TECHNICAL FIELD
The present disclosure relates a lamp for vehicles. Particularly, the present disclosure
5 relates to a LED low beam projector lamp which provides adequate illumination.
BACKGROUND
The information in this section merely provides background information related to the
present disclosure and may not constitute prior art(s).
10
Since long time, vehicle manufacturers have been providing a vehicle with several types
of lamps. The lamps are categorized based on their different functions. The various
lamps such as headlamp, tail-lamp, fog lamp, Daytime running lamp (DRL), Front
positioning lamp (FPL), Rear positioning lamp (RPL), Stop lamp and parking lamp are
15 provided to illuminate in in different condition.
Particularly, the projector lamps are provided to illuminate the road in darkness. Such
projector lamps provide illuminance with two types of beams: low beam and high beam.
20 More particularly, low beam projector lamps provide forward and lateral illuminance,
directs towards the eyes of other road users to control glare. Such low beam projector
lamps play a significant role in traffic safety.
Generally, low beam projector lamps are provided with a light source such as tungsten
25 filament, tungsten halogen, high intensity discharge etc. for illuminance.
With an advancement of technology, researchers have come up with light emitting
diodes (LED’s) as light source for low beam projector lamps. Although these LED’s
are less power consuming, however a major disadvantage with the use of LED’s is the
30 inadequate illuminance.
It is also experienced that the existing lamps gets heat-up after working continuously
for a long time.
3
In conclusion, the existing lamps do not provide adequate illumination. Also, the
existing lamps do not have heat management system that dissipate heat for a long time.
Therefore, there is an immense need to provide lamps for vehicle that is capable of
5 dissipation of heat generated inside the lamp and overcomes the one or more limitations
of the existing lamps. Specifically, the inventor of the present disclosure provides a
LED low beam projector lamp that has adequate illumination.
SUMMARY OF THE PRESENT DISCLOSURE
10 One or more drawbacks of conventional lamps as described in the prior art are
overcome and additional advantages are provided through LED low beam projector
lamp as claimed in 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
15 of the claimed disclosure.
The present disclosure relates to a LED low beam projector lamp for vehicles. The lamp
comprises a lens holder, a lens, a light source, a reflector, a driver PCB and a heat sink.
The lens holder has a front portion and a rear portion. The light source is disposed at
20 the rear portion of the lens holder. The light source is a light emitting diode (LED) light
source. The light source is electronically connected to the driver PCB to receive power.
The reflector is disposed at the rear portion of the lens holder. The reflector is
configured to scatter light from the light source towards the front portion of the lens
holder. The reflector is made of an ellipsoidal shape. The heat sink is configured at the
25 rear portion of the lens holder. The heat sink is integrated to the driver PCB. The heat
sink is configured to dissipate heat of the lamp.
In an embodiment, a LED board is configured to accommodate the LED light source.
30 In an embodiment, the lens is disposed at the front portion of the lens holder.
In an embodiment, a plurality of locators is configured at the lens holder for attachment
the LED board, the reflector and the lens with the lens holder.
4
In an embodiment, each locator of the plurality of locators has protrusion part for
inserting in a corresponding hole of the LED board, the heat sink and the lens.
In an embodiment, the heat sink includes a plurality of fins.
5
In an embodiment, the heat sink has a cavity to accommodate the driver PCB therein.
In an embodiment, the heat sink comprises a driver casing configured to cover the driver
PCB.
10
In an embodiment, the driver casing is attached to the driver PCB and the heat sink by
means of a plurality of screws.
The foregoing summary is illustrative only and is not intended to be in any way limiting.
15 In addition to the illustrative aspects, embodiments, and features described above,
further aspects, embodiments, and features will become apparent with reference to the
drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
20 The novel features and characteristics of the disclosure are set forth in the appended
description. The disclosure itself, however, as well as a preferred mode of use, further
objectives and advantages thereof, will best be understood by reference to the following
detailed description of an illustrative embodiment when read in conjunction with the
accompanying figures. One or more embodiments are now described, by way of
25 example only, with reference to the accompanying figures wherein like reference
numerals represent like elements and in which:
Figure 1 illustrates a side view of a LED low beam projector lamp according to present
disclosure.
30
Figure 2 illustrates a front view of a LED low beam projector lamp according to the
present disclosure.
5
Figure 3 illustrates a rear view of a LED low beam projector lamp according to the
present disclosure.
Figure 4 illustrates a cut-sectional side view of a LED low beam projector lamp
5 according to the present disclosure.
Figure 5 illustrates an exploded view of a heat sink integrated with a driver PCB of the
LED low beam projector lamp of Figure 1, according to an embodiment of the present
disclosure.
10
The figures depict embodiments of the disclosure for purposes of illustration only. One
skilled in the art will readily recognize from the following description that alternative
embodiments of the assemblies and methods illustrated herein may be employed
without departing from the principles of the disclosure described herein.
