DESC:FRONT COWL MOUNTING ASSEMBLY
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202321090079 filed on 30/12/2023, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
Generally, the present disclosure relates to a mounting mechanism of lighting equipment(s) on vehicles. Particularly, the present disclosure relates to the mounting mechanism of headlamp for vehicle(s).
BACKGROUND
The increasing need for more cost-effective and efficient vehicles, along with consumer desires for more powerful lighting systems, has driven automotive manufacturers to innovate in order to satisfy these demands. As a result, the automotive industry has consistently worked to enhance vehicle lighting systems, aiming to improve performance, reduce weight, and achieve greater cost-effectiveness.
Conventionally, a headlamp assembly comprises a headlamp unit that is positioned in a fixed location at the front of the vehicle, near the handlebars, or at the front fork. Further, the headlamp unit is directly mounted to the vehicle front fork or frame. The headlamp unit is fastened to the front fork or frame of the vehicle using metal brackets or plates, which are secured with bolts or screws. Furthermore, the mounting brackets are designed to wrap around the fork or frame, securing the headlamp unit in place. Consequently, the connection points at the mounting are rigid, with no adjustment options.
However, there are certain underlining problems associated with the above-mentioned mounting mechanism of the headlamp of vehicles. For instance, the headlamp unit alignment and angle are fixed once installed, therefore, the mounting does not account for adjusting the position of the headlamp for optimal lighting angles. Further, as the headlamp unit is physically attached to the front fork or frame via brackets, the mounting is vulnerable to vibration from the suspension, or uneven road surfaces causing slight movements in the headlamp unit, leading to misalignment.
Therefore, there exists a need for a mounting mechanism of headlamp of vehicles that is efficient, safe, and overcomes one or more problems as mentioned above.
SUMMARY
An object of the present disclosure is to provide a headlamp mounting assembly for a vehicle.
Another object of the present disclosure is to provide a mounting mechanism capable of providing additional support to the headlamp assembly by strengthening the connection between the headlamp unit and the vehicle frame.
In accordance with an aspect of the present disclosure, there is provided a headlamp mounting assembly for a vehicle, the headlamp mounting assembly comprises:
- a headlamp crown;
- a headlamp unit;
- a plurality of mounting brackets; and
- at least one front fork connected to a vehicle frame,
wherein the headlamp unit is connected to the vehicle frame via the plurality of mounting brackets connected to the at least one front fork.
The headlamp assembly for a vehicle, as described in the present disclosure, is advantageous in terms of providing a headlamp assembly with enhanced stability and security. Beneficially, the mounting of the headlamp unit via the plurality of mounting brackets ensures that the headlamp unit remains firmly in place during the vehicle operation under vibrations or external impacts. Further, the mounting of the headlamp unit via a plurality of fasteners ensures that the headlamp remains properly aligned and securely positioned, maintaining optimal performance for visibility, and safety.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figure 1 illustrates a detailed view of a headlamp assembly mounting arrangement, in accordance with an embodiment of the present disclosure.
Figure 2 illustrates a detailed view of a headlamp assembly comprising mounting brackets, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
As used herein, the terms “headlamp mounting assembly” and “assembly” are used interchangeably and refer to a complete unit of lighting apparatus installed at the front of a vehicle, designed for visibility in low-light conditions. The headlamp assembly consists of the headlight housing, lens, light source, reflectors, and electrical connectors. The assembly is mounted on the front of the vehicle and is positioned to provide an optimal beam pattern for forward visibility. The headlamp assembly may include, but not limited to, high and low beam settings, turn signals, and daytime running lights, all integrated into a single unit.
As used herein, the terms “headlamp crown” and “crown” are used interchangeably and refer to the surrounding or enclosing component that forms the outer structure or casing of the headlamp unit. The headlamp crown serves as a protective outer structure that houses the internal components of the headlamp. Further, the headlamp crown maintains the shape and integrity of the headlamp by providing mounting points for attaching the headlamp to the vehicle. Additionally, the headlamp crown also serves as an aesthetic function, contributing to the overall design and appearance of the vehicle.
