FORM 2
THE PATENTS ACT 1970
(39 of 1970)
AND
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(SECTION 10, Rule 13)
LED MODULE FOR HEADLAMP OF AN AUTOMOBILE
APPLICANT ABHISHEK GUPTA C/o Shri Dinesh Gupta, 8/24, Panda Pura, Lateri, District Vidisha, MP, India-464114
The following specification particularly describes the nature of this invention and the manner in which it is to be performed

FIELD OF INVENTION
[0001] The present invention relates to an automobile and more particularly to a LED lighting system for headlamp of an automobile.
BACKGROUND OF THE INVENTION
[0002] Lightings systems that basically consist of Headlamps, Turn signal lamps, Fog lamps, and Tail lamps consumes most of the power either from the vehicle battery or from alternator in the vehicle. Halogen based lamps are the preferred choice of most of the vehicle manufacturers because of the lower costs incurred for implementation and replaceability. Because of the high power consumption of conventional halogen based lamps, the LED systems are used right from the low power Tail lamps and Turn signal lamps to the high power Headlamps.
[0003] During the development of LED headlamp for 2-3 wheelers, it is observed that the junction temperature of LED module is a critical parameter for the life of LED module. The increase of junction temperature beyond a limit (typically 85°C) drastically reduces the life of the LED module. The LEDs are mounted on a Metal Core

Printed Circuit Board (MCPCB) for better heat dissipation. Thus, the LED junction temperature is controlled. Moreover, the Metal Core Printed Circuit Board (MCPCB) is attached to a heat sink of Aluminium/Copper metal base which makes the whole LED module to be of a bigger size which results into more cost.
[0004] In spite of such arrangements for dissipation of heat generated at the LED junction, under higher ambient temperature conditions an increase in temperature is observed that demands for protection of the LEDs against damage and burn out. Hence, there is a need for an effective heat sink for such a LED module.
[0005] US20180023795A1 discloses an LED lamp using a flexible metal belt as a heat sink. At least one light emitting diode is attached to a circuit board that is mounted on a heat conducting member. The flexible heat sink is attached to the heat conducting member, such that heat generated by the light emitting diode and circuit board is conducted to the flexible heat sink. The flexible heat sink can be deformed to fit in a variety of spaces. The flexible heat sink dissipates the heat generated by the LED lamp without the need for a fan. The flexible heat sink may be made from braided copper fabric or even a plurality of flexible metal sheets. This flexible heat

sink occupies a larger volume, is bigger in size which makes the headlamp bigger and increases the overall cost of the headlamp.
[0006] A vehicle headlamp is generally provided with a high beam and a low beam. In a non LED type headlamp two separate filaments are used, one for a "low beam" and a "high beam". Since a filament due to its thin size doesn't obstruct the light emanating from another filament, in a non LED type headlamp, two separate filaments can be used wherein the filaments are placed on a single axis. But, since a LED will obstruct another LED's light due to its bigger size, the LEDs corresponding to the "low beam" and "high beam" cannot be placed on same axis.
BRIEF SUMMARY OF THE INVENTION
[0007] Hence to provide a solution for the above problems of a bigger heat sink and low beam and high beam provisions, the present invention describes a plurality of conical shaped heat sinks integrated to platform of an LED module and a provision for low beam and high beam in the LED module by disposing the LED light elements so that low beam and high beam can be effectively obtained using a single cantilever in the LED module. Thus the LED module according to the present invention has better heat dissipating

capacity, is smaller in size, and possesses LED elements disposed at proper location for providing low beam and high beam lights for an automobile. The present invention describes elongated frustum shaped LED heat sinks placed at a predetermined distance from each other arranged on a platform. The platform is joined to a base and a support and the support is joined to a cantilever on which LED elements for low beam and high beam are disposed. The platform, base, support and the cantilever are preferably made up of a material having significant heat transferring property. Due to frustum shaped heat sinks, the effective area of exposure of the heat sinks is increased due to which efficient heat exchange takes place. In yet another embodiment of the present invention, the platform, base, support and the cantilever are preferably made up of same material and are integrated with each other. The LED elements are suitably placed on the cantilever-using strip and the strip is fastened to the cantilever using suitable fasteners. The thermal conduction takes place from LED element to strip to fastener or cantilever, fastener or cantilever to support, support to base and base to heat sink and the platform.
[0008] Furthermore, the LED elements are suitably placed on the cantilever using strips to direct the light emitted from the LED