15
DETAILED DESCRIPTION
While the disclosure is subject to various modifications and alternative forms, specific
embodiment thereof has been shown by way of example in the figures and will be
described below. It is to be noted that a person skilled in the art can be motivated from
20 the present disclosure and can perform various modifications. However, such
modifications should be construed within the scope of the disclosure.
The terms “comprises”, “comprising”, or any other variations thereof, are intended to
cover a non-exclusive inclusion, such that an assembly, setup, system, device
that comprises a list of components does not include only those components but may
25 include other components not expressly listed or inherent to such system or device or
setup. In other words, one or more elements in the system or apparatus or device
proceeded by “comprises a” does not, without more constraints, preclude the existence
of other elements or additional elements in the assembly or system or apparatus.
30 Accordingly, it is an aim of the present disclosure to provide a LED low beam projector
lamp for vehicle that provides adequate illumination.
Another aim of the present disclosure is to develop a LED low beam projector lamp
having design flexibility.
6
Accordingly, the present disclosure relates to a LED low beam projector lamp for
vehicles provides adequate illumination. The LED low beam Projector lamp is
configured to mount on the front of the vehicle. The different vehicles may have
5 different mounting configurations to accommodate the LED low beam projector lamp.
The LED low beam projector lamp may be varying in size to mount on the vehicle of
different sizes. The LED low beam projector lamp provides adequate illumination, even
in worst environment such as rainstorm, dust-storm, typhoon etc. in cooperation with
the tolerances of optical, thermal and mechanical behaviour. The LED low beam
10 projector lamp is a retrofit lamp. The LED low beam projector lamp is herewith in
referred to as the lamp.
As shown in figures 1 to 5, the lamp (1) comprises a lens holder (3), a light source (5),
a reflector (7), a lens (2), a driver PCB (6), a LED board (4) and a heat sink (9). The
15 lens holder (3) is configured to mount different mountings of the lamp (1). The LED
board (4), the lens (2) and the heat sink (9) are mounted to the lens holder (3). The lens
holder (3) along with other mountings makes an adjustable mechanical system. The
adjustable mechanical system is configured to maintain the same light pattern even after
adjusting the LED board (4) at some extent.
20
As shown in figure 2, the lens holder (3) has a plurality of locators (12). Each locator
of the plurality of the locators (12) is formed with a protrusion part (not shown). The
protrusion part may have different size corresponds to the size of a hole of different
mountings such as LED board (4), lens (2) and heat sink (9) etc. The protrusion part of
25 the plurality of locators (12) is configured for inserting in a corresponding hole of the
LED board (4), lens (2) and heat sink (9) so as to adjustably attach to the lens holder
(3). The lens holder (3) has a front portion (3a) and a rear portion (3b).
As shown in figure 4, the light source (5) is disposed at the rear portion (3b) of the lens
30 holder (3). The light source (5) is one or more light emitting diode (LED) light source.
The one or more LED light source is mounted on the LED board (4). The LED board
(4) may have different shapes such as rectangular, circular, triangular, square and
combination thereof. The LED board (4) is located at the rear portion (3b) of the lens
7
holder (3). The LED light source is electronically connected to the driver PCB (6) to
receive power and the driver PCB (6) is connected to the power source of the vehicle.
As shown in figure 4, the reflector (7) is disposed at the rear portion (3b) of the lens
5 holder (3). The reflector (7) is configured to scatter light from the light source (5)
towards the front portion (3a) of the lens holder (3). The reflector (7) has an internal
surface (7a) and an external surface (7b). The reflector (7) is located at some distance
from the light source (5) such that maximum amount of the light emitted by the light
source (5) can incident on the internal surface of the reflector (7) so as to scatter the
10 light.
In an embodiment, the reflector (7) is made of an ellipsoidal shape. The ellipsoidal
shape of the reflector (7) covers the LED light source such that the maximum amount
of the light concurrent at the centre of the reflector (7) to scatter towards the lens (2).
15
As shown in figures 1, 2 and 4, the lens (2) is disposed at the front portion (3a) of the
lens holder (3). The lens (2) is configured to direct light outwardly. The lens (2) may
have different shapes and surface texture. The lens (2) is designed corresponds to the
ellipsoidal shape of the reflector (7) so as to spread light adequately on the road.
