Claims:We claim:
1. A headlamp support structure for front fascia in a vehicle, the headlamp support structure includes a bracket (100) comprising:
a horizontal top surface (102) extending in progression with a slant bridging surface (104) in the vehicle transverse direction; and
a claw protrusion (106) formed in the horizontal top surface (102) and protruding towards a longitudinal direction of the vehicle for receiving the headlamp,
characterized in that, the bracket (100) comprises:
a plurality of flanges (114A, 114B, 114C) extending from an end of the slant bridging surface (104), wherein the plurality of flanges (114A, 114B, 114C) are being mounted on a front end module (402) of the vehicle.
2. The headlamp support structure as claimed in claim 1, wherein the bracket (100) comprises a pair of apertures (108A, 108B) formed adjacent to each other on the horizontal top surface (102), wherein one end of each of the apertures (108A, 108B) being extending parallel to each other in downward direction to form a pair of mounting flanges (110A, 110B).
3. The headlamp support structure as claimed in claim 1, wherein the bracket (100) comprises a guiding flange (112) extending from front side of the horizontal top surface (102) for guiding the mounting of the headlamp on the bracket (100).
4. The headlamp support structure as claimed in claim 1, wherein the bracket (100) comprises the horizontal top surface (102) for resting of the headlamp.
5. The headlamp support structure as claimed in claim 1, wherein the bracket (100) comprises the claw protrusion (106) forming a flexible, zig-zag structure, capable of receiving and coupling with a snap-fit locking structure of the headlamp.
6. The headlamp support structure as claimed in claim 1, wherein the bracket (100) comprises the mounting flanges (110A, 110B) including supporting holes (118A, 118B) to receive and mount a support structure of a vehicle accessory.
7. The headlamp support structure as claimed in claim 1, wherein the bracket (100) comprises the plurality of flanges (114A, 114B, 114C) including a front flange (114A), a middle flange (114B) and a rear flange (114C).
8. The headlamp support structure as claimed in claim 7, wherein the bracket (100) comprises the front flange (114A), the middle flange (114B) and the rear flange (114C) are welded on a front vertical surface (402A), a side vertical surface (402B), and a rear vertical surface (402C) of the front end module (402) of the vehicle.
9. The headlamp support structure as claimed in claim 8, wherein the bracket (100) comprises the rear flange (114C) comprises a cutout (116) providing access to the mounting flanges (110A, 110B).
10. The headlamp support structure as claimed in claim 1, wherein the bracket (100) comprises the slant bridging surface (104) in its central region comprises a bead structure (104-B).
11. The headlamp support structure as claimed in claim 1, wherein the bracket (100) comprises the width of the bracket (100) gradually decreases from an outer end of the horizontal top surface (102) to an outer end of the slant bridging surface (104).

Description: A HEADLAMP SUPPORT STRUCTURE FOR FRONT FASCIA IN A VEHICLE

TECHNICAL FIELD
[0001] The present subject matter described herein relates to a fitment of a headlamp supporting structure for front fascia in a vehicle. In particular, the present subject matter relates to a bracket coupled with the front end of the vehicle for mounting the headlamp, controlling the undesired movement of headlamp, and improving the front fascia appearance around the headlamp periphery.

BACKGROUND
[0002] A headlamp is a housing of light producing elements attached to the front of a vehicle to light the road ahead while driving. The headlamp serves a vital function to offer ease of driving and improves the overall use of the vehicle.
[0003] The headlamp is mounted on the vehicle body structure with multiple mountings and is attached with the bumper system present in front of the vehicle with support of additional bumper holder. As, there is absence of bottom support for headlamp therefore, by the passage of time it gets sag in downward direction which results in abnormal gap variation in the vehicle and have impact on the vehicle aesthetic appeal.
[0004] In several known techniques in the industry, vehicle manufactures produced solutions to provide the mounting of the headlamp on the vehicle front body. In one such technique, the headlamp is mounted on three locations on the front end structure of the vehicle such as:
a) On horizontal top panel of front end frame structure of the vehicle;
b) On vertical frame structure of the front end structure;
c) On stay bracket welded on front section of long member of the front end structure.
[0005] Further, such an assembly is coupled with the bumper assembly of the vehicle. The front end structure is coupled with the bumper using a holder. The holder is mounted on the headlamp which then provides configuration to be coupled with the front end structure and the bumper assembly of the vehicle.
[0006] But such techniques have its demerits.
