Embodiment of the present invention relates to automotive lighting systems and more particularly to a round class-c single chip LEDs headlamp with a single PCB and small size reflector.
BACKGROUND OF THE INVENTION
The increasing rate of the road accident demands for improvement in the current design of the automotive lighting systems. The automobile lighting system may be one of the headlamps, auxiliary lamps, parking lights in front, taillights in the rear, rear registration plate lamp, and the like. The headlamps are one of the important parts of the vehicle. Vehicular headlamps help drivers to have a clear vision of the road ahead in low-light conditions and at night. The vehicular headlamps include a reflector, bezel, light source etc. The light source in a vehicular headlamp may be filament bulbs, HIDs etc. that could only provide limited illumination. But with the introduction of LEDs, the traditional bulbs and/or HIDs as a light source are being replaced by the LEDs in the vehicular headlamps.
The LEDs require multiple electronic circuits for High beam generation and low beam generation. The vehicular LEDs have two separate electronic configurations of PCBs for low-beam and high beam. The use of multiple PCBs leads to space constraints. The design of reflector and bezel is also one of the important factors which cause the limited space for the arrangement of an electronic circuit of the headlamp. The traditional design of headlamps uses screws for fixing the different parts of the headlamp, which increases the assembly time. The design of traditional headlamp is complicated, power-consuming, bulky, costly, and heavy.
Therefore, there is a need in the art to provide a class-c single chip LED headlamp with single PCB and small size reflector that does not suffer from the above-mentioned deficiencies and provide an effective and viable solution.
OBJECT OF THE INVENTION
The object of the proposed invention is to provide a round class-c headlamp with a single chip LEDs with a single PCB and small size reflector.
Another object of the present invention is to provide a compact size round class-c headlamp.
Yet another object of the present invention is to provide less energy-consuming round class-c single headlamp.
Yet another object of the present invention is to provide screwless round class-c single chip LEDs headlamp arrangement.
Yet another object of the present invention is to merge the bezel and reflector to reduce overall weight and cost of the round class-c single chip LEDs headlamp.
SUMMARY OF THE INVENTION
Embodiments of the present invention aim to provide a round class-C headlamp with single chip LEDs and a single PCB with a small size reflector.
According to an aspect of the present invention, the round class-C single chip LEDS headlamp with a single PCB and small size reflector comprises a housing configured to house a reflector unit, a printed circuit board (PCB) sandwiched between the housing and the reflector unit, comprises a plurality of holes on surface of the PCB; one or more single chip Light-emitting diodes (LEDs), positioned in the reflector unit, connected with the PCB, configured to produce a low beam and a high beam of light. Further, the reflector unit comprises a plurality of clamp ribs, and a plurality of guide pins. Furthermore, the plurality of clamp ribs and the plurality of guide pins are adapted to be received in the plurality of holes on the surface of the PCB. Moreover, the one or more clamp ribs are configured to restrict movement of the PCB.
In accordance with an embodiment of the present invention, the plurality of the guide pins are configured to direct the plurality of holes on the PCB.
In accordance with an embodiment of the present invention, the housing comprises one or more housing ribs. Further the one or more housing ribs are configured to restrict the motion of the PCB and the reflector unit.
In accordance with an embodiment of the present invention, the reflector unit comprises a reflector mounted over surface of the reflector unit. Furthermore, the reflector is configured to provide ease of metallization.
In accordance with an embodiment of the present invention, the headlamp comprises a transparent lens adapted to cover the reflector unit, the one or more single LEDs positioned therein and the housing.
In accordance with an embodiment of the present invention, the headlamp comprises a rim, positioned over the transparent lens and attached with the housing using screws, adapted to provide aesthetic value to the headlamp.
In accordance with an embodiment of the present invention, the housing comprises a connector and wire assembly.
In addition, the connector is configured to provide an electrical connection between a power source and the connected PCB via the wire assembly.
In accordance with an embodiment of the present invention, the headlamp comprises one or more breathers, connected with the housing at tail end of the headlamp, configured to dissipate heat produced inside the headlamp.
