Description:A HEADLAMP ASSEMBLY
TECHNICAL FIELD
[0001]
The present subject matter relates generally to lighting system in vehicles and in particular, to a headlamp assembly for a vehicle.
BACKGROUND
[0002]
Generally, a two-wheeled or a three-wheeled vehicle comprises of a frame assembly extending rearwardly from a head tube. The frame assembly acts as a 5 skeleton and a structural member for the vehicle that supports the vehicle loads. At least one front wheel is connected to a front portion of the frame assembly through one or more front suspension(s). The handlebar assembly is positioned on the front wheel to enable steering of the vehicle.
[0003]
The frame assembly comprises of a prime mover coupled to it. An 10 instrument cluster is disposed on the handlebar assembly. The instrument cluster is generally comprised of a number of switches with each switch configured for carrying out at least one vehicle operation. The instrument cluster also includes one or more displays on which various vehicle parameters are displayed. The instrument cluster is a vital component that provides essential information to the 15 rider. Mounted directly on the handlebars or the front of the vehicle, the instrument cluster is strategically positioned within the rider's line of sight, ensuring easy visibility and quick access to crucial data during the ride. A headlamp stay mounts to a frame member and accommodates the headlight as part of a headlamp assembly. 20
[0004]
In conventional motorcycles, the headlamp stay is traditionally constructed using metal plates and inserts. The headlamp assembly is typically mounted onto the frame through a headlamp stay, which extends with an overhang and is affixed onto the overhanging portion of the frame. The headlamp stay commonly consists of a smaller plastic portion. There are variations such as fixed 25 type headlamp stay for independently rotating headlamps and movable type headlamp stay mounted onto the suspensions.
3
[0005]
The existing headlamp stay design has a conventional profile comprising horizontal and vertical portions nearly perpendicular to each other, with an overhang ranging from 15 to 22 mm. This design necessitates the inclusion of metal inserts as part of the frame assembly that form the overhang members to accommodate the headlamp assembly, adding to the overall weight of the 5 headlamp stay. The weight-bearing capacity is further challenged by the headlamp, weighing around 5 kgs, resting on the headlamp stay. Additionally, the frame includes a metal bracket extending approximately 70 mm to accommodate the headlamp stay. Furthermore, providing a provision for wire routing though the metallic inserts and the overhanging frame member is difficult. 10
[0006]
The inclusion of metal inserts in traditional headlamp assemblies contributes to increased overall weight, potentially compromising the two-wheeled vehicle's weight distribution, handling, and overall performance.
[0007]
Conventional headlamp stays often exhibit insufficient structural strength, leading to potential failures or deformations, jeopardizing the longevity and 15 durability of the headlamp assembly.
[0008]
Uneven load distribution in traditional designs can result in stress concentration, accelerating wear and tear and diminishing the structural integrity of the headlamp stay, posing risks of premature failures.
[0009]
The combination of excessive weight and concentrated loads on the 20 headlamp stay can lead to compromised handling, stability, and overall vehicle efficiency, impacting the rider's experience and safety.
[00010]
Conventional headlamp stays lacking sufficient structural strength may fail to withstand dynamic forces, risking deformations or failures that could impact the headlamp assembly's reliability and performance. 25
[00011]
Ineffective load distribution across the headlamp stay can result in stress concentration, hastening wear and reducing the overall reliability of the headlamp assembly, potentially leading to safety concerns during operation.
[00012]
Challenges in securely accommodating the headlamp assembly due to conventional mounting methods may result in misalignment, vibrations, and safety 30 hazards during vehicle operation, affecting overall stability and rider confidence.
4
[00013]
Limited compatibility of conventional designs with diverse headlamp types and suspension configurations restricts design flexibility for manufacturers, hindering the integration of advanced technologies and features in two-wheeled vehicle headlamp assemblies.
[00014]
It is a challenge to enhance the design of the headlamp stay in motorcycles, 5 specifically addressing issues related to weight, structural strength, and ease of assembly.
[00015]
Therefore, there is an essential requirement for a solution that addresses the above mentioned problems of excessive weight, limited structural strength, and challenges in load distribution, impacting the overall efficiency and durability of 10 the headlamp assembly with headlamp assemblies for two wheeled vehicles.
SUMMARY
[00016]
Aspects of the present invention pertain to a headlamp assembly designed for use in vehicles. The headlamp assembly comprises a headlamp and a headlamp stay, where the headlamp stay is configured with a first portion intended to 15 accommodate the headlamp and a second portion extending rearwardly from the first portion. The second portion is adapted to couple to a frame member of the vehicle, enhancing the structural integrity of the headlamp assembly.