As used herein, the term “headlamp unit” refers to the complete assembly of components designed to provide forward illumination for a vehicle. It typically includes lenses, light sources (such as bulbs or LEDs), reflectors, and electrical connections that work together to ensure proper illumination of the road ahead. Further, the headlamp unit provides different lighting functions, such as low beams, high beams, bi-functional, and Day-time Running Lights (DRLs). The design of the unit ensures that the light is distributed evenly to avoid glare for other drivers while providing optimal visibility for the driver. The headlamp unit may further include adaptive lighting systems that automatically adjust the direction or intensity of the light based on driving conditions, such as steering angle, vehicle speed, or road elevation.
As used herein, the term “mounting bracket” refers to a structural component used to securely attach and support various parts or assemblies to a frame. Further, the mounting bracket is made of metal (such as steel or aluminium), composite materials, or plastic materials. The mounting brackets are designed to provide a stable base for fixing components in place while ensuring that they remain properly aligned and resistant to external forces such as vibrations, shocks, or mechanical stress. Moreover, the mounting brackets are designed in various shapes and sizes to fit specific components of the vehicle, such as (but not limited to) headlamps, steering assembly, and batteries, ensuring that the attached components are securely held within the system without the risk of misalignment or detachment during operation. The mounting brackets offer structural integrity and reliability by distributing the load of the mounted part across a larger surface area, thereby reducing the wear, deformation, or failure of the mounted part.
As used herein, the term “front fork” refers to a suspension component that connects a front wheel to a vehicle frame, allowing for controlled steering and shock absorption. The front fork consists of two main tubes that house the axle of the front wheel and is designed to absorb the forces generated during driving, such as bumps, road irregularities, and braking. Consequently, the front wheel maintains consistent contact with the road, improving handling, stability, and overall ride comfort. Further, the front fork connects to the vehicle steering mechanism, allowing the rider to turn the front wheel in response to steering inputs. Moreover, the material and construction of the front fork are optimized for lightweight strength, durability, and reduced weight to support the vehicle overall performance.
As used herein, the terms “vehicle frame” and “frame” are used interchangeably and refer to a structural component that provides the foundation for all other parts of the vehicle, including the motor, battery pack, wheels, suspension, and body. Specifically, the front fork serves as the skeleton of the vehicle, ensuring that all components are securely attached and properly aligned. Further, the frame is designed to support the electric powertrain involving higher torque and weight distribution considerations compared to traditional internal combustion engine (ICE) vehicles. The frames are constructed from materials such as (but not limited to) aluminium, steel, or composite materials to achieve a balance between strength, rigidity, and overall weight reduction. Furthermore, the frame also incorporates crumple zones to absorb impact energy in the event of a collision, enhancing the rider safety.
As used herein, the term “source of illumination” refers to any device that emits light to provide visibility in dark or low-light environments. Specifically, in a vehicle, the source of illumination is the light bulb or LED within the headlamp or lighting unit for producing the light. The illumination source affects the brightness, colour temperature, energy efficiency, and lifespan of the lighting system. Further, advanced lighting technologies such as adaptive headlights adjust the illumination based on vehicle speed, steering angle, or elevation, improving road safety. As automotive lighting technology continues to evolve, sources of illumination are becoming more energy-efficient and capable of offering better control over light distribution, reducing energy consumption while maximizing performance and safety.
As used herein, the terms “fastener” and “plurality of fasteners” are used interchangeably and refer to a means that physically joins or affixes two or more objects together. Additionally, the fasteners are used to build non-permanent joints that can be separated or dismantled without damaging the joining components. The fasteners may include, but not limited to, screws, nuts and bolts, clips and retainers, push-to-connect fasteners, and adhesives.
As used herein, the term “main tube” refers to a core structural element, providing a cylindrical foundation for mounting ensuring that the vehicle load is evenly distributed. The main tube acts as a cover tube for the front fork to pass through and provides a stable and secure mounting point for the front fork ensuring the overall rigidity and structural integrity of the headlamp assembly. The design of the main tube is critical for ensuring that the forces generated during riding are actively absorbed and distributed across the frame.
