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Technical Field
[0001] The present subject matter described herein generally
relates to a motorcycle and particularly relates to a headlamp housing assembly for a motorcycle. Background
[0002] Typically, a headlamp unit of a motorcycle is housed in a
headlamp housing assembly that includes a front housing cover, a rear housing cover and a mounting stay. Whereas the front housing cover and the rear housing cover detachably attached to each other aid in housing the headlamp unit, a pair of turn signals lamps, a speedometer and the like, the mounting stay aids in mounting the headlamp housing assembly including the front housing cover and the rear housing cover to a front fork assembly of the motorcycle. Particularly, the rear housing cover supports the pair of turn signal lamps, the speedometer, and a number plate, and is provided with a plurality of mounting structures such as metal mounting brackets, mounting bosses and the like at each mounting location for receiving the same. Moreover, the rear housing cover is also provided with mounting structures for receiving the front housing cover. For example, in a known disclosure, the rear housing cover includes individual mounting brackets for receiving the pair of turn signal lamps, the front housing cover and the speedometer. The rear housing cover therefore acts as a load carrying member of the headlamp housing assembly and is subject to cyclic stresses at each of the mounting brackets during motorcycle running

condition, resulting in rattling of the headlamp unit and breakage of
mounting brackets. Therefore, in order to ensure stiffness of the headlamp
housing assembly, a plurality of stiffening members are provided in the
front housing cover and the rear housing cover, thereby resulting in high
part count and increased weight of the headlamp housing assembly.
Particularly, a top portion of the rear housing cover lacks support and
becomes less stiff due to weight of surrounding parts, causing it to act as a
cantilever beam, leading to vibration and rattling, as well as leading to
formation of uneven gap with the front housing cover.
[0003] There is therefore a need to increase stiffness of the front
housing cover and the rear housing cover without leading to increase in
part count and overall weight of the headlamp housing assembly.
Summary of the Invention
[0004] The present invention has been made in view of the above
circumstances.
[0005] It is an object of the present invention to provide a headlamp
housing assembly that aids in reliably accommodating a headlamp unit, a
pair of turn signal lamps, a visor, a speedometer etc. without involving the
use of a plurality of stiffener members.
[0006] It is another object of the present invention to provide a
headlamp housing assembly including a front housing cover and a rear
housing cover reliably secured to one another without involving the use of
a plurality of mounting members and stiffening members.

[0007] It is yet another object of the present invention to provide a
headlamp housing assembly including a mounting stay adapted to
detachably attach a front housing cover to the rear housing cover.
[0008] It is one more object of the present invention to provide a
headlamp housing assembly including a mounting stay adapted to stiffen at least a portion of a rear housing cover of said headlamp housing assembly.
[0009] The above and other objects are achieved by providing a
headlamp housing assembly according to the present invention. The
headlamp housing assembly comprises a front housing cover covering at
least a front portion of a headlamp unit, a rear housing cover covering at
least a rear portion of the headlamp unit, and a mounting stay adapted to
detachably attach the front housing cover to the rear housing cover.
[0010] As per an embodiment of the present invention, the
mounting stay includes a pair of first mounting arms, a pair of second mounting arms, and an inverted Y shaped supporting arm. Whereas the pair of second mounting arms is rigidly attached to the pair of first mounting arms at its one end, at its other end the same is rigidly attached to a pair of tubular legs of said mounting stay, the pair of first mounting arms is rigidly attached to a first bridge member of said mounting stay at its one end. Further, at least a portion of the inverted Y shaped supporting arm is rigidly attached to the pair of first mounting arms, at its other end. Furthermore, a construction of the inverted Y shaped supporting arm is