[0007] With the passage of time, the bumper tends to sag in downward directions due to its own weight. The bumper does not remain tight fixed to its place, thus causing the entire headlamp assembly coupled with it to also slump. An absence of a firm structure affects the entire headlamp assembly and causes an undesired non-uniform gap between the headlamp and the bumper.
[0008] This results in undesired non-uniform gap around the headlamp affecting the aesthetic appeal of the vehicle.
[0009] Thus, it is required to offer an improved solution with a firm structure to control the undesired movement of the headlamp in downward, backward or forward direction.
OBJECTS OF THE DISCLOSURE
[0010] It is therefore the object of the present disclosure to overcome the aforementioned and other drawbacks in prior method/product/apparatus.
[0011] It is a primary object of the present disclosure to provide a support structure for the headlamp and control the undesired non-uniform gap around the headlamp.
[0012] It is an object of the present invention, to provide a clamping claw protrusion to engage the headlamp and controlling movement of the headlamp in forward or backward direction.
[0013] It is an object of the present disclosure, to provide a firm base to the headlamp providing base support to rest thus controlling movement of the headlamp in downward direction.
[0014] It is a further object of the present disclosure, to securely attach headlamp with the front end structure of the vehicle and eliminate the effects of slumping or sagging with the period of usage and time.
[0015] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present subject matter are illustrated.

SUMMARY
[0016] Solution to one or more drawbacks of existing technology and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be a part of the claimed disclosure.
[0017] The solution to overcome the deficiencies of the known techniques in the industry is offered by the present disclosure. The present disclosure provides a support structure for mounting the headlamp. The support structure includes a bracket, secured to the front end structure of the vehicle with multiple welding points. The bracket includes a horizontal top surface extending in progression with a slant bridging surface, and a claw protrusion formed in the horizontal top surface and protruding towards a longitudinal direction of the vehicle for receiving the headlamp. The bracket further includes a plurality of flanges extending from an end of the slant bridging surface, the plurality of flanges being mounted on a front end module of the vehicle. The bracket further includes a pair of apertures formed adjacent to each other on the horizontal top surface, one end of each of the apertures being extending parallel to each other in downward direction to form a pair of mounting flanges.
[0018] In an aspect, the bracket includes a guiding flange extending from a front side of the horizontal top surface for guiding the mounting of the headlamp on the bracket.
[0019] In an aspect, the horizontal top surface is for resting of the headlamp.
[0020] In an aspect, the claw protrusion forms a flexible, zig-zag structure, capable of receiving and coupling with a snap-fit locking structure of the headlamp.
[0021] In an aspect, the mounting flanges includes supporting holes to receive and mount a support structure of a vehicle accessory.
[0022] In an aspect, the plurality of flanges includes a front flange, a middle flange, and a rear flange.
[0023] In an aspect, the front flange, the middle flange, and the rear flange are welded on a front vertical surface, a side vertical surface, and a rear vertical surface of the front end module of the vehicle.
[0024] In an aspect, the rear flange includes a cutout providing access to the mounting flanges.
[0025] In an aspect, the slant bridging surface in its central region includes a bead structure.
[0026] In an aspect, the width of the bracket gradually decreases from an outer end of the horizontal top surface to an outer end of the slant bridging surface.
[0027] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS
[0028] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the present disclosure may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0029] FIG. 1 illustrates an isometric view of a headlamp support structure in accordance with an embodiment of the present disclosure;
[0030] FIG. 2 illustrates a top view of the headlamp support structure in accordance with an embodiment of the present disclosure;
[0031] FIG. 3 illustrates a side-view of the headlamp support structure in accordance with an embodiment of the present disclosure; and
[0032] FIG. 4 illustrates the headlamp support structure coupled with a front end module of a vehicle in accordance with an embodiment of the present disclosure.
[0033] The figures depict embodiments of the present subject matter for illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION
[0034] While the embodiments of the disclosure are subject to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
[0035] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.
[0036] FIGS. 1-3 illustrate different views of a headlamp support structure for front fascia in a vehicle, which includes a bracket 100 in accordance with an embodiment of the present disclosure. In accordance with the embodiment of the present disclosure, the bracket 100 may be understood as a support structure on top surface of which a headlamp is to be rested. The bracket 100 provides arrangement and configurations to clamp the headlamp securely and cease any undesired movements.
[0037] Further, in accordance with an embodiment of the present disclosure, the bracket 100 includes a horizontal top surface 102 extending in progression with a slant bridging surface 104. The horizontal top surface 102 is formed parallel to a vehicle front structure. That is, the horizontal top surface 102 is formed parallel to the width wise (transverse) direction of the vehicle.
[0038] Referring to FIGS. 1 and 2, the slant bridging surface 104 on its central region is formed with a bead structure 104-B. The bead structure 104-B is capable of decreasing the stress received on the slant structure of the bracket 100. Further, the width of the bracket 100 gradually decreases from an outer end of the horizontal top surface 102 to an outer end of the slant bridging surface 104 so as to divert the stress towards the bead structure 104-B.
[0039] The horizontal top surface 102 includes a claw protrusion 106 formed on the horizontal top surface 102 and protruding towards a longitudinal direction of the vehicle for receiving the headlamp.
[0040] The horizontal top surface 102 further includes a pair of apertures 108A, 108B formed adjacent to each other on the horizontal top surface 102. The apertures are formed by slitting or cutting the three sides of the aperture area and bending the one end (slitted or cut surface) downwards, i.e., one end of each of the apertures 108A, 108B extend parallel to each other in downward direction to form a pair of mounting flanges 110A, 110B.
[0041] Those skilled in the art can appreciate that the claw protrusion 106 and the pair of mounting flanges 110A, 110B are formed with the same material. That is, at time of manufacturing of the bracket (100), the claw protrusion and the pair of mounting flanges 110A, 110B both are formed on the horizontal top surface 102 without requiring any other additional material. In an alternative aspect, the material used for manufacturing of the claw protrusion 106 and the pair of mounting flanges 110A, 110B can be selected different from the material of the bracket 100, without deviating from the scope of the present disclosure.
[0042] Further, in an aspect, the claw protrusion 106 is a flexible, zig-zag structure, capable of receiving and coupling with a snap-fit locking structure of the headlamp for assembly of the headlamp on the bracket 100. Further, the claw protrusion 106 includes at least three step portions extending from the horizontal top surface 102. The headlamp is mounted on the horizontal top surface 102 after being guided over the horizontal top surface 102 through a guiding flange 112. The guiding flange 112 extends from front side of the horizontal top surface 102 to guide the movement of the headlamp on the horizontal top surface 102 so as to prevent the undesired movement of the headlamp.
[0043] The claw protrusion 106 and the guiding flange 112, acting as an extended appendage of the horizontal top surface 102 snap fits the headlamp and cease the movement of the headlamp in either forward or backward direction towards the longitudinal axis of the vehicle.
[0044] As, the headlamp rest of the horizontal top surface 102, the horizontal top surface 102 acts as a bottom to support the headlamp. This ceases the undesired movement of headlamp in downward direction of the vehicle.
[0045] The bracket 100 further includes a plurality of flanges 114A, 114B, 114C extending from an end of the slant bridging surface 104. The plurality of flanges 114A, 114B, 114C are being mounted on a front end module 402 of the vehicle, as can be seen from FIG. 4.
[0046] As can be appreciated by those skilled in the art, the front end module 402 of the vehicle can be understood as a radiator body or a front grill structure of the vehicle front frame. The front end module 402 is not to be restricted with any limited vehicle body part but shall be understood as the principal vehicle frame in a front portion of the vehicle.
[0047] Further, the plurality of flanges 114A, 114B, 114C includes a front flange 114A, a middle flange 114B and a rear flange 114C. The front flange 114A and the rear flange portion 114C are extending towards downward direction from top of slant bridging surface 104 of the bracket 100, while the middle flange 114B is extending towards upward from top slant bridging surface 104 of the bracket 100. The front flange 114A, the middle flange 114B, and the rear flange 114C are welded on a front vertical surface 402A, a side vertical surface 402B, and a rear vertical surface 402C of the front end module 402 of the vehicle as shown in FIG. 4.
[0048] Referring to FIG. 3, the rear flange 114C comprises a cutout 116 providing access to the mounting flanges 110A, 110B. The cutout 116 is provided in the rear flange 114C, so that an operator has the ease of access while fastening the support structure of a vehicle accessory, say, siren, on supporting holes 118A, 118B formed in the mounting flanges 110A, 110B extending from the pair of apertures 108.
[0049] Thus, in an advantageous effect of the invention, the assembly of headlamp mounted on the bracket 100 and the secured fastening of the bracket 100 with the front end module 402 of the vehicle provides a support structure to control the movement of the headlamp in undesired directions. Thus, the headlamp is secured at a desired place increasing the aesthetic appeal of the vehicle.
[0050] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation, no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to disclosures containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. Also, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general, such construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general, such construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
[0051] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present disclosure contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the disclosure, and other dimensions or geometries are possible. Also, while a feature of the present disclosure may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present disclosure. The present disclosure also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.