As used herein, the term “support bracket” refers to a structural component used to securely fasten and support various parts of the vehicle, such as the front fork, motor, battery pack, or headlamp unit, to the vehicle frame. The support brackets are designed to withstand the forces and stresses encountered during the vehicle operation. Further, the support bracket acts as a connecting element that transfer loads and stresses from one part of the vehicle to another, providing stability and structural integrity. Furthermore, the support bracket includes slotted holes or multi-point fastening systems that allow for precise positioning and easy modification of components. The support bracket may also adjust the angle of the front fork or the mounting position of the battery, optimizing handling or weight distribution.
As used herein, the term “steering assembly” refers to an assembly of interconnected components that enables the rider to control the direction of the vehicle by turning the front wheels or front fork. The steering assembly includes parts such as the steering column, steering rack or fork, bearings, and linkages, which work together to transform the rider input into the movement of the front wheel. Further, the steering assembly directly connects to the front fork, allowing the rider to manoeuvre the vehicle efficiently. The design of the steering assembly impacts the overall handling of the vehicle, including factors such as turning radius, responsiveness, and comfort. Furthermore, the electric steering systems are also employed to provide additional adjustments in steering effort such as traction control or stability management.
As used herein, the term “guiding members” refers to components designed to assist the precise alignment and positioning of key parts, such as the front fork or headlamp unit, ensuring that these components are properly mounted and secured within the vehicle frame. The guiding members are integrated into the vehicle structure or the mounting assemblies, providing a reference point that guides the attachment or adjustment of parts. Consequently, a clear and stable positioning reference reduces the risk of misalignment or incorrect installation during assembly or maintenance. Further, the guiding members distribute the mechanical stresses evenly and thereby reduce the potential for wear, damage, or malfunction over time. Moreover, the guiding members are designed with slots, grooves, or adjustable fittings, allowing for fine-tuning and flexible positioning of parts to accommodate different design requirements.
In accordance with an aspect of the present disclosure, there is provided a headlamp mounting assembly for a vehicle, the headlamp assembly comprises:
- a headlamp crown;
- a headlamp unit;
- a plurality of mounting brackets; and
- at least one front fork connected to a vehicle frame,
wherein the headlamp unit is connected to the vehicle frame via the plurality of mounting brackets connected to the at least one front fork.
Referring to figure 1, in accordance with an embodiment, there is described headlamp mounting assembly for a vehicle. The headlamp assembly 100 comprises a headlamp crown 102, a headlamp unit 104, a plurality of mounting brackets 106, and at least one front fork 108 connected to a vehicle frame 110. Further, the headlamp unit 104 is connected to the vehicle frame 110 via the plurality of mounting brackets 106 connected to the at least one front fork 108. Furthermore, the headlamp crown 102 comprises a front-end 102A and a rear-end 102B. Furthermore, the at least one front fork 108 is connected to the vehicle frame 110 via a steering assembly 120.
The headlamp mounting assembly 100 connecting the headlamp unit 104 to the vehicle frame 110 through the mounting brackets 106, which in turn connected to the front fork, provides a stable and secure mounting ensuring that the headlamp unit 104 is firmly attached to the vehicle frame 110. Consequently, the headlamp mounting assembly 100 with the plurality of mounting brackets 102 resists the dynamic forces encountered during vehicle operation, such as vibrations, road shocks, and impacts. Further, the plurality of fasteners 112 ensures that the headlamp remains properly aligned and securely positioned, maintaining optimal performance for visibility, and safety. Additionally, the integration of the front fork 108 into the headlamp mounting assembly 100 allows for efficient load distribution, reducing the stress on individual components and improving the longevity of the overall headlamp mounting assembly 100. Furthermore, the front fork 108 as part of the mounting structure minimizes the need for additional complex support structures or mounting points and thereby results in a more compact and efficient assembling. Furthermore, in terms of maintenance, the above-mentioned configuration allows for easier adjustment, replacement, or realignment of the headlamp unit, ensuring that the vehicle issues related to headlamp positioning or performance is addressed promptly.
