 504 may be formed of Aluminium. In various embodiments, each of the heat sinks 502, 504 may be formed of any thermally conductive material known in the art, without departing from the scope of the present disclosure.

In the illustrated embodiment, the first heat sink 502 may be adapted to support the first lighting module 302-1, i.e., the Low Beam lighting module, and adapted to conduct heat from the first lighting module 302-1. Construction details of the first heat sink 502 are explained in detail in the description of Figure 6a, Figure 6b, and Figure 6c of the present disclosure.

Figures 6a and 6b illustrate different perspective views of the first heat sink 502 of the cooling module 304, according to an embodiment of the present disclosure. Figure 6c illustrates a rear view of the first heat sink 502, according to an embodiment of the present disclosure. As mentioned earlier, the first heat sink 502 may be adapted to support the first lighting module 302-1. In the illustrated embodiment, the first heat sink 502 may include a first horizontal portion 602 and a first longitudinal portion 604. The first horizontal portion 602 may be adapted to support the first lighting module 302-1.

In an embodiment, the first horizontal portion 602 may include a first outer surface 606 and a first inner surface 608 distal to the first outer surface 606. The first inner surface 608 may be adapted to support the first lighting module 302-1 on the first heat sink 502. The first inner surface 608 may be provided with a plurality of apertures adapted to receive fasteners for coupling the first lighting module 302-1 to the first heat sink 502. In an embodiment, the fasteners may include, but is not limited to, screws, bolts, threaded inserts, threaded rods, and snap fasteners.

Further, the first longitudinal portion 604 of the first heat sink 502 may extend in a longitudinal direction from the first horizontal portion 602 of the first heat sink 502. In the illustrated embodiment, the first longitudinal portion 604 may include a second outer surface 610 and a second inner surface 612 distal to the second outer surface 610. Further, the first longitudinal portion 604 may include a connecting portion 614 extending downwardly in the longitudinal direction from the first longitudinal portion 604.

In an embodiment, the connecting portion 614 may be provided with a plurality of apertures adapted to receive fasteners for coupling the second heat sink 504 with the first heat sink 502. In an embodiment, the second heat sink 504 may be removably coupled to the first heat sink 502 through the fasteners including, but not limited to screws, bolts, threaded inserts, and threaded rods. Constructional details of the second heat sink 504 are explained in detail in the description of Figure 7a, Figure 7b, and Figure 7c of the present disclosure.

In an embodiment, the first heat sink 502 may include a first set of fins 616-1, 616-2 exposed to the ambient air such that the heat from the first heat sink 502 is conducted to the ambient air. The first set of fins 616-1, 616-2 may individually be referred to as the first set of fins 616-1 and the first set of fins 616-2, without departing from the scope of the present disclosure. In the illustrated embodiment, the first set of fins 616-1 may be formed on the first outer surface 606 of the first horizontal portion 602 of the first heat sink 502. Further, the first set of fins 616-2 may be formed on the second outer surface 610 of the first longitudinal portion 604 of the first heat sink 502. In an embodiment, the first set of fins 616-2 may be also formed on the connecting portion 614 of the first heat sink 502.

Figures 7a and 7b illustrate different perspective views of the second heat sink 504 of the cooling module 304, according to an embodiment of the present disclosure. Figure 7c illustrates a rear view of the second heat sink 504, according to an embodiment of the present disclosure. In an embodiment, the second heat sink 504 may be adapted to support the second lighting module 302-2 and the third lighting module 302-3 of the headlamp assembly 100. In an embodiment, the second heat sink 504 may include a second horizontal portion 702 and a second longitudinal portion 704. The second horizontal portion 702 and the second longitudinal portion 704 may be adapted to support the second lighting module 302-2. In an embodiment, the second lighting module 302-2 may be removably coupled to the second horizontal portion 702 and the second longitudinal portion 704 through fasteners including, but not limited to, screws, bolts, threaded inserts, and threaded rods. Further, the second heat sink 504 may be adapted to conduct the heat from the second lighting module 302-2.

