# Patent

## Title
Headlamp assembly for a saddle-type vehicle

## Abstract

A headlamp assembly for a saddle-type vehicle ensures a generous light-emitting area of an upper lamp, and can make a gap formed between upper and lower lamps hard to see. The headlamp assembly includes upper and lower lamps, each including a light source and a reflector, with the lower lamp arranged below the upper lamp. The headlamp assembly also includes extension members, which extend in a substantially horizontal direction and approach front ends of the reflectors from a front side thereof, where flange portions are attached to and extend downwardly from the lower edges of the reflectors.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims priority under 35 USC 119 based on Japanese patent application No. 2013-059910, filed on Mar. 22, 2013. The entire subject matter of this priority document, including specification claims and drawings thereof, is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a headlamp assembly for a saddle-type vehicle. In a particular embodiment hereof, the headlamp assembly is provided with at least one light source on each of upper and lower portions thereof.
2. Background Art
The following Patent Literature 1 discloses a headlight device for a vehicle where lamps are arranged on upper and lower sides. The headlight device has the structure where an extension which extends horizontally is arranged such that the extension approaches a front end of a lower edge of a reflector for an upper light.

    [Patent Literature 1] JP-A-2000-57807


However, in the above-mentioned Patent Literature 1, to make a gap formed between an upper lamp (upper lamp) and a lower lamp (lower lamp) hard to see, the extension is arranged at a position higher than the lower edge of the reflector of the upper lamp. Accordingly, a light-emitting area of the upper lamp is decreased.
Accordingly, it is an object of the present invention to provide a headlamp assembly for a saddle-type vehicle which can ensure a light-emitting area of an upper lamp and can make a gap formed between the upper lamp and a lower lamp hard to see.
SUMMARY OF THE INVENTION
Reference numbers are included in the following description corresponding to the reference numbers used in the drawings. Such reference numbers are provided for illustration and are not intended to limit the invention.
A lighting equipment (10) of a saddle-type vehicle (12) according to the invention has the following technical features.
First Technical Feature:
The lighting equipment (10) of a saddle-type vehicle (12) comprising:
an upper lamp (110L, 110R) having a first light source (114) and a first reflector (116) which reflects light from the first light source (114) toward a front side;

    
    
        a lower lamp (112L, 112R) having a second light source (118) and a second reflector (120) which reflects light from the second light source (118) toward the front side, the lower lamp (112L, 112R) being arranged below the upper lamp (110L, 110R);
        a housing (100) which supports the upper lamp (110L, 110R) and the lower lamp (112L, 112R) while covering the upper lamp (110L, 110R) and the lower lamp (112L, 112R) from behind; and
        a lens (102) which covers a front side of the upper lamp (110L, 110R) and a front side of the lower lamp (112L, 112R) while allowing a light emitted from the upper lamp (110L, 110R) and a light emitted from the lower lamp (112L, 112R) to pass therethrough,
    
    