[00017]
In an embodiment, the second portion is provided with a plurality of first openings to couple to the frame member of the vehicle. 20
[00018]
In an embodiment, the first portion is provided with a plurality of second openings to couple the headlamp to the headlamp stay.
[00019]
In an embodiment, the first portion is extended angularly upwards at a transitional interface of the first portion and the second portion and the slot to accommodate the wire harness is positioned immediately adjacent to the 25 transitional interface of the first portion and the second portion.
[00020]
In an embodiment, the first portion is provided with a cut out to accommodate a mounting member and a plurality of third openings to mount the mounting member. In an embodiment, the transitional interface is provided with a ribbed portion underneath the cut out. 30
5
[00021]
In an embodiment, the wire harness being mounted on the frame member and adapted to route through the slot extending into a plurality of end connectors.
[00022]
In an embodiment, the plurality of end connectors are one or more of a turn signal lamp connection, a display unit connection, one or more switches, a phone charger connection and a vehicle console connection. 5
[00023]
Further aspects of the present invention pertain to a vehicle comprising a frame assembly, a headlamp assembly, the headlamp assembly provided with a headlamp and a headlamp stay comprising a first portion to accommodate the headlamp and a second portion protruded rearwardly from the first portion and the second portion is adapted to couple to a frame member of the vehicle, wherein the 10 first portion is provided with a slot to accommodate a wire harness.
[00024]
In an embodiment, the second portion is provided with a plurality of first openings to couple to the frame member of the vehicle and the first portion provided with a plurality of second openings to couple the headlamp to the headlamp stay. 15
[00025]
In an embodiment, the first portion is extended angularly upwards at a transitional interface of the first portion and the second portion and the slot to accommodate the wire harness is positioned immediately adjacent to the transitional interface of the first portion and the second portion.
[00026]
In an embodiment, the transitional interface is provided with a ribbed 20 portion underneath a cut out, the cut out being adapted to accommodate a mounting member.
[00027]
The first portion of the headlamp stay is equipped with a slot designed to accommodate a wire harness, facilitating the organized routing and connection of electrical components around the frame. Additionally, the first portion is extended 25 angularly upwards at a transitional interface with the second portion.
[00028]
Further embodiments of the headlamp stay include the provision of a plurality of first openings on the second portion, specifically designed for coupling to the frame member of the vehicle. This feature ensures secure attachment and stability of the headlamp assembly to the vehicle's frame. Moreover, the first 30 portion of the headlamp stay is furnished with a plurality of second openings,
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strategically positioned to facilitate the coupling of the headlamp to the headlamp
stay. The first portion of the headlamp stay is also configured with a cutout, creating a designated space to accommodate a mounting member. Adjacent to this cutout, a ribbed portion is situated at the transitional interface between the first and second portions, adding structural reinforcement to this critical area of the 5 headlamp stay.
[00029]
Yet another embodiment involves the organization and routing of the wire harness. The wire harness is mounted on the frame member of the vehicle and extends through the slot in the first portion of the headlamp stay. This wire harness then connects to a plurality of end connectors, each serving a specific function. 10 These end connectors may include, but are not limited to, connections for a turn signal lamp, a display unit, one or more switches, a phone charger, and a vehicle console.
[00030]
Furthermore, the invention extends to a complete vehicle incorporating the described headlamp assembly. In this embodiment, the vehicle includes a frame 15 assembly and the aforementioned headlamp assembly, wherein the headlamp stay is coupled to a frame member of the vehicle, and the first portion accommodates the headlamp and the wire harness slot. The vehicle embodiment also includes the plurality of first openings on the second portion for attachment to the frame member, along with the plurality of second openings on the first portion for 20 coupling the headlamp to the headlamp stay. Additionally, the transitional interface between the first and second portions includes a ribbed portion underneath a cutout, designed to accommodate a mounting member.
BRIEF DESCRIPTION OF THE DRAWINGS
[00031]
The accompanying drawings, which are incorporated in and constitute a 25 part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. The detailed description of the present subject matter is described with reference to the accompanying figures. Same numbers are used throughout the drawings to reference like features and components. 30
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[00032]
Fig. 1 illustrates a left side view of an exemplary two-wheeled vehicle, in accordance with an embodiment of the present subject matter.