provided in manner such that it clears surrounding parts such as the speedometer and associated wiring in order to prevent interference with the speedometer and its associated wiring.
[0011] Particularly, the pair of second mounting arms extending
substantially perpendicularly from said pair of tubular legs receives the
pair of turn signal lamps. The pair of turn signal lamps is sandwich
mounted to the mounting stay through the rear housing cover. The pair of
first mounting arms extending substantially in a motorcycle width direction
is adapted to receive the first housing cover combinedly with rear housing
cover. Further, the Inverted Y shaped supporting arm extending away from
the pair of first mounting arms towards an apical portion of the rear
housing cover, serves to support the rear housing cover. Thus, the
mounting stay serves to support the front housing cover and the rear
housing cover without involving the use of a plurality of mounting
structures and a plurality of support structures. Moreover, in particular, the
mounting stay serves to locally improve stiffness of the rear housing cover.
[0012] Thus, the mounting stay as per an aspect of the present
invention not only serves as a stiffener member, but also as a mounting member in the headlamp housing assembly, thereby eliminating the need for additional individual stiffening or mounting structures to be provided either in the front housing cover or the rear housing cover of said headlamp housing assembly.

[0013] Summary provided above explains the basic features of the
invention and does not limit the scope of the invention. The nature and
further characteristic features of the present invention will be made clearer
from the following descriptions made with reference to the accompanying
drawings.
Brief Description of Drawings
[0014] The above and other features, aspects, and advantages of
the subject matter will be better understood with regard to the following
description and accompanying drawings where:
[0015] FIG.1 illustrates a side view of a motorcycle comprising a
headlamp housing assembly in accordance with an embodiment of the
present invention.
[0016] FIG.2 illustrates a side view of the headlamp housing
.assembly in accordance with an embodiment of the present invention.
[0017] FIG.3a is a front perspective view of the headlamp housing
assembly in accordance with an embodiment of the present invention.
[0018] FIG.3b is an exploded view depicting mounting of said front
housing cover to the rear housing cover in accordance with an
embodiment of the present invention.
[0019] FIG-4 is a rear view of the headlamp housing assembly in
accordance with an embodiment of the present invention.

[0020] FIG.5 illustrates a front view of a rear housing cover of the
headlamp housing assembly as mounted to a mounting stay in
accordance with an embodiment of the present invention.
[0021] FIG-6 illustrates a front perspective view of the mounting stay
in accordance with an embodiment of the present invention.
Detailed Description of the Preferred Embodiments
[0022] Exemplary embodiments detailing features of the headlamp
housing assembly and its arrangement, in accordance with the present invention will be described hereunder with reference to the accompanying drawings. Various aspects of different embodiments of the present invention will become discernible from the following description set out hereunder. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the invention. Further, it is to be noted that terms "upper", "lower", "right", "left", "front", "forward", "rearward", "downward", "upward", "top", "bottom" and like terms are used herein based on the illustrated state or in a standing state of the motorcycle with a driver riding thereon. Furthermore, a longitudinal axis refers to a front to rear axis relative to the scooter type motorcycle, while a lateral axis refers to a side to side, or left to right axis relative to the scooter type motorcycle. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0023] FIG. 1 illustrates a side view of motorcycle 10 in accordance
with the present invention. The motorcycle 10 includes a body frame 11 to
support body of said motorcycle 10. A head pipe 12 is provided at a front
end of the body frame 11. The head pipe 12 supports a steering shaft (not
shown) rotatably in a certain range. In an upper portion of the head pipe
12, a handlebar 13 is rotatably connected to the steering shaft through an
upper bracket 12a. The handlebar 13 is used to steer the motorcycle 10
and is connected to a front wheel 14 through a front fork assembly 16. An
upper portion of the front wheel 14 is covered by a front fender 15 which
prevents mud and water from getting deflected towards the steering shaft.
Further, the front fork assembly 16 is supported on the front fender 15.
[0024] In a front portion of the body frame 11 a fuel tank 18 is
arranged immediately behind the handlebar 13 and is disposed over an
engine 20. A seat 22 is placed behind the fuel tank 18. The seat 22
includes a front rider portion and rear pillion portion.
[0025] For the safety of the rider and in conformance with the traffic
rules, a headlamp unit 25 and a pair of turn signal lamps 26 is provided in
the front portion of the motorcycle 10- The headlamp unit 25 and the pair
of turn signal lamps 26 are housed in a headlamp housing assembly 30,
which includes a front housing cover 30a and a rear housing cover 30b
attached to each other through a housing stay 30c (shown in FIG.2).
[0026] Suspension systems are provided for comfortable steering of
the motorcycle 10 on the road; The front fork assembly 16, which forms