Further, the second heat sink 504 may be adapted to support the third lighting module 302-3. In an embodiment, the second horizontal portion 702 of the second heat sink 504 may be adapted to support the third lighting module 302-3. In the illustrated embodiment, the third lighting module 302-3 may be removably coupled to the second horizontal portion 702 through the fasteners including, but not limited to, screws, bolts, threaded rods, and threaded inserts. Further, the second heat sink 504 may be adapted to conduct the heat from the third lighting module 302-3.

In an embodiment, the second heat sink 504 may include a second set of fins 706 formed on the second horizontal portion 702 and the second longitudinal portion 704. The second set of fins 706 may be adapted to be exposed to the ambient air entering through the at least one inlet such that the heat from the second heat sink 504 is conducted to the ambient air, which is explained in detail in the description of the Figure 8c, Figure 8b, and Figure 8c of the present disclosure.

Figures 8a, 8b, and 8c illustrate different sectional views of the headlamp assembly 100 depicting a flow of the ambient air within the headlamp assembly 100, according to an embodiment of the present disclosure. For the sake of brevity, details of the headlamp assembly 100 that are already explained in detail in the description of Figure 1, Figure 2, Figure 3, Figure 4, Figure 5, Figure 6a, Figure 6b, Figure 6c, Figure 7a, Figure 7b, and Figure 7c are not explained in detail in the description of Figure 8a, Figure 8b, and Figure 8c.

Referring to Figure 8a, during operation of the headlamp assembly 100, light sources of each of the lighting modules 302 may generate heat which further increases overall temperature the headlamp assembly 100. In order to reduce the overall temperature of the headlamp assembly 100, as explained earlier, the lighting modules 302 may be coupled to the cooling modules 304 such that heat from the lighting modules 302 may be conducted to the cooling module 304.

In particular, the heat generated during operation of the first lighting module 302-1 may be absorbed by the first heat sink 502. Similarly, the heat generated during operation of at least one of the second lighting module 302-2 and the third lighting module 302-3 may be absorbed by the second heat sink 504. Further, as explained earlier, the first heat sink 502 and the second heat sink 504 may be coupled such that the heat may be conducted between each of the first heat sink 502 and the second heat sink 504.

Further, as explained earlier, the housing member 202 may include the inlet 402 adapted to allow the flow of the ambient air, denoted with A’, within the inner chamber, such as an inner chamber 802 of the headlamp assembly 100. In an embodiment, when the vehicle having the headlamp assembly 100 at the front end moves in a forward direction, the flow of the ambient air may enter within the inner chamber 802 through the inlet 402 of the housing member 202.

Subsequently, the flow of the ambient air may come in contact with the first heat sink 502 and the second heat sink 504 of the headlamp assembly 100. In particular, the first heat sink 502 and the second heat sink 504 may be positioned in the headlamp assembly 100 such that the flow of the ambient air entering within the housing member 202 may come in contact with the first set of fins 616-1, 616-2 formed on the first heat sink 502 and the second set of fins 706 formed on the second heat sink 504.

Owing to the flow of the ambient air over the first set of fins 616-1, 616-2 and the second set of fins 706, the heat may be conducted from the first heat sink 502 and the second heat sink 504 to the ambient air within the inner chamber 802, through the natural convention. Subsequently, temperature of the ambient air may increase owing to conduction of the heat from the first heat sink 502 and the second heat sink 504. In the present embodiment, the ambient air with increased temperature may interchangeably be referred to as the hot air, without departing from the scope of the present disclosure.