In accordance with an embodiment of the present invention, the reflector unit including a plurality of reflective portions configured to reflect light from a light source in a predetermined direction. Further, the plurality of reflective portions comprising a first reflective portion for a high beam configuration and a second reflective portion for a low beam configuration. In addition, the reflector unit has a plurality of cavities cut out corresponding to the plurality of reflective portions. Additionally, the plurality of cavities include a first cavity corresponding to the first reflective portion and a second cavity corresponding to the second reflective portion.
In accordance with an embodiment of the present invention, the respective plurality of reflective portions and the respective plurality of cavities are adapted to receive the one or more single LEDs.
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. 1 illustrates an exploded view of a round class-C single chip LEDs headlamp, in accordance with an embodiment of the present invention;
Fig. 2 illustrates a cross sectional view of the round class-C single chip LEDs headlamp, in accordance with an embodiment of the present invention;
Fig.3 illustrates a reflector unit of the round class-C single chip LEDs headlamp, in accordance with an embodiment of the present invention;
Fig. 4 illustrates position of breathers in the round class-C single chip LEDs headlamp, in accordance with an embodiment of the present invention; and
Fig. 5 illustrates a perspective view of the round class-C single chip LEDs headlamp, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
While the present invention is described herein by way of example using embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modification/s, equivalent/s and alternative/s falling within the scope of the present invention as defined by the appended claim. The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claim. 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" means "at least one” 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. Language such as "including", "comprising", "having", "containing", or "involving" and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the likes are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
In this disclosure, whenever an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element or group of elements with transitional phrases “consisting of”, “consisting”, “selected from the group of consisting of”, “including”, or “is” preceding the recitation of the composition, element or group of elements and vice versa.
This invention described herein may 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 claims. 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.
Figure 1 illustrates an exploded view of a round class-C single chip LEDs headlamp (100). In accordance with an embodiment of the present invention, a round class-c single chip LEDs (108) headlamp (100) with single PCB (106) and small size reflector is described. The round class-c headlamp (100) comprises a Printed circuit board (PCB) (106), a housing (102) configured to house a reflector unit (104), one or more single chip Light-emitting diodes (LEDs) (108) positioned in the reflector unit (104), a transparent lens (116), rim (118), wire assembly (122) and connector (120) as shown in figure 1.
In accordance with an embodiment of the present invention, the PCB (106) is sandwiched between the housing (102) and the reflector as shown in figure 1. The PCB (106) may be selected from a group comprising of, but not limited to, a single layer, double layer, multi-layer, Rigid-PCB (106), flexible, Rigid-Flex, High-frequency, Aluminium-backed printed circuit board, and the like. The PCB (106) is envisaged to comprise a plurality of holes on surface of the PCB (106). The one or more LEDs (108) are embedded in the PCB (106). The one or more single chip LEDs (108) are configured as a light source. The light source may be used for a low beam of light and/or a high beam of light in the headlamp (100) assembly.
In accordance with an embodiment of the present invention, the plurality of holes are adapted to connect the PCB (106) with the reflector. The reflector unit (104) comprises a plurality of clamp ribs (not shown) and a plurality of guide pins (not shown). The plurality of clamp ribs and a plurality of guide pins are adapted to be received in the holes of the PCB (106). The plurality of clamp ribs are configured to restrict the upward directional movement of PCB (106). The plurality of the guide pins are mountings designed in the reflector unit (104). The plurality of the guide pins may be used for directing holes on the PCB.
Further, figure 2 illustrates a cross sectional view of the round class-C single chip LEDs (108) headlamp (100). In accordance with an embodiment of the present invention, as shown in figure 2, the housing (102) of the headlamp (100) is used to house a reflector unit (104) with the PCB (106). The housing (102) comprises one or more housing ribs. The one or more housing ribs are configured for fixing and restricting the motion of the PCB (106) and reflector unit (104). In an alternative or additional embodiment, the PCB (106) and the reflector unit (104) may be latched on to the ribs with the help of may be, but not limited to, a plurality of grooves, bolts, metal welding, adhesives, or sealant.