the front suspension system, serves as rigidity component just like the
body frame. The front fork assembly 16 clamped to the head pipe 12
through the upper bracket 12a and a lower bracket 12b is capable of being
moved to the left and right. Further, a rear suspension system, which is a
hydraulic damped arrangement, is connected to the body frame 11. The
rear suspension system comprises of at least one rear suspension 17
preferably on a left hand side of the motorcycle 10. However, in a
motorcycle with two rear suspensions, the same may be disposed on the
left side and the right side respectively of said motorcycle.
[0027] The engine 20 is mounted to a front lower portion of the body
frame 11 by means of an engine mounting bracket 21. The engine 20 is equipped with an exhaust system that includes an exhaust pipe (not shown) connected to the engine 20 and a muffler (not shown) connected to the exhaust pipe. The muffler (not shown) extends rearwards along the right side of the rear wheel 40.
[0028] Further, a swing arm 35 extending rearwards is swingably
connected to a lower rear portion of the body frame 11. The rear wheel 40 is rotatably supported at a rear end of the swing arm 35. Power from the engine 20 is transmitted to the rear wheel 40 through a power drive mechanism, such as a drive chain, so as to drive and rotate the rear wheel 40.
[0029] A rear fender 45 for covering an upper side of the rear wheel
40 is mounted to a rear portion of body frame 11 to prevent mud and water

splashed by the rotating rear wheel 40 from entering the muffler, the engine 20 and other parts disposed close by.
[0030] To enhance the overall aesthetics of the motorcycle 10 and
to prevent undesired foreign particles from entering parts of the motorcycle, a plurality of rear covers 50 is attached to a rear portion of the body frame 11.
[0031] FIG.2 illustrates a side view of the headlamp housing
assembly 30 in accordance with an embodiment of the present invention. The headlamp housing assembly 30 is held in a front portion of the body frame 11. Particularly, the headlamp housing assembly 30 is combinedly supported to the head pipe 12 along with the front fork assembly 16 through the mounting stay 30c provided therein. The headlamp housing assembly 30 thus supported, houses a headlamp unit 25. The headlamp housing assembly 30 as per the present embodiment also receives a pair of turn signal lamps 26, a visor 27, and a speedometer (not shown). According to an embodiment of the present invention, the headlamp housing assembly 30 includes a front housing cover 30a, a rear housing cover 30b and a mounting stay 30c. The mounting stay 30c detachably attaches the front housing cover 30a to the rear housing cover 30b. Particularly, while the headlamp unit 25 and the visor 27 are mounted to the front housing cover 30a, the pair of turn signal lamps 26, and the speedometer (not shown) are mounted to the rear housing cover 30b.

Further, the front housing cover 30b is also adapted to receive a number plate (not shown) at a bottom portion thereof.
[0032] Particularly, the headlamp housing assembly 30 including
the front housing cover 30a, and the rear housing cover 30b made of polymeric material such as plastic are prone to flexing in areas lacking sufficient stiffness. More particularly, since the rear housing cover 30b is a load bearing member of the headlamp housing assembly 30, it has greater tendency to flex. For example an apical portion of the rear housing cover 30b surrounding the speedometer is more prone to flexing due to lack of sufficient support, leading to uneven gap between the front housing cover 30a and the rear housing cover 30b. There is therefore a need to provide sufficient support to the rear housing cover 30b without increasing overall weight of the headlamp housing assembly 30.
[0033] An arrangement of the front housing cover 30a* the rear
housing cover 30b and the mounting stay 30c with respect to each other is made with reference to FIG.3a-FIG.5.
[0034] FIG.3a is a front perspective view of the headlamp housing
assembly 30. As per an embodiment of the present invention, the mounting stay 30c serves to combinedly mount both the front housing cover 30a and the rear housing cover 30b. The mounting stay 30c as per the present embodiment includes a pair of first mounting arms 30ca, a pair of second mounting arms 30cb and an inverted Y shaped supporting arm 30cc. As may be seen in the figure, the pair of second mounting arms