elements to fall on a reflector and the light rays gets reflected from the reflector to reflect the light beam in at least one of the high beam and the low beam.
[0009] Thus, a single compact LED module enables a better heat exchanging and fulfills the requirement of the high beam and low beam.
BRIEF DESCRIPTION OF DRAWINGS
Figure 1 shows an isometric view of LED module according to an embodiment of the present invention.
Figure 2 shows the LED module in an orientation in which it is installed on the vehicle.
Figure 3 shows front view of the LED module in an orientation in which it is installed on the vehicle as seen from the front of the vehicle.
Figure 4 shows rear view of. the LED module in an orientation in which it is installed on the vehicle as seen from the rear of the vehicle headlamp.
DETAILED DESCRIPTION OF THE INVENTION

[00010] Figure 1 shows an isometric view of LED (light
emitting diode) module according to an embodiment of the present invention. Figure 1 shows LED module 100, Platform 101, cut out 102, heat sink 103, Base 104, supportl05, cantilever 106, LED 107, fastener 108, power cable 109, 1st portion A, 2nd portion B, Strip S. According to one embodiment of the present invention, the platform 101, cut out 102, heat sink 109, Base 104, support 105, and cantilever 106 are formed integrally and are of the same material. The strip S is fastened to the cantilever 106 through the fastenerl08. The LED 107 is attached to the strip. S and power terminals of the LED are connected to the power cable 109. Though according to the preferred embodiment the platform 101, cut out 102, heat sink 109, base 104, support 105, and cantilever 106 are formed integrally in yet another embodiment of the present invention, they are formed separately and are joined to each other using suitable fasteners. The LED module 100 is placed in a cutout in a headlamp by aligning the projections 110 and the cutout 102 is used to clamp the holder to the headlamp. The plurality of heat sinks 109 attached to the platform 101 helps in radiating heat to the outer atmosphere thereby cooling the LED module. The thermal conduction takes place from LED element 107 to strip S to fastener 108 or cantilever 106,

fastener 108 or cantilever 106 to support 105, support 105 to base 104 and base 104 to the platform 101 and the heat sink 109.
[00011] Figure 2 shows the LED module in an orientation in
which it is installed on the vehicle. Figure 2 shows platform 101, heat sink 103, Base 104, support 105, cantilever 106, power cable 109, LED LB 201, LED HB 202, end width 203, start width 204, 1st strip S1 and 2nd strip S2. As explained in Figure 1, the thermal conduction takes place from LED elements 201, 202 to:strip S1 & S2 respectively and from strip S1 & S2 to fastener 108 or cantilever 106, fastener 108 or cantilever 106 to support 105, support 105 to base 104 and base 104 to the platform 101 and the heat sink 109. Figure 2 mainly illustrates the low beam and high beam projection mechanism in the LED module 100.
[00012] , During a low beam operation, the area nearer to the vehicle is lit and during the high beam, an area farther from the vehicle is lit. Once the LED module is assembled in a headlamp with a reflector and other essential parts, the light rays emitted from the LED LB 201 gets reflected from the reflector and forms the low beam light array. Similarly, the light rays emitted from the LED HB 202 gets reflected from the reflector and forms the high beam light array.

At a given instance the headlamp is operated at either the high beam or a low beam and hence, the respective LED is operational and the required light from the headlamp is obtained. According to the present invention, though LED LB 201 is described to provide a low beam and LED HB 202 is described to provide a high beam, with the described configuration of the reflector and other essential parts such as lenses and other optical instruments, either of the LED LB201 or LED HB 202 can be used to achieve either a low beam or a high beam. It is further described that the cantilever 106 has a larger width d1 towards the end closer to the support 105 compared with the width d2 at the tip. This difference in the width helps in aligning the LED LB 201 and the LED HB 202 for projecting the low beam and the high beam on the road ahead of an automobile. In yet another embodiment of the present invention, the LED LB 201 and LED HB 201 are disposed at a predetermined distance from the platform 101.
[00013] Figure 3 shows front view of the LED module in an
orientation in which it is installed on the vehicle as seen from the front of the vehicle. Figure 3 shows platform 101, support 105, and cantilever 106. The cantilever 106 is offset from the center of the platform 101. The disposing of the LED LB 201 and LED HB 202 on the cantilever with an offset from the center of the platform helps in