In an embodiment, the headlamp unit 104 comprises at least one source of illumination. At least one source of illumination within the headlamp unit 104 ensures that the vehicle has the necessary lighting to operate safely in low-light or nighttime conditions. Further, based on the type of illumination source used, the headlamp unit 104 provides different levels of brightness, beam width, and energy efficiency. The source of illumination facilitates a compact, streamlined design and delivers optimal lighting performance without additional components.
Referring to figure 2, in accordance with an embodiment, there is described a headlamp assembly comprising mounting brackets for a vehicle. The headlamp assembly 100 comprises a headlamp crown 102, a headlamp unit 104, a plurality of mounting brackets 106, and at least one front fork 108 connected to a vehicle frame 110. Further, the headlamp unit 104 is connected to the vehicle frame 110 via the plurality of mounting brackets 106. Furthermore, the headlamp crown 102 comprises a front-end 102A and a rear-end 102B. Furthermore, the headlamp unit 104 is connected to the rear-end 102B of the headlamp crown 102 via a plurality of headlamp fasteners 112. Furthermore, each mounting bracket of the plurality of mounting brackets 106 comprises a main tube 114 and a support bracket 116. Furthermore, the support bracket 116 of the plurality of mounting brackets 106 is connected to the headlamp unit 104 via a plurality of fasteners 118. Furthermore, the headlamp unit 104 comprises a pair of guiding members 120 configured to align the support bracket 116 with the headlamp unit 104
In an embodiment, the headlamp unit 104 is connected to the rear end 102B of the headlamp crown 102 via a plurality of headlamp fasteners 112. The mounting of the headlamp unit 104 onto the rear end 102B of the headlamp crown 102 via a plurality of fasteners 106 enhances the stability and durability of the headlamp unit 104, ensuring that remains firmly in place during the vehicle operation. Specifically, mounting via the plurality of fasteners 106 reduces the risk of misalignment or shifting of the headlamp unit 104 during the vehicle operation and therefore, ensures that the headlamp unit 104 remains in the correct orientation and delivers consistent illumination. Further, the plurality of the fasteners 106 allows for simpler disassembly during repairs or replacements of the headlamp assembly 100. Furthermore, the positioning of the headlamp unit 104 at the rear end 102B of the headlamp crown 102 allows for optimized space utilization, minimizing the overall size of the headlamp assembly 100. Therefore, the above-mentioned configuration improves the structural integrity of the headlamp assembly 100, contributing to longer service life and consistent performance.
In an embodiment, each mounting bracket of the plurality of mounting brackets 106 comprises a main tube 114 and a support bracket 116. Advantageously, the inclusion of a main tube 114 and a support bracket 116 provides a robust and versatile structure for securely holding the vehicle components in place within a larger operational area. Further, the main tube 114 acts as the core structural element, providing a cylindrical foundation for mounting and the support bracket 116 provides extra stability ensuring that the load is evenly distributed. The combination of the main tube 114 and the support bracket 116 allows the mounting bracket to absorb and distribute mechanical stresses, enhancing the overall durability of the headlamp mounting assembly 100. Further, the support brackets 116 are designed with specific angles or geometries, ensuring that the component is held securely, minimizing the risk of shifting or misalignment during the vehicle operation. Additionally, the above-mentioned design simplifies manufacturing, and assembly processes and thereby reduces the complexity by integrating two essential components into one unit.
In an embodiment, the support bracket 116 of the plurality of mounting brackets 106 is connected to the headlamp unit 104 via a plurality of fasteners 118. The secure attachment of the support bracket 116 to the headlamp unit 104 effectively reduces the vibrations and prevents the misalignment of the headlamp unit 104 during vehicle operation. Consequently, the headlamp unit 104 maintains a consistent alignment, providing optimal illumination and visibility for the rider. Furthermore, the connection of the support bracket 116 to the headlamp unit 104 enhances the overall rigidity of the assembly, preventing excessive movement or instability even in rough terrain or high-speed conditions. Further, the connection of the support bracket 116 to the headlamp unit 104 via a plurality of fasteners 118 ensures a secure and stable attachment thereby maintaining the proper alignment and functionality of the headlamp during operation. Further, the multiple fasteners 118 distribute the load more evenly across the support bracket 116, reducing the loosening or failure due to vibrations or external forces encountered during vehicle operation.