wherein an extension member (126L, 126R) which is arranged in an extending manner in the horizontal direction such that the extension member (126L, 126R) approaches a front end of a lower edge of the first reflector (116) from a front side,
and wherein a flange portion (152L, 152R) which extends downwardly from the lower edge of the first reflector (116) is formed on the first reflector (116).
Second Technical Feature:
The extension member (126L, 126R) is fixedly supported on the lens (102) or the housing (100), the upper lamp (110L, 110R) and the lower lamp (112L, 112R) are configured to be subjected to the aiming adjustment in the vertical direction integrally with each other relative to the housing (100), and vertical aiming axes (176L, 176R) of the upper lamp (110L, 110R) and the lower lamp (112L, 112R) are arranged at a position close to the flange portion (152L, 152R) than an upper edge of the upper lamp (110L, 110R) or a lower edge of the lower lamp (112L, 112R) as viewed in a front view.
Third Technical Feature:
The second light source (118) is an LED, and light irradiated downwardly from the second light source (118) is reflected forwardly by the second reflector (120).
Fourth Technical Feature:
The second reflector (120) includes a concave surface portion (121a) which reflects light from the second light source (118) forwardly, and a forwardly extending portion (121b) extending forwardly from an end portion of the concave surface portion (121a), and the flange portion (152L, 152R) extends downwardly to an extent that at least the concave surface portion (121a) is not visible through a gap (155).
Advantages of the Invention
According to the first technical feature of the invention, the flange portion which extends downwardly from the lower edge of the first reflector is formed on the first reflector and hence, when the lighting equipment is viewed from a front side or a front upper side over the lens, a gap formed between the first reflector and the second reflector becomes hard to see and hence, the light-emitting area of the first light source can be ensured whereby the degree of freedom in design is enhanced.
To make the gap formed between the first reflector and the second reflector become hard to see, it is necessary to make the lower edge of the first reflector and the extension member approach each other. According to the second technical feature of the invention, the vertical aiming axes of the upper lamp and the lower lamp, which are subjected to an aiming adjustment in the vertical direction, are integrally arranged in the vicinity of the flange portion and hence, it is possible to prevent the first reflector from largely moving in the longitudinal direction with respect to the extension member due to the aiming adjustment, whereby the gap formed between the lower edge of the first reflector and the extension member can be easily set, thus simplifying the designing of the flange portion.
According to the third technical feature of the invention, light irradiated downwardly from the second light source is reflected forwardly by the second reflector and hence, an upper portion of the lower lamp becomes dark compared to a lower portion of the lower lamp. Accordingly, even when the flange portion extends downwardly from the lower edge of the first reflector of the upper lamp, the flange portion hardly influences the light-emitting area and the external appearance of the lower lamp.
According to the fourth technical feature of the invention, the flange portion extends downwardly to an extent that at least the concave surface portion of the second reflector is not visible through the gap. Accordingly, the concave surface portion is almost not visible through the gap formed between the first reflector and the extension member and hence, the external appearance of the lighting equipment can be enhanced.
For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in conjunction with the accompanying drawings. Throughout the following detailed description and in the drawings, like numbers refer to like parts.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a left side view showing an external appearance of a motorcycle which is a kind of saddle-type vehicle on which a lighting equipment according to an embodiment is mounted.
FIG. 2 is a front view of the motorcycle of FIG. 1.
FIG. 3 is a front view of the lighting equipment of FIG. 1.
FIG. 4 is a view of the lighting equipment of FIG. 3 when an outer lens is removed.
FIG. 5 is a view of the lighting equipment of FIG. 4 when an extension cover is removed.
FIG. 6 is a view of the lighting equipment of FIG. 5 when an inner lens is removed.
FIG. 7 is a plan view of the lighting equipment of FIG. 5.
FIG. 8 is a cross-sectional view as viewed in the direction indicated by an arrow VIII-VIII in FIG. 3.
FIG. 9 is a back view of the lighting equipment of FIG. 3.
FIG. 10 is a bottom plan view of a license lamp.
FIG. 11 is a front view of the license lamp.
FIG. 12 is a cross-sectional view as viewed in the direction indicated by an arrow XII-XII in FIG. 11.
FIG. 13 is a cross-sectional view as viewed in the direction indicated by an arrow XIII-XIII in FIG. 11.
FIG. 14 is a cross-sectional view as viewed in the direction indicated by an arrow XIV-XIV in FIG. 10.



DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
Hereinafter, a headlamp assembly for a saddle-type vehicle according to the invention is explained in detail in conjunction with a selected illustrative embodiment of the present invention, with reference to the attached drawings.
FIG. 1 is a left side view showing an external appearance of a motorcycle 12, which is a kind of saddle-type vehicle on which a headlamp assembly 10 according to an embodiment is mounted, and FIG. 2 is a front view of the motorcycle 12 of FIG. 1. Unless otherwise specified, the directions “forwardly”, “rearward”, “upward”, “downward”, “leftward” and “rightward” are explained in accordance with the directions indicated by arrows in FIG. 1 and FIG. 2.
The motorcycle 12 includes: a vehicle body frame 14; a head pipe 16 which is mounted on a front end portion of the vehicle body frame 14; a pair of left and right front forks 18 which are pivotally supported on the head pipe 16; a front wheel 20 which is supported on the front forks 18 in a rotatable manner; and a steerable handlebar 22 which is operatively attached to upper portions of the left and right front forks 18.
The vehicle body frame 14 includes: a pair of left and right main frames 24 which extend rearwardly from the head pipe 16; a pair of left and right pivot plates 26 arranged behind the pair of left and right main frames 24; and a pair of left and right seat frames 28 which are mounted on the pair of left and right pivot plates 26 and extend obliquely in the rearward and upward direction. A power unit 30 which includes an engine and a transmission is mounted on the left and right main frames 24. A swing arm 34 which rotatably and pivotally supports the rear wheel 32 is swingably supported on the pivot plates 26.
A fuel tank 36 which stores fuel therein is arranged on the pair of left and right main frames 24. A driver's seat 38 on which a rider is seated is arranged behind the fuel tank 36 and above the pair of left and right seat frames 28. A pillion seat 40 on which a passenger is seated is arranged behind the driver's seat 38. A front fender 42 is mounted on the pair of left and right front forks 18, and a rear fender 44 is mounted on rear portions of the pair of left and right seat frames 28. A license plate 46, a license lamp 48 which illuminates the license plate 46, and rear turn signals 50 are mounted on the rear fender 44.
The motorcycle 12 includes: an upper cowl 52 which is mounted on the vehicle body frame 14 and protects a front side of the motorcycle 12; a wind screen 54 which is arranged above the upper cowl 52; back mirrors 56 which are mounted on an upper portion of the upper cowl 52 and enable a rider to confirm an area behind the motorcycle 12; a headlamp assembly 10 which is mounted on a front portion of the upper cowl 52 and constitutes a headlight for illuminating an area in front of the motorcycle 12; a middle cowl 58 which protects a front side portion of the motorcycle 12; an under cover 60 which is arranged behind the middle cowl 58 and on a lower side of the motorcycle 12; side covers 62 which are arranged above the seat frames 28 and cover areas ranging from upper portions of the seat frames 28 to a lower portion of the driver's seat 38; and a rear cover 64 which is arranged behind the seat frame 28. A front turn signal 56a is incorporated into the back mirror 56.
FIG. 3 is a front view of the headlamp assembly 10. As shown in FIG. 3, the headlamp assembly 10 includes a housing 100 and an outer lens (lens) 102 which is arranged in front of the housing 100 and allows light to pass therethrough. A portion (a region indicated by hatching in FIG. 3) of the outer lens 102 is covered with the upper cowl 52.
FIG. 4 is a view of the headlamp assembly 10 shown in FIG. 3 with the outer lens 102 removed, FIG. 5 is a view of the headlamp assembly 10 shown in FIG. 4 with an extension cover 104 additionally removed, FIG. 6 is a view of the headlamp assembly 10 shown in FIG. 5 with an inner lens 106 also removed, FIG. 7 is a top plan view of the headlamp assembly 10 shown in FIG. 5, FIG. 8 is a cross-sectional view as viewed in the direction indicated by an arrow VIII-VIII in FIG. 3, and FIG. 9 is a back view of the headlamp assembly 10 shown in FIG. 3.
The headlamp assembly 10 includes upper lamps (lamps) 110L, 110R for a headlight which are supported on the housing 100 and are arranged on left and right sides of the headlamp assembly 10 respectively, and lower lamps (lamps) 112L, 112R for a headlight which are supported on the housing 100 and are arranged on left and right sides of the headlamp assembly 10 respectively. The lower lamps 112L, 112R are arranged below the upper lamps 110L, 110R. The headlamp assembly 10 has a left-right symmetrical shape and hence, the upper lamp 110L and the lower lamp 112L are in left-right symmetry with the upper lamp 110R and the lower lamp 112R respectively. Other components and elements of the headlamp assembly 10 are also arranged in left-right symmetry.
The upper lamp 110L, 110R for a low beam includes a light source (first light source) 114 which is a light-emitting element such as an LED (Light-emitting Diode) (see FIG. 8) and a reflector (first reflector) 116 which reflects light emitted from the light source 114 forwardly. In the same manner as the upper lamp 110L, 110R, the lower lamp 112L, 112R for a high beam also includes a light source (second light source) 118 which is a light-emitting element such as an LED (see FIG. 8) and a reflector (second reflector) 120 which reflects light emitted from the light source 118 forwardly.