30cb serves to receive the pair of turn signal lamps 26 together with the
rear housing cover 30b. In other wqrds, the rear housing cover 30b is
sandwich mounted together with the pair of turn signal lamps 26 to the pair
of second mounting arms 30cb. Further, the pair of first mounting arms
30ca receives the front housing cover 30a together with the rear housing
cover 30b- Particularly as may be seen in FIG.3b, the pair of first mounting
arms 30ca is sandwich mounted to an L shaped mounting lug 30aa of the
front housing cover 30a along with a rear side portion of the rear housing
cover 30b. A fastener 29 passing through a mounting hole 30ba each in
left and right rear side portion of the rear housing cover 30b is used to
combinedly fasten the rear housing cover 30b with the pair of first
mounting arms 30ca of the mounting stay 30c. Thus, the front housing
cover 30a is secured to the rear housing cover 30b through the mounting
stay 30c. Further, the front housing cover 30a is also provided with a '
. bottom mounting bracket 30ab to be attached to a bracket receiving
member 30cr provided in a bottom portion of the mounting stay 30c. Said
bracket receiving member 30cr extending from a second bridge member
30cf of the mounting stay 30c has a pair of adjustment slots.
[0035] Thus, the front housing cover 30a to which the headlamp
unit is attached, is not directly mounted to the rear housing cover 30b, but the same is achieved by sandwich mounting with the mounting stay 30c. Thus, the mounting stay 30c contributes in sharing load along with the rear housing cover 30b. In the present embodiment, the mounting stay

30c not only-serves to mount the front housing cover 30a and the rear housing cover 30b to the front fork assembly 16 (shown in FIG.1), but also serves to support the rear housing cover 30b. In the present embodiment, the inverted Y shaped supporting arm 30cc serves to support the rear housing cover 30b at an apical portion 30ba (shown in FIG.5) thereof. Particularly, the headlamp housing assembly 30 is secured to the front fork assembly 16 through a pair of tubular legs 30cd of said mounting stay 30c.
[0036] As per an aspect of the present invention, the pair of first
mounting arms 30ca and the pair of second mounting arms 30cb made of material such as a metal or an alloy serve to increase the stiffness of a side portion of the rear housing cover 30b, whereas ihe Inverted Y shaped supporting arm 30cc also made of a metal or an alloy serves to increase stiffness of the apical portion 30ba of the rear housing cover 30b. As may be seen in FIG.4, the inverted Y shaped supporting arm 30cc extends towards the apical portion 30ba of the rear housing cover 30b from the pair of first mounting arms 30ca. Particularly, the Inverted Y shaped supporting arm 30cc is disposed centrally in a manner such that it clears its surrounding parts such as a rear portion of the headlamp unit 25, and such that the speedometer (not shown) can be located in a cut out 31 surrounding the inverted Y shaped supporting arm 30cc, said cut out 31 being provided in the rear housing cover 30b.

[0037] Constructional details of the mounting stay 30c are
elaborated with respect to FIG.5 and FIG.6. FIG.5 is a front view of the rear housing cover 30b as mounted to the mounting stay 30c. As per the present embodiment, mounting stay 30c includes the pair of second
5 mounting arms 30cb which is rigidly attached to a pair of side tubular members 30cd thereof. Particularly, each second mounting arm of the pair of second mounting arms 30cb extends substantially perpendicularly from each tubular leg of the pair of tubular legs 30cd and parallel to a side portion of the rear housing cover 30b, and further at least a portion of each
3 second mounting arm extends upwards towards each first mounting arm of the pair of mounting arms 30ca. Also, each second mounting arm of the pair of second mounting arms 30cb is provided with a mounting hole to receive one turn signal lamp of the pair of turn signal lamps 26. Further, the pair of first mounting arms 30ca is rigidly attached to at least a portion
5 of the second mounting arms 3'0ca at one end, and to a first bridge member 30ce at the other end. Furthermore, each first mounting arm of the pair of first mounting arms 30ca extends substantially inclinedly from the first bridge member 30ce towards a side portion of the rear housing cover 30b and is adapted to receive the front housing cover 30a together
) with the rear housing cover 30b. Further, the inverted Y shaped supporting arm 30cc is rigidly attached to at least a portion of the pair of first mounting arms 30ca and extends substantially upwards therefrom towards the apical portion 30ba of the rear housing cover 30b. Particularly, a