In an embodiment, the at least one front fork 108 passes through the main tube 114 of the plurality of mounting brackets 106. The at least one front fork 108 passing through the main tube 114 provides a stable and secure mounting point for the front fork 108 ensuring the overall rigidity and structural integrity of the headlamp assembly 100. Further, the front fork 108 passing directly through the main tube 114 effectively distributes the load across the entire mounting bracket 106 structure and enhances the resistance to stress and impact forces. Consequently, the front fork 108 remains firmly in place, reducing the risk of misalignment or failure during operation and providing better control and handling. Further, the need for separate attachment points or supports is minimized, leading to a more compact and lightweight design.
In an embodiment, the at least one front fork 108 connected to the vehicle frame 110 via a steering assembly 118. Advantageously, the connection of the front fork 108 to the vehicle frame 110 via the steering assembly 118 provides a precise and controlled mechanism for steering, enabling the front fork 108 to pivot and respond accurately to the rider input. Further, the steering assembly 118, incorporating steering stem, bearings, and handlebars, allows for smooth and responsive manoeuvring of the vehicle. Furthermore, the above-mentioned setup ensures that the front fork 108 maintains proper alignment with the vehicle frame during turns or adjustments, resulting in enhanced stability, control, and safety for the vehicle.
In an embodiment, the headlamp unit 104 comprises a pair of guiding members 120 configured to align the support bracket 116 with the headlamp unit 104. The inclusion of a pair of guiding members 120, ensures precise and consistent positioning of the headlamp unit during installation and assembling. Further, the guiding members provide a structured path for the support bracket 116, preventing misalignment and ensuring that the headlamp is mounted securely in the projected orientation. Furthermore, the headlamp unit 104 facilitates an accurate alignment between the headlamp unit 102 and the support bracket 116, the above-mentioned configuration minimizes the risk of improper installation. Furthermore, the guiding members 120 simplifies the assembling process, thereby reducing the need for manual adjustments and ensuring that the components fit together seamlessly.
Based on the above-mentioned embodiments, the present disclosure provides significant advantages such as (but not limited to) enhanced stability and durability of the headlamp unit, reduced misalignment of the lamp, focused beam of illumination, ease of disassembly, and thereby, the headlamp assembly is more user-friendly and cost-effective
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combinations of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, and “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A headlamp mounting assembly (100) for a vehicle, the headlamp mounting assembly (100) comprises:
- a headlamp crown (102);
- a headlamp unit (104);
- a plurality of mounting brackets (106); and
- at least one front fork (108) connected to a vehicle frame (110),
wherein the headlamp unit (104) is connected to the vehicle frame (110) via the plurality of mounting brackets (106) connected to the at least one front fork (108).

2. The headlamp mounting assembly (100) as claimed in claim 1, wherein the headlamp crown (102) comprises a front end (102A) and a rear end (102B).

3. The headlamp mounting assembly (100) as claimed in claim 1, wherein the headlamp unit (104) comprises at least one source of illumination.

4. The headlamp mounting assembly (100) as claimed in claim 1, wherein the headlamp unit (104) is connected to the rear end (102B) of the headlamp crown (102) via a plurality of headlamp fasteners (112).

5. The headlamp mounting assembly (100) as claimed in claim 1, wherein each mounting bracket of the plurality of mounting brackets (106) comprises a main tube (114) and a support bracket (116).

6. The headlamp mounting assembly (100) as claimed in claim 1, wherein the support bracket (116) of the plurality of mounting brackets (106) is connected to the headlamp unit (104) via a plurality of fasteners (118).

7. The headlamp mounting assembly (100) as claimed in claim 1, wherein the at least one front fork (108) passes through the main tube (114) of the plurality of mounting brackets (106).

8. The headlamp mounting assembly (100) as claimed in claim 1, wherein the at least one front fork (108) is connected to the vehicle frame (110) via a steering assembly (120).

9. The headlamp mounting assembly (100) as claimed in claim 1, wherein the headlamp unit (104) comprises a pair of guiding members (122) configured to align the support bracket (116) with the headlamp unit (104).