[00033]
Fig. 2 illustrates a left side view of an exemplary headlamp assembly, in accordance with an embodiment of the present disclosure.
[00034]
Fig. 3 illustrates an exploded view of an exemplary headlamp assembly in 5 accordance with an embodiment of the present disclosure.
[00035]
Fig. 4a depicts a front view of the headlamp assembly, in accordance with an embodiment of the invention.
[00036]
Fig. 4b depicts a rear view of the headlamp assembly, in accordance with an embodiment of the invention. 10
[00037]
Fig. 5 depicts a perspective rear view of the headlamp assembly, illustrating the wire harness routed in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[00038]
Exemplary embodiments are described with reference to the 15 accompanying drawings. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations, and other implementations are possible without departing from the spirit and scope of the disclosed embodiments. It is intended that the following 20 detailed description be considered as exemplary only, with the true scope and spirit is indicated by the following claims.
[00039]
The embodiments of the present invention will now be described in detail with reference to a wheel along with the accompanying drawings. However, the present invention is not limited to the present embodiments. The present subject 25 matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the 30
8
present subject matter, as well as specific examples thereof, are intended to
encompass equivalents thereof.
[00040]
It is an object of the present invention to reduce the weight of the headlamp assembly.
[00041]
It is yet another object of the present invention to enhance structural 5 strength and load distribution.
[00042]
It is yet another object of the present invention to simplify the design for ease of assembly.
[00043]
It is yet another object of the present invention to provide versatility for accommodating different headlamp types onto a single headlamp mounting 10 provision.
[00044]
Fig. 1 illustrates a left side view of an exemplary two-wheeled vehicle 100, in accordance with an embodiment of the present subject matter. Arrows provided in the top right corner of each figure depicts direction with respect to the vehicle, wherein an arrow F denotes front direction, an arrow R indicates rear 15 direction, an arrow Up denotes upward direction, and an arrow Dw denotes downward direction. The vehicle 100 includes a frame assembly 101 that extends rearward from a head tube 101A. The frame assembly 101 extends along in a longitudinal direction F-R of the vehicle 100. The frame assembly 101 includes a mainframe comprising a main tube 101B extending rearward from a rear portion 20 of the head tube 101A and a down tube 101C that extends rearwardly downward from the head tube 101A. The frame assembly 101 may further comprise a sub-frame formed by a pair of rear tubes that extend obliquely rearward from the main frame. A prime mover 106 is mounted to the main frame of the frame assembly 101. The prime mover 106 may be covered by side panels provided to form a 25 housing around the prime mover 106. The prime mover 106 acts as the power unit of the vehicle 100, and may be a battery operated motor or an IC engine.
[00045]
In an embodiment, the power unit may also include a traction/electrical motor (not shown). When the prime mover 106 is an engine, coupled to an exhaust assembly 110 that scavenges exhaust gases there through. A front portion of a 30 swing arm 115 is swingably connected to the frame assembly 101 and a rear portion
9
of the swing arm 115 rotatably supports a rear wheel 120. The rear wheel 120 is
functionally coupled to the prime mover 106 through a transmission system/member 125. In a preferred embodiment, the transmission system 125 includes a chain drive coupled to an output of manual gear transmission. However, the transmission system 125 may include an automatic transmission or 5 continuously variable transmission. Similarly, a pair of front forks 130 supports a front wheel 135 and is steerably supported by the head tube 101A. A handlebar assembly 140 is connected to an upper portion of the pair of front forks 130. Further, a front fender 145 covers at least a portion of the front wheel 135 and the front fender assembly 145 is mounted to the front forks 130. 10
[00046]
A fuel tank 150 is mounted to the main tube 101B of the frame assembly 101 and disposed rearwardly of the handlebar assembly 140. A seat assembly including a rider seat 155 and a pillion seat 160 is disposed rearwardly of the fuel tank assembly 150 and is supported by the rear tubes. A pair of rider foot pegs 165 is disposed on either sides and is mounted to the frame assembly 101 of the vehicle 15 that supports rider foot. A rear fender 170 is disposed upwardly of the rear wheel 120 covering at least a portion of the rear wheel 120.
[00047]
Furthermore, the vehicle 100 includes various electrical and electronic systems including a starter motor (not shown), a headlamp assembly 175, a vehicle control unit, and a tail lamp 180. The grab rails 190 extend upwardly outwards 20 from underneath the pillion seat 160. In addition, the vehicle includes safety systems including a synchronous braking system (not shown), and an anti-lock braking system.