20
As shown in figure 5, the heat sink (9) is positioned at the rear portion (3b) of the lens
holder (3). The heat sink (9) is configured to dissipate excess heat of the lamp (1)
outwardly. The heat sink (9) has a plurality of fins (8). The plurality of fins (8) is located
at the outer of the heat sink (9). Preferably, the plurality of fins is located at behind of
25 the reflector to optimize the size of the heat sink. The plurality of the fins (8) is
configured to receive heat from inside of the heat sink (9) and convey towards outside
of the lamp (1). The plurality of fins (8) is designed such that the shape of the plurality
of fins (8) is constructed as folded from the top to enhance surface area, thereby the
heat sink (9) can dissipate heat substantially to maintain the temperature of the LED
30 light source (5) under ‘junction temperature’ so as to optimize the thermal performance
thereof. Here, the term ‘junction temperature’ is used to define a highest operating
temperature of the LED light source (5). As the person skilled in the art may be known
that the optical performance of the LED light source (5) depends on the thermal
performance of the LED light source (5), accordingly, the heat sink (9) optimizes
8
thermal performance of the LED light source (5) to achieve optimum optical
performance of the LED light source (5), even after working from a long time
continuously.
5 In an embodiment, the heat sink (9) is configured to optimize thermal performance of
the LED light source (5) lies in range of 0 to 16 watts.
In an embodiment, the heat sink (9) is integrated to the driver PCB (6). The heat sink
(9) has a cavity (10). The cavity (10) of the heat sink (9) is configured to accommodate
10 the driver PCB (6). The heat sink (9) comprises a driver casing (13), as shown in figure
5. The driver casing (13) is configured for covering the driver PCB (6). Thus, the driver
PCB (6) being safe even in worst environment.
In non-limiting embodiment, the driver PCB (6) and the driver casing (13) are attached
15 to the heat sink (9) by means of a plurality of screws (11). Alternatively, the driver PCB
(6) and the driver casing (13) may be attached to the heat sink (9) by means of the
plurality of locators (12), a group of fasteners, sealings means and the like.
20
25
9
List of Reference Numerals
5
10
15
20
25
30
Sr. No. Description
1 LED low beam projector lamp
2 Lens
3 Lens holder
3a Front portion
3b Rear portion
4 LED board
5 Light source
6 Driver PCB
7 Reflector
7a Internal surface
7b External surface
8 Plurality of fins
9 Heat sink
10 Cavity
11 Plurality of screws
12 Plurality of locators
13 Driver casing
10
Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those
having skill in the art can translate from the plural to the singular and/or from the
singular to the plural as is appropriate to the context and/or application. The various
5 singular/plural permutations may be expressly set forth herein for sake of clarity.
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 “having” should be interpreted as “having at
10 least,” 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.
15 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
20 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. In addition, 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
25 modifiers, typically means at least two recitations, or two or more recitations). 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
30 understood to include the possibilities of “A” or “B” or “A and B.”
While various aspects and embodiments have been disclosed herein, other aspects and
embodiments will be apparent to those skilled in the art. The various aspects and
11
embodiments disclosed herein are for purposes of illustration and are not intended to
be limiting, with the true scope and spirit being indicated by the following claims.

We claim:
1. A LED low beam projector lamp (1) for vehicles, the lamp (1) comprising:
- a lens holder (3) having a front portion and a rear portion;
- a light source (5) being disposed at the rear portion of the lens holder (3),
5 wherein the light source (5) is a light emitting diode (LED) light source,
wherein, the LED light source is electronically connected to a driver PCB
(6) to receive power;
- a reflector (7) disposed at the rear portion of the lens holder (3), the reflector
(7) being configured to scatter light from the light source (5) towards the
10 front portion of the lens holder (3), wherein the reflector (7) is made of an
ellipsoidal shape; and
- a heat sink (9) being configured at the rear portion of the lens holder (3),
wherein the heat sink (9) is integrated to the driver PCB (6) and is
configured to dissipate heat of the lamp (1).
15
2. The lamp (1) as claimed in claim 1, wherein a LED board (4) is configured to
accommodate the LED light source.
3. The lamp (1) as claimed in claim 1, wherein a lens (2) is disposed at the front
20 portion of the lens holder (3).
4. The lamp (1) as claimed in claims 1, 2 and 3, wherein a plurality of locators (12)
is configured at the lens holder (3) for attachment the LED board (4), the
reflector (7) and the lens (2) with the lens holder (3).
25
5. The lamp (1) as claimed in claims 1, 2 and 3, wherein each locator of the
plurality of locators (12) has protrusion part for inserting in a corresponding
hole of the LED board (4), the heat sink (9) and the lens (2).
30 6. The lamp (1) as claimed in claim 1, wherein the heat sink (9) includes a plurality
of fins (8).
7. The lamp (1) as claimed in claim 1, wherein the heat sink (9) has a cavity (10)
to accommodate the driver PCB (6) therein.
13
8. The lamp (1) as claimed in claim 1, wherein the heat sink (9) comprises a driver
casing (13) configured to cover the driver PCB (6).
5 9. The lamp (1) as claimed in claims 1 and 8, wherein the driver casing (13) is
attached to the driver PCB (6) and the heat sink (9) by means of a plurality of
screws (11)