supporting bracket 32 rigidly attached to a top portion of the inverted Y
shaped supporting arm 30cc is fastened to the apical portion 30ba of the
rear housing cover 30b to provide local stiffness thereto. Providing local
support to the apical portion 30ba of the rear housing cover 30b ensures
that the rear housing cover 30b does not flex due to load.
[0038] As per another embodiment of the present invention, the
front housing cover 30a may be fastened to the rear housing cover 30b through the supporting bracket 32 at the apical portion of said rear housing cover 30b, thereby ensuring additional support to the rear housing cover 30b. Additionally, one or more routing brackets may be provided on the inverted Y shaped supporting arm 30cc for guiding wiring harness emerging from the headlamp unit 25.
[0039] As is apparent from the above teaching, the mounting stay
provided with the Inverted Y shaped supporting arm serves to receive the front housing cover and the rear housing cover in addition to providing additional support to the rear housing cover so as to secure the same from flexing, the need for additional individual mounting members and stiffener members is eliminated. Moreover, since the mounting stay is one integral member, time required for assembling the same together with the front and rear housing cover is also reduced, improving efficiency and productivity of manufacturing.
[0040] While the present invention has been shown and described
with reference to the foregoing preferred embodiments, it will be apparent

:ts-ez • - ■
to those skilled in the art that changes in form, connection, and detail may
be made therein without departing from the spirit and scope of the
invention as defined in the appended claims.

4 r *~
I/We Claim:
1. A headlamp housing assembly (30) for a motorcycle (10), said
headlamp housing assembly (30) comprising:
a front housing cover (30a) at least partially covering a front portion of a headlamp unit (25);
a rear housing cover (30b) at least partially covering a rear portion of the headlamp unit (25);
a mounting stay (30c) at least adapted to detachably attach said front housing cover (30a) to said rear housing cover (30b), said mounting stay (30c) including a pair of tubular legs (30cd) for securing the headlamp housing assembly (30) to a front fork assembly (16), a first bridge member (30ce) bridging the pair of tubular legs (30cd), and a pair of first mounting arms (30ca) rigidly attached to said first bridge member (30ce), and extending towards either side, portions of said rear housing cover (30b);
characterized in that,
the mounting stay (30c) further includes an inverted Y shaped supporting arm (30cc) rigidly attached to the pair of first mounting arms (30ca) and extending substantially upwards therefrom towards an apical portion (30ba) of the rear housing cover (30b) and supported thereto.

2. The headlamp housing assembly (30) as claimed in claim 1, wherein the mounting stay (30c) includes a pair of second mounting arms (30cb), each second mounting arm of said pair of second mounting arms (30cb) rigidly attached to each tubular leg of the pair of tubular legs (30cd), and extending substantially perpendicularly therefrom and substantially parallely to the side portion of the rear housing cover (30b), and further extending upwards towards each first mounting arm of said pair of first mounting arms (30ca) and rigidly attached thereto.
3. The headlamp housing assembly as claimed in claim 1 or claim 2, wherein at least a portion of the rear housing cover (30b) is mounted to the pair of second mounting arms (30cb).
4. The headlamp housing assembly (30) as claimed in claim 1, wherein the front housing cover (30a) is sandwich mounted along with the rear housing cover (30b) to the pair of first mounting arms (30ca).
5. The headlamp housing assembly (30) as claimed in claim 1, wherein the front housing cover (30a) includes a bottom mounting bracket (30ab).
6. The headlamp housing assembly (30) as claimed in claim 1 or claim 5, wherein the mounting stay (30c) includes a second bridge member (30cf) provided with a bottom mounting bracket receiving member (30cr) to receive said bottom mounting bracket (30ab) and

enable detachable attachment of said front housing cover (30a) to said mounting stay (30c). 7. A motorcycle including the headlamp housing assembly (30) as claimed in claims 1-6.