[00048]
Fig. 2 illustrates a left side view of an exemplary headlamp assembly 175, in accordance with an embodiment of the present disclosure. The headlamp 25 assembly 175 consists of a headlamp 200 detachably mounted to the headlamp stay 250. The headlamp assembly 175 for a vehicle 100 comprises a headlamp 200 and a headlamp stay 250. The headlamp stay 250 consists of a first portion 202 to accommodate the headlamp and a second portion 204 protruding rearwardly from the first portion. The second portion is adapted to couple to a frame member 101D 30
10
of the vehicle. The first portion features a slot 32
0 designed to accommodate a wire harness 400 (shown in Figs. 3, 4 and 5). The second portion 204 of the headlamp stay 250 is equipped with a plurality of first openings 210 for secure coupling to the frame member 101D of the vehicle 100. Additionally, the first portion 202 has a series of second openings 300 designed for coupling the headlamp 200 to the 5 headlamp stay 250. Fig. 3 illustrates an exploded view of an exemplary headlamp assembly 175 in accordance with an embodiment of the present disclosure. The first portion (202) extends angularly upwards at a transitional interface with the second portion (204). The slot (320) for the wire harness is positioned immediately adjacent to this transitional interface. The first portion (202) is equipped with a cut-10 out (312) designed to accommodate a mounting member, and a series of third openings (302) for mounting the said member. The transitional interface features a ribbed portion (310) underneath the cut-out, providing additional structural support. The wire harness (400) is mounted on the frame member (101D) and routed through the slot (320) extending into a plurality of end connectors (404-1, 15 404-2). These end connectors can serve various functions, including turn signal lamp connection, display unit connection, switches, phone charger connection, and vehicle console connection. The vehicle (100) comprises a frame assembly (101) and the aforementioned headlamp assembly (175). The headlamp assembly includes a headlamp (200) and a headlamp stay (250) with a first portion (202) 20 accommodating the headlamp and a second portion (204) coupling to the frame member (101D). The first portion is equipped with a slot (320) for wire harness accommodation.
[00049]
Fig. 4a depicts a front view of the headlamp assembly 175, in accordance with an embodiment of the invention. In the vehicle 100 context, the first portion 25 202 of the headlamp stay 250 extends angularly upwards at a transitional interface with the second portion 204. The slot 320 for the wire harness 400 is positioned immediately adjacent to this interface. The transitional interface is further enhanced with a ribbed portion 310 underneath a cut-out 312. The cut-out 312 is specifically adapted to accommodate a mounting member. 30
11
[00050]
Fig. 4b depicts a rear view of the headlamp assembly 175, in accordance with an embodiment of the invention. The plurality of third openings 302 are adapted to receive a mounting member. Any end user device may be connected to the mounting member including a charging socket, a speedometer unit, an instrument cluster and the like. 5
[00051]
Fig. 5 depicts a perspective rear view of the headlamp assembly 175, illustrating the wire harness 400 routed in accordance with an embodiment of the invention. The wire harness 400 may extend into a plurality of wiring harnesses 400-1, 400-2. In an embodiment, these plurality of wiring harnesses 400-1, 400-2 may supply power form a battery to the turn signal lamps. The wiring harness 400 10 may be located in place on the frame member 101D by one or more fastening members 402. In an embodiment, the fastening member 402 is provided on the second portion 204 of the headlamp stay 250.
[00052]
The claimed invention, as described, involves a specific and concrete headlight assembly with the extended second portion that contributes to reduced 15 weight and increased structural strength. It is an advantage of the invention that it ensures weight reduction of the frame assembly as no overhang member is required as part of the frame assembly to accommodate the headlamp assembly.
[00053]
It is a further advantage of the claimed invention that the cut-out enables accommodation of multiple types of end devices and the ribbed portion provides 20 improved structural strength.
[00054]
It is yet another advantage that the entire structure leads to a simplified assembly process that reduces the overall assembly time and maintenance time.
[00055]
These specific functionalities demonstrate a practical and non-abstract nature of the invention. The choice and application of these technologies contribute 25 to the invention's non-abstract nature.
[00056]
In view of the above, the claimed limitations as discussed above are not routine, conventional, or well understood in the art, as the claimed limitations enable the above solutions to the existing problems in conventional technologies.
[00057]
In view of the above, the claimed invention may not be considered abstract 30 and may not be obvious to a person skilled in the art.