The reflector 116, 120 has the cup-shaped structure where a lateral width of the reflector 116, 120 is gradually narrowed as the reflector 116, 120 extends rearward (see FIG. 7). As shown in FIG. 8, the reflector 160, 120 includes a concave surface portion 117a, 121a and a forwardly extending portion 117b, 121b which extends forwardly from an end portion of the concave surface portion 117a, 121a. The light source 114, 118 irradiates light downwardly and the concave surface portion 117a, 121a of the reflector 116, 120 reflects light irradiated from the light source 114, 118 forwardly.
An opening portion 116a, 120a is formed on the upper forwardly extending portion 117b, 121b of the reflector 116, 120, and light emitted from the light source 114, 118 reaches an inner reflection surface of the concave surface portion 117a, 121a after passing through the opening portion 116a, 120a. Inner edges of the reflector 116, 120 are formed such that the inner edges become further away from each other as the inner edges extend upward.
An extension cover 104 is arranged in front of the upper lamps 110L, 110R and the lower lamps 112L, 112R, and is configured such that the extension cover 104 covers outer edge portions of the upper lamps 110L, 110R and the lower lamps 112L, 112R. In the extension cover 104, opening portions 124UL, 124UR, 124DL, 124DR are formed, which allow light emitted from the upper lamps 110L, 110R and light emitted from the lower lamps 112L, 112R to pass therethrough and to advance toward a front side.
The extension cover 104 includes extension members 126L, 126R. The extension member 126L partitions the opening portion 124UL and the opening portion 124DL from each other, and the extension member 126R partitions the opening portion 124UR and the opening portion 124DR from each other. The extension members 126L, 126R extend in the horizontal direction so as to approach front ends of lower edges (the lower forwardly extending portions 117b) of the upper lamps 110L, 110R (to be more specific, the reflectors 116) (see FIG. 8).
A respective turn signal lamp 130 is arranged on each of the left and right lower sides, respectively, of the extension cover 104. An inner lens 106 which functions as a lens of the turn signal lamp 130 is arranged along and below the extension cover 104 on left and right sides. The inner lens 106 allows light reflected forwardly by the reflector 132 (see FIG. 6) of the turn signal lamp 130 arranged behind the inner lens 106 to pass therethrough. The reflector 132 reflects light forwardly, where such light has been emitted from an additional light source (not shown in the drawing) of the turn signal lamp 130.
On an inner side of a mounting surface 101 of a rear surface wall 100a of the housing 100 (in the inside of the headlamp assembly 10), a signal-lamp driver (driver) 140 which drives the light source for the turn signal lamp and has an approximately plate shape or an approximately box shape is mounted. On an outer side of the mounting surface 101 of the rear surface wall 100a of the housing 100, a headlight-use driver (driver) 142 which drives the light sources 114, 118 is mounted. That is, the signal-lamp driver 140 and the headlight-use driver 142 are mounted on the housing 100 in a state where the rear surface wall 100a of the housing 100 is sandwiched between these drivers 140, 142 and the thickness direction of these drivers 140, 142 is directed in the longitudinal direction (see FIG. 7). The mounting surface 101 has an approximately planar shape.
The signal-lamp driver 140 and the headlight-use driver 142 are mounted on an upper center portion of the rear surface wall 100a such that an area where the signal-lamp driver 140 is mounted on the rear surface wall 100a of the housing 100 and an area where the headlight-use driver 142 is mounted on the rear surface wall 100a of the housing 100 overlap with each other (see FIG. 5, FIG. 9). The reflectors 116 of the upper lamps 110L, 110R are arranged in a more spaced-apart manner in the lateral direction than the reflectors 120 of the lower lamps 112L, 112R are (see FIG. 7). The signal-lamp driver 140 and the headlight-use driver 142 are arranged above the reflectors 120, while the signal-lamp driver 140 and the headlight-use driver 142 are arranged at the same height.
The rear surface wall 100a of the housing 100 on left and right sides bulges in a rearwardly projecting manner. Due to such bulging of the rear surface wall 100a, a recessed portion 144 which is indented forwardly is formed on the rear surface wall 100a of the housing 100 at the center, and the headlight-use driver 142 is mounted on a mounting surface 101 of the recessed portion 144. The rear surface wall 100a of the housing 100 on left and right sides bulges in a rearwardly projecting manner and hence, wide spaces can be ensured behind heat sinks 160, 162 provided in the inside of the headlamp assembly 10 (see FIG. 8) whereby air around the heat sinks 160, 162 can easily form convention flows. Accordingly, it is possible to suppress the elevation of temperature of air in the inside of the headlamp assembly 10 caused by a quantity of heat generated by the light source 114, 118. Further, the interference between the headpipe 16 and the headlamp assembly 10 can be prevented by the recessed portion 144.