directing the light outside the headlamp during both the low beam and the high beam. In yet another embodiment of the present invention, the platform 101 is evenly disposed in the headlamp cavity in which the LED module 100 is installed and the LED LB 201 and LED HB 202 are disposed on the cantilever with an offset from the center of the platform.
[00014] Figure 4 shows rear view of the LED module in an
orientation in which it is installed on the vehicle as seen from the rear of the vehicle headlamp. Figure 4 shows heat sink 103, power cable 109. The power cable 109 originates from the first side 211 and transmits electric power to the second side 212 through a conducting extension inform of an electricity conducting means. The conducting means may be a wire, a bus or a known conducting strip. The plurality of heat sinks 103 are frustum shaped or cylindrical shaped projections originating from the first side 211 and extending in a direction away from the platform 101. The plurality of projections 110 aid in mounting the assembly to the headlamp.
[00015] The LED lighting system for headlamp of an
automobile comprises of a platform 101 having a first side 211 and a second side 212, the first side 211 of platform 101 providing a

surface for supporting a plurality of heat sinks 103, the second side 212 of the platform providing a base 104 for support 105, the support 105 holds a cantilever 106 with at least one power cable 109 conducting electric supply from said first side of the platform 101 to said second side of the platform 101; and a plurality of LED LB 201 and a LED HB 202 located on different sides of the cantilever 106. The cantilever 106 has an end width 203 and a start width 204 such that the start width 204 is larger than the end width 203; The start width 204 is attached to the support 105. The 1st strip S1 and a 2nd strip S2 are laid on the cantilever 106 and the 1st strip S1 and the 2nd strip S2 holding a plurality of LED 201, 202. The plurality of heat sinks 103 are frustum shaped. The plurality of heat sinks 103 are cylindrical shaped. The cantilever 106 are cylindrical shaped. The cantilever 106 are frustum shaped.
[00016] The LED LB 201 belongs to the low beam LED and the
LED HB 202 belong to the high beam LED and the LED LB 201 belonging to the low beam LED is placed at opposite sides with respect to LED HB 202 belong to the high beam LED on said cantilever 106. The low beam LED is installed above the high beam LED. The platform 101, the base 104 for support 105 and the cantilever 106 are integrally formed of a heat radiating material.

I Claim:
1. A LED lighting system for headlamp of an automobile, the LED lighting system for headlamp comprising:
a platform 101 having a first side 211 and a second side 212, the first side 211 of platform 101 providing a surface for supporting a plurality of heat sinks 103, the second side 212 of the platform providing a base 104 for support 105, the support 105 holds a cantilever 106;
at least one power cable 109 conducting electric supply from said first side of the platform 101 to said second side of the platform 101; and
a plurality of LED LB 201 and a LED HB 202 located on different sides of the cantilever 106.
2. The LED lighting system for headlamp of an automobile as claimed in claim 1 wherein the cantilever 106 has an end width 203 and a start width 204 such that the start width 204 is larger than the end width 203.
3. The LED lighting system for headlamp of an automobile as claimed in claim 2 wherein start width 204 is attached to the support 105.
4. The LED lighting system for headlamp of an automobile as claimed in
claim 1 wherein a 1st strip S1 and a 2nd strip S2 are laid on the
cantilever 106 and the 1st strip S1 and the 2nd strip S2 holding a
plurality of LED 201,202.

5. The LED lighting system for headlamp of an automobile as claimed in claim 1 wherein the plurality of heat sinks 103 are frustum shaped.
6. The LED lighting system for headlamp of an automobile as claimed in claim 1 wherein the plurality of heat sinks 103 are cylindrical shaped.
7. The LED lighting system for headlamp of an automobile as claimed in claim 1 wherein cantilever 106 are cylindrical shaped.
8. The LED lighting system for headlamp of an automobile as claimed in claim 1 wherein cantilever 106 are frustum shaped.
9. The LED lighting system for headlamp of an automobile as claimed in claim 1 wherein the LED LB 201 belongs to the low beam LED and the LED HB 202 belong to the high beam LED and the LED LB 201 belonging to the low beam LED is placed at opposite sides with respect to LED HB 202 belong to the high beam LED on said cantilever 106.
10. The LED lighting system for headlamp of an automobile as claimed in claim 1 wherein the low beam LED is installed above the high beam LED.
11. The LED lighting system for headlamp of an automobile as claimed in claim 1 wherein the platform 101, the base 104 for support 105 and the cantilever 106 are integrally formed of a heat radiating material.