12
[00058]
The terms “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some embodiments”, and “one embodiment” mean “one or more (but not all) embodiments of the invention(s)” unless expressly specified otherwise. The terms “including”, “comprising”, “having” and variations thereof mean “including but 5 not limited to”, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.
[00059]
Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore 10 intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
[00060]
While various aspects and embodiments have been disclosed herein, other 15 aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope as indicated by the following claims.
[00061]
A person with ordinary skills in the art will appreciate that the assemblies, sub-assemblies have been illustrated and explained to serve as examples and 20 should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[00062]
While the present disclosure has been described with reference to certain 25 embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be 30
13
limited to the particular embodiment disclosed, but that the present disclosure will
include all embodiments falling within the scope of the appended claims.
[00063]
It is to be understood that the aspects of the embodiments are not necessarily limited to the features described herein. Many modifications and variations of the present subject matter are possible in the light of above disclosure. 5 Therefore, within the scope of claims of the present subject matter, the present disclosure may be practiced other than as specifically described.
[00064]
It is to be understood that the aspects of the embodiments are not necessarily limited to the features described herein. Many modifications and variations of the present subject matter are possible in the light of above disclosure. 10 Therefore, within the scope of claims of the present subject matter, the present disclosure may be practiced other than as specifically described. , Claims:We claim:
1.
A headlamp assembly (175) for a vehicle comprising:
a headlamp (200);
a headlamp stay (250), the headlamp stay (250) comprising a first portion (202) to accommodate the headlamp (200) and a second portion (204) protruded rearwardly from the first portion (200) and the second portion (204) being adapted to couple to a frame member (101A) of the vehicle (100), wherein the first portion (202) being provided with a slot (320) to accommodate a wire harness (400).
2.
The headlamp assembly (175) as claimed in claim 1, wherein the second portion (204) is provided with a plurality of first openings (210) to couple to the frame member (101D) of the vehicle (100).
3.
The headlamp assembly (175) as claimed in claim 1, wherein the first portion (202) is provided with a plurality of second openings (300) to couple the headlamp (200) to the headlamp stay (250).
4.
The headlamp assembly (175) as claimed in claim 1, wherein the first portion (202) extended angularly upwards at a transitional interface of the first portion (202) and the second portion (204) and the slot (320) to accommodate the wire harness (400) is positioned immediately adjacent to the transitional interface of the first portion (202) and the second portion (204).
5.
The headlamp assembly (175) as claimed in claim 4, wherein the first portion (202) being provided with a cut out (312) to accommodate a mounting member and a plurality of third openings (302) to mount the mounting member.
15
6.
The headlamp assembly (175) as claimed in claim 5, wherein the transitional interface being provided with a ribbed portion (310) underneath the cut out (312).
7.
The headlamp assembly (175) as claimed in claim 7, wherein the wire harness (400) being mounted on the frame member (101D) and adapted to route through the slot (320) extending into a plurality of end connectors (404-1, 404-2).
8.
The headlamp assembly (175) as claimed in claim 6, wherein the plurality of end connectors (404-1, 404-2) being one or more of a turn signal lamp connection, a display unit connection, one or more switches, a phone charger connection and a vehicle console connection.
9.
A vehicle (100) comprising:
a frame assembly (101);
a headlamp assembly (175), the headlamp assembly (175) provided with a headlamp (200) and a headlamp stay (250), the headlamp stay (250) comprising:
a first portion (202) to accommodate the headlamp (200) and a second portion (204) protruded rearwardly from the first portion (202) and the second portion (204) being adapted to couple to a frame member (101D) of the vehicle (100), wherein the first portion (202) being provided with a slot (320) to accommodate a wire harness (400).
10.
The vehicle (100) as claimed in claim 9, wherein the second portion (204) is provided with a plurality of first openings (210) to couple to the frame member (101D) of the vehicle (100) and the first portion (202) provided with a plurality of second openings (300) to couple the headlamp (200) to the headlamp stay (250).
16
11.
The vehicle (100) as claimed in claim 9, wherein the first portion (202)extended angularly upwards at a transitional interface of the first portion(202)and the second portion (204) and the slot (320) to accommodate thewire harness (400) is positioned immediately adjacent to the transitional interface of the first portion (202) and the second portion (204).
12.
The vehicle (100) as claimed in claim 9, wherein the transitional interfacebeing provided with a ribbed portion (310) underneath a cut out (312), thecut out (312) being adapted to accommodate a mounting member.