Figure 3 illustrates a reflector unit (104) of the round class-C single chip LEDs (108) headlamp (100), in accordance with an embodiment of the present invention. As shown in figure 3, the reflector unit (104) comprises a reflector (114). The reflector (114) may be mounted over the surface of the reflector unit (104). The reflector (114) may be configured to provide ease of metallization.
The material for the reflector (114) may have the property of being highly reflective, anti-corrosive, and temperature resistant. The material may be, but not limited to, polycarbonate (PC), polypropylene (PP), polybutylene terephthalate, nylon, Acrylonitrile Butadiene Styrene (ABS), Polymethyl Methacrylate (PMMA), and Polyethylene terephthalate (PET), bulk moulding compound (BMC), acrylic mirror, glass mirror, polished metal, and chromic reflectors.
Further, in an additional or alternate embodiment of the present invention, as shown in figure 3, the reflector unit (104) may include a plurality of reflective portions (1042). The plurality of reflective portions (1042) are configured to reflect light from a light source in a predetermined direction. Further, the plurality of reflective portions (1042) may comprise a first reflective portion. The first reflective portion may be adapted for a high beam configuration. The plurality of reflective portions (1042) may further comprise a second reflective portion. The second reflective portion may be adapted for a low beam configuration.
In addition, the reflector unit (104) has a plurality of cavities cut out. The plurality of cavities cut out may be corresponding to the plurality of reflective portions (1042). The plurality of cavities include a first cavity corresponding to the first reflective portion. The plurality of cavities further include a second cavity corresponding to the second reflective portion. In accordance with an embodiment of the present invention, the respective plurality of reflective portions and the respective plurality of cavities are adapted to receive the one or more single LEDs (108).
Referring figure 1, in accordance with an embodiment of the present invention, the transparent lens (116) is used to cover the reflector, the one or more LEDs (108) positioned therein and the housing (102). The material for transparent lens (116) may be transparent and rigid. The material may be, but not limited to, glass, fiber glass, polypropylene, polybutylenes terephthalate, nylon, and the like. In an alternative or additional embodiment, the transparent lens (116) may be position over the transparent lens (116) and attached with the housing (102) using screws. The rim (118) is provided to give aesthetic value to the headlamp (100). In accordance with an embodiment of the present invention, the housing (102) further comprises a connector (120) and wire assembly (122). The connector (120) is configured to provide an electrical connection between a power source and the PCB (106). The connector (120) is electrically connected with the PCB (106) through the wire assembly (122) as shown in Figure 1.
Figure 4 illustrates position of breathers (124) in the round class-C single chip LEDs (108) headlamp (100). In accordance with an embodiment of the present invention, the round class-C single chip LED headlamp (100) further comprises one or more breathers (124) as shown in figure 4. The one or more breathers (124) are connected with housing (102) at the tail end of the headlamp (100). The one or more breathers (124) are configured to provide dissipation to the heat generated inside the headlamp (100). The one or more breathers (124) may remove heat from the headlamp (100) using fluid circulation such as air inside the headlamp (100).
Figure 5 illustrates a perspective view of the round class-C single chip LEDs (108) headlamp (100), in accordance with an embodiment of the present invention. In an embodiment, the PCB (106) is controlled by a switch (not shown). The switch may be operated by a user. The switch may be placed in a place easily operable by the user. The switch may be placed may be, but not limited to, on a handle bar, on dash board, on steering wheel, on the head lamp or anyplace of a vehicle easily approachable to the user. The PCB (106), on actuation of the switch, supplies the electrical power to the one or more single chip LEDs (108). The one or more single chip LEDs (108) produce light. The light from the one or more single chip LEDs (108) passes through the transparent lens (116). In an additional or alternative embodiment, the transparent lens (116) may be configured to converge or diverge low-intensity light of the one or more LEDs (108) in order to adjust intensity of LEDs (108).
In accordance with an embodiment of the present invention, the light incident on the surface of the reflector (114) is reflected. The reflector (114) is designed in a shape, preferably, in a parabolic concave shape so that the light incident on the surface of the reflector (114) is converged in a direction. The light incident on the reflector is reflected from the surface of reflector which focuses light on the transparent lens (116). Through the transparent lens (116), the light exits and falls on the road in front of the vehicle.