Thereafter, the hot air may flow in an upward direction within the inner chamber 802. Owing to such flow of the hot air, a draft may be generated which further pulls the ambient air from surrounding within the inner chamber 802 through the inlet 402. The ambient air entering within the inner chamber 802 from the inlet 402 may be at a lower temperature in comparison to the temperature of the hot air. Subsequently, the ambient air may conduct the heat from the first heat sink 502 and the second heat sink 504. This results in a natural flow of air within the headlamp assembly 100 in order to reduce the temperature of the headlamp assembly 100 by conducting the heat from the cooling module 304.

Referring to Figure 8b and Figure 8c, as explained earlier, the hot air may flow in the upward direction which generates the draft to pull the ambient air from the surrounding through the inlet 402. Further, the hot air may egress from the inner chamber 802 through the outlets 404-1, 404-2 of the housing member 202, as indicated by an arrow A’’. Owing to egress of the hot air and ingress of the ambient air, the heat may be effectively conducted from various sub-components, and in particular from the cooling module 304 of the headlamp assembly 100.

Figure 9 illustrates perspective views depicting an exemplary sequence of assembling the headlamp assembly 100, according to an embodiment of the present disclosure. Referring to Figure 9, firstly, the LB lighting module 302-1 may be coupled to the first heat sink 502 through the fasteners in order to form a LB sub-assembly 902. Similarly, the HB lighting module 302-3 may be coupled to the second heat sink 504 through the fasteners in order to form a HB sub-assembly 904. Further, the DRL lighting module 302-2 may be coupled to the HB sub-assembly 904. In particular, the DRL lighting module 302-2 may be coupled to second heat sink 504 of the HB sub-assembly 904. Subsequently, the LB sub-assembly 902 and the HB sub-assembly 904 may be coupled through the fasteners in order to form a headlamp sub-assembly 906. Further, the housing member 202 may be attached at a rear end of the headlamp sub-assembly 906. Furthermore, the lens 204 and the mask 206 may be attached at a form end of the headlamp sub-assembly 906 in order to form the headlamp assembly 100.

As explained earlier, the headlamp assembly 100 may include the cooling module 304 for supporting the plurality of lighting modules 302. The cooling module 304 includes the first heat sink 502 and the second heat sink 504 which is coupled with the first heat sink 502. Each of the first heat sink 502 and the second heat sink 504 may support various sub-components, such as the light sources 306-1, 308-1, 310-1, the PCBs 306-3, 308-3, 310-3, and the reflectors 306-2, 308-2, 310-2 of the each of the lighting modules 302. Therefore, requirement of auxiliary supporting arrangements for supporting the lighting modules 302 are substantially eliminated, and thereby providing overall compact structure of the headlamp assembly, i.e., the headlamp assembly 100. Also, owing to deployment of the cooling module 304 for conducting the heat, requirement of moving components, such as fan, for cooling of the headlamp assembly 100 may be substantially eliminated. This further eliminates complexity involved during assembling process of the headlamp assembly 100 and servicing of the headlamp assembly 100.

Further, the cooling module 304 may be adapted to conduct the heat from the plurality of lighting modules 302. The first heat sink 502 may conduct heat generated from the first lighting module 302-1. Similarly, the second heat sink 504 may conduct the heat generated from the second lighting module 302-2 and the third lighting module 302-3. Also, the first heat sink 502 and the second heat sink 504 may conduct the heat from each other. For instance, when only the first lighting module 302-1, i.e., the LB lighting module is in operation, then the heat generated by the first lighting module 302-1 may be conducted by the first heat sink 502. Subsequently, the second heat sink 504 may conduct the heat from the first heat sink 502. Therefore, the heat may be effectively distributed between the first heat sink 502 and the second heat sink 504. Thereby, in such an instance, overall area available for heat distribution is substantially increased which results in improved heat conduction by the ambient air through natural convection. This may also substantially increase an overall service life of the headlamp assembly 100. Therefore, the present disclosure offers the headlamp assembly 100 that is efficient, economical, compact, flexible, and effective for illuminating path in front of the vehicle.

While specific language has been used to describe the present subject matter, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment.