Embodiment of the present invention relates to automotive lighting systems and more particularly to a screwless PCB arrangement in a headlamp assembly of a vehicle.
BACKGROUND OF THE INVENTION
Lighting systems are one of the most important aspects in automobiles, be it two-wheelers, four wheelers etc. They are responsible for ensuring proper illumination of the way ahead is provided for the vehicle’s driver to see. For this purpose of achieving adequate illumination efficiently, engineers and designers all over the world keep trying to innovate and develop new light sources for headlamps. Now-a-days, LED headlamps are getting increasingly popular all over the world. They are being used in all kinds of two-wheeler, four-wheelers etc. as they provide adequate illumination as well as add to the beautiful aesthetics of the vehicle.
In the presently available LED headlamps, arrangement of a PCB plays a key role. To glow the LED Headlamp according to the regulation requirements, a position of LED is decided. Presently, once the LED position is decided, PCB is fixed to that position with the help of screws. But in this kind of arrangement of the PCB in the headlamp increases the assembly time because screws are required to be fastened separately. This is a time-consuming process as well as breaks the process flow in the assembly line. This further has an adverse effect on production rate because more the time required for assembly, less is the production rate.
Therefore, there is a need in the art a screwless PCB arrangement in a headlamp assembly of a vehicle that does not suffer from above-mentioned deficiencies and provide an effective and viable solution.

OBJECT OF THE INVENTION
The object of the proposed invention is to provide a screwless PCB arrangement in a headlamp assembly of the vehicle.
Another object of the present invention is to sandwich a PCB between housing and reflector of the headlamp.
SUMMARY OF THE INVENTION
Embodiments of the present invention aim to provide a Headlamp assembly for a vehicle.
According to an aspect of the present invention, a headlamp assembly having a screwless Printed Circuit Board (PCB) arrangement is provided. The headlamp assembly may comprise a housing configured to house a reflector, one or more Light-emitting diodes (LEDs) positioned in the reflector, a PCB disposed between the housing and the reflector, and a glass cover adapted to be connected with the housing to cover the reflector and the one or more LEDs positioned therein. Further, the PCB may comprise a plurality of holes adapted to connect the PCB with the reflector and the one or more LEDs. Furthermore, the reflector may comprise a plurality of clamp ribs and a plurality of guide pins adapted to be received in the holes of the PCB. In addition, the one or more clamp ribs may be configured to restrict the upward directional movement of PCB. Moreover, the plurality of the guide pins may be mountings designed in the reflector to be received in the plurality of holes of the PCB to provide a stable connection between the PCB and the reflector, thereby affixing the PCB over the reflector. Additionally, the housing may comprise one or more housing ribs configured to hold the PCB at the required position, thereby sandwiching the PCB between the housing and the reflector while restricting all the possible degrees of motion of PCB without using any screw.
The PCB may be selected from a one or more of single layer, double layer, multi-layer, Rigid-PCB, flexible, Rigid-Flex, High-frequency and/or Aluminium-backed printed circuit board.
The glass cover may be made of a material selected from, but not limited to, polypropylene, polybutylenes terephthalate and nylon.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments.
These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:
Fig. 1a and 1b illustrate a side view of a headlamp assembly in accordance with an embodiment of the present invention;
Fig. 2a and 2b illustrates a front view of the headlamp assembly in accordance with an embodiment of the present;
Fig. 3 invention illustrates an uncovered view of the headlamp assembly in accordance with an embodiment of the present invention;
Fig. 4 illustrates a rear view of the headlamp assembly in accordance with an embodiment of the present invention; and
Fig. 5a and 5b illustrates a perspective view of the headlamp assembly in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS
The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the invention In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment. As used throughout this description, the word "may" is used in a permissive sense (i.e. meaning having the potential to), rather than the mandatory sense, (i.e. meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope.
The systems, methods, and examples provided herein are only illustrative and not intended to be limiting. The present invention can be understood by way of following embodiments below:
In accordance with an embodiment of the present invention, there is provided a screwless PCB (114) arrangement in a headlamp assembly (100) for a vehicle. Figure 1a and 1b illustrate a side view of the headlamp assembly (100) in accordance with an embodiment of the present invention. As shown in figure 1a and 1b, the headlamp assembly (100) may comprise, but not limited to, a Printed circuit board (PCB (114)), a housing (116), a reflector (104), one or more Light-emitting diodes (LED (106)) positioned in the reflector (104) and a glass cover (112). The PCB (114) being sandwiched between the housing (116) and the reflector (104). The PCB (114) may be, but not limited to, a single layer, double layer, multi-layer, Rigid-PCB, flexible, Rigid-Flex, High-frequency, Aluminium-backed.
Further, the PCB (114) is envisaged to comprise a plurality of holes on the surface. The position of the PCB (114) is decided according to the position of the one or more LEDs (106) in the headlamp assembly (100). The LEDs (106) may be arranged anywhere on the headlamp assembly (100), however, preferably, the LEDs (106) are arranged on upper portion of the headlamp assembly (100). The plurality of holes are adapted to connect the PCB (114) with the reflector (104). The plurality of holes further connects PCB (114) with the one or more LEDs (106).
Figure 2a and 2b illustrates a front view of the headlamp assembly (100) in accordance with an embodiment of the present invention. Figure 2 shows the arrangement of the reflector (104), the LEDs (106) encased inside the housing. Further, the housing, the reflector (104) and the LEDs (106) are clamped using the the plurality of clamp ribs (108).
Figure 3 illustrates an uncovered view of the headlamp assembly (100) in accordance with an embodiment of the present invention. As shown in figure 3, the reflector (104) may comprise the plurality of clamp ribs (108) and a plurality of guide pins (110). The plurality of clamp ribs (108) and the plurality of guide pins (110) are adapted to be received in the holes of the PCB (114). The one or more clamp ribs (108) may be configured to restrict the upward directional movement of the PCB (114). The plurality of the guide pins (110) are mountings designed in the reflector (104) for directing the holes on the PCB (114).
Figure 4 illustrates a rear view of the headlamp assembly (100) in accordance with an embodiment of the present invention. As shown in figure 4, the housing (116) of the headlamp is used to house the reflector (104) with the PCB (114). In accordance with an embodiment of the present invention, the housing (116) may further comprise one or more housing ribs (not shown). The one or more housing ribs are configured for restricting the motion of PCB (114).
Figure 5a and 5b illustrate a perspective view of the headlamp assembly (100) in accordance with an embodiment of the present invention. The one or more LEDs (106) are connected with the PCB (114) and positioned in the reflector (104) based on the desired optics. The light source may be, but not limited to, incandescent light bulb or LEDs (106) and may be used for purpose of headlamps or indicators. Further, as shown in figure 5, the glass cover (112) is adapted to be connected with the housing (116) to cover the reflector (104) and the one or more LEDs (106) positioned therein.
The housing (116) may comprise the one or more housing ribs configured to hold the PCB (114) at the required position. The housing (116) and the reflector (104) therefore so arranged thereby sandwiching the PCB (114) between the housing (116) and the reflector (104) while restricting all the possible degrees of motion of PCB (114) without using any screw. The material for glass cover (112) may be, but not limited to, polypropylene, polybutylenes terephthalate, and nylon.
The invention works in following manner:
In accordance with an embodiment of the present, firstly, the PCB (114) is placed over the one or more clamp ribs (108). The one or more clamp ribs (108) is used to fix the PCB (114) over reflector (104) to restrict the upward movement of the PCB (114). After that, plurality of the guide pins (110) are received in the plurality of holes of the PCB (114). The plurality of the guide pins (110) directs the correct position of PCB (114) and provides a stable connection between the PCB (114) and the reflector (104), thereby affixing the PCB (114) over the reflector (104). The PCB (114) with the reflector (104) is then placed over housing. The one or more housing ribs hold the PCB (114) at the required position, thereby sandwiching the PCB (114) between the housing (116) and reflector (104) without the use of any screw. This completes the screwless PCB (114) arrangement in a headlamp assembly (100) of a vehicle. Further, the one or more LEDs (106) may be positioned in the reflector (104) and are connected with the PCB (114). The PCB (114) may be used to supply electrical energy to the illuminate the one or more LEDs (106) for the headlamp assembly (100).
The present invention provides several advantages. The present invention provides a screwless PCB (114) arrangement in a headlamp assembly (100). The screwless PCB (114) arrangement provides an easy way to assemble the PCB (114) with the lamp. The screwless PCB (114) arrangement consumes less assembly time which results in increase in the production rate of the headlamp. The present invention provides a cost-effective solution to the problems of the prior art.
Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention.

We Claims:
1. A headlamp assembly (100) having a screwless Printed Circuit Board (PCB) (114) arrangement, the headlamp assembly (100) comprising:
a housing (116) configured to house (116) a reflector (104);
one or more Light-emitting diodes (LEDs) (106) positioned in the reflector (104);
a PCB (114) disposed between the housing (116) and the reflector (104); and
a glass cover (112) adapted to be connected with the housing (116) to cover the reflector (104) and the one or more LEDs (106) positioned therein;
wherein the PCB (114) comprises a plurality of holes adapted to connect the PCB with the reflector (104) and the one or more LEDs (106);
wherein the reflector (104) comprises a plurality of clamp ribs (108) and a plurality of guide pins (110) adapted to be received in the holes of the PCB (114);
wherein the one or more clamp ribs (108) are configured to restrict the upward directional movement of PCB (114);
wherein the plurality of the guide pins (110) are mountings designed in the reflector (104) to be received in the plurality of holes of the PCB (114) to provide a stable connection between the PCB (114) and the reflector (104), thereby affixing the PCB (114) over the reflector (104); and
wherein the housing (116) comprises one or more housing ribs configured to hold the PCB (114) at the required position, thereby sandwiching the PCB (114) between the housing (116) and the reflector (104) while restricting all the possible degrees of motion of PCB (114) without using any screw.
2. The headlamp assembly (100) as claimed in claim 1, wherein the PCB (114) is selected from a one or more of single layer, double layer, multi-layer, Rigid-PCB, flexible, Rigid-Flex, High-frequency and/or Aluminium-backed printed circuit board.
3. The headlamp assembly (100) as claimed in claim 1, wherein the glass cover (112) is made of a material selected from polypropylene, polybutylenes terephthalate and nylon.