In accordance with an embodiment of the present invention, the switch may have access to select any of the high beam configuration or low beam configuration. When the user of the vehicle selects a low beam configuration on the switch, the switch allows the electric current to flow to the PCB (106) to turn on the plurality of LEDs (106) received in the plurality of reflective portions (1042) configured to generate a low beam of light. Whereas, if the user of the vehicle selects a high beam configuration, the switch allows the electric current to flow to the PCB (106) to turn on the plurality of LEDs (108) received in the plurality of reflective portions (1042) configured to generate a high beam of light.
The present invention provides several advantages. The present invention uses LEDs (108) as a power source as a result of providing the better white color of light and much lesser consumption of battery (energy source). The present invention merges the bezel and reflector to reduce the overall weight & cost of the lamp. The invention provides also a screwless reflector (114) and PCB (106) arrangement in a headlamp (100) due to which assembly time is reduced. The compact size and less power consumption of the present invention make it 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 provided broadest scope 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 and the appended claims.

We Claims:

1.A round class-C single chip LEDS headlamp (100) with a single PCB (106) and small size reflector, the headlamp (100) comprising:
a housing (102) configured to house a reflector unit (104);
a printed circuit board (PCB) (106), sandwiched between the housing (102) and the reflector unit (104), comprising a plurality of holes on surface of the PCB (106);
one or more single chip Light-emitting diodes (LEDs) (108), positioned in the reflector unit (104), connected with the PCB (106), configured to produce a low beam and a high beam of light;
wherein the reflector unit (104) comprising:
a plurality of clamp ribs; and
a plurality of guide pins;
wherein the plurality of clamp ribs and the plurality of guide pins are adapted to be received in the plurality of holes on the surface of the PCB (106); and
wherein the plurality of clamp ribs are configured to restrict movement of the PCB (106).
2. The headlamp (100) as claimed in claim 1, wherein the plurality of the guide pins are configured to direct the plurality of holes on the PCB (106).
3. The headlamp (100) as claimed in claim 1, wherein the housing (102) comprises one or more housing ribs;
wherein the one or more housing ribs are configured to restrict the motion of the PCB (106) and the reflector unit (104).
4. The headlamp (100) as claimed in claim 1, wherein the reflector unit (104) comprises a reflector (114) mounted over surface of the reflector unit (104);
wherein the reflector (114) is configured to provide ease of metallization.
5. The headlamp (100) as claimed in claim 1, comprising a transparent lens (116) adapted to cover the reflector unit (104), the one or more single LEDs (108) positioned therein and the housing (102).
6. The headlamp (100) as claimed in claim 5, comprising a rim (118), positioned over the transparent lens (116) and attached with the housing (102) using screws, adapted to provide aesthetic value to the headlamp (100).
7. The headlamp (100) as claimed in claim 1, wherein the housing (102) comprises a connector (120) and wire assembly (122);
wherein the connector (120) is configured to provide an electrical connection between a power source and the connected PCB (106) via the wire assembly (122).
8. The headlamp (100) as claimed in claim 1, comprising one or more breathers (124), connected with the housing (102) at tail end of the headlamp (100), configured to dissipate heat produced inside the headlamp (100).
9. The headlamp (100) as claimed in claim 1, wherein the reflector unit (104) including a plurality of reflective portions (1042) configured to reflect light from a light source in a predetermined direction;
wherein the plurality of reflective portions (1042) comprising a first reflective portion for a high beam configuration and a second reflective portion for a low beam configuration;
wherein the reflector unit (104) has a plurality of cavities cut out corresponding to the plurality of reflective portions;
wherein the plurality of cavities include a first cavity corresponding to the first reflective portion and a second cavity corresponding to the second reflective portion.
10. The headlamp (100) as claimed in claim 9, wherein the respective plurality of reflective portions and the respective plurality of cavities are adapted to receive the one or more single LEDs (108).