Lateral widths of the reflectors 116, 120 are gradually narrowed as the reflectors 116, 120 extend rearward (to be more specific, the reflectors 116,120 have inclined surfaces 119 whose rear surfaces extend in the direction separating from each other as the reflectors 116, 120 extend rearward) and hence, there exists a relatively wide space between the left and right reflectors 116, 120 and behind and in the vicinity of the left and right reflectors 116, 120. Accordingly, in arranging the signal-lamp driver 140 between the left and right upper lamps 110L, 116R and the headlight-use driver 142 between the left and right lower lamps 112L, 112R, the headlamp assembly 10 can be miniaturized also by making use of the space.
The reason why the signal-lamp driver 140 is arranged inside the headlamp assembly 10 and the headlight-use driver 142 is arranged outside the headlamp assembly 10 is explained. A quantity of light for a low beam and a quantity of light for a high beam are stipulated in laws in many cases and hence, the number of cases where electric power fluctuates depending on a type of motorcycle is relatively small and hence, the headlight-use driver 142 is applicable to other types of motorcycles in many cases. Accordingly, it is often the case where the headlight-use driver 142 having a waterproof function is used so that the headlight-use driver 142 can be arranged at any portion of a motorcycle. The headlight-use driver 142 also consumes a large quantity of electric power. Accordingly, in this embodiment, by arranging the headlight-use driver 142 having a waterproof function outside the headlamp assembly 10, the cooling structure in the inside of the headlamp assembly 10 can be simplified and the headlamp assembly 10 per se can be miniaturized.
On the other hand, the turn signal lamp 130 is provided for enhancing the aesthetic appearance of the motorcycle in many cases and hence, it is often the case where an output performance and a quantity of electric power largely differ depending on the type of a motorcycle and hence, the turn signal lamp requires dedicated designing in many cases. Under such circumstances, unlike the headlight-use driver 142, there has been a demand for omitting functions such as a waterproof function which can be omitted from functions of the signal-lamp driver 140 for reducing a manufacturing cost. In this embodiment, the signal-lamp driver 140 is arranged inside the headlamp assembly 10 so that a waterproof function can be omitted from the functions of the signal-lamp driver 140 whereby a manufacturing cost of the signal-lamp driver 140 can be reduced.
A pair of left and right eaves portions 146L, 146R is arranged below the signal-lamp driver 140 and between the lower lamps 112L, 112R. The eaves portion 146L is provided for blocking light from the lower lamp 112L which advances rightward such that the light from the lamp 112L cannot be seen through a gap formed between the lower lamp 112L and the extension cover 104 when the headlamp assembly 10 is viewed from a right side. In the same manner as the eaves portion 146L, the eaves portion 146R is provided for blocking light from the lower lamp 112R which advances leftward such that the light from the lower lamp 112R cannot be seen through a gap formed between the lower lamp 112R and the extension cover 104 when the headlamp assembly 10 is viewed from a left side. Power lines 150R, 150R which extend from a lower side of the signal-lamp driver 140 pass through between the eaves portions 146L, 146R and are connected to a printed circuit board not shown in the drawing on which the light source for the turn signal lamp 130 is mounted.
On the reflectors 116 of the upper lamps 110L, 110R, flange portions 152L, 152R which extend downwardly from lower edges of the reflectors 116 are mounted respectively (see FIG. 5, FIG. 8). The flange portion 152L mounted on the reflector 116 of the upper lamp 110L extends to a right edge of the reflector 116, and the flange portion 152R mounted on the reflector 116 of the upper lamp 110R extends to a left edge of the reflector 116.
The flange portion 152L, 152R is provided for concealing a gap 154 (see FIG. 8) formed between a lower edge of the reflector 116 and an upper edge of the reflector 120, and the flange portion 152L, 152R extends downwardly from an area in the vicinity of the upper edge of the reflector 120 or from the upper edge of the reflector 120. Further, the flange portion 152L, 152R extends downwardly to an extent that the concave surface portion 121a of the reflector 120 cannot be seen through a gap 155 formed between the extension member 126L, 126R and the forwardly extending portion 117b formed on a lower side of the reflector 116. The extension members 126L, 126R are arranged at the substantially same height as the flange portions 152L, 152R.
As shown in FIG. 8, the light sources 114, 118 are mounted on lower surfaces of the printed circuit boards 156, 158 respectively, and upper surfaces of the printed circuit boards 156, 158 are connected to the heat sinks 160, 162. The heat sinks 160, 162 are provided for cooling heat which the light sources 114, 118 generate, and have an L shape so as to cover upper sides and rear sides of the reflectors 116, 120 respectively.
As shown in FIG. 8 and FIG. 9, the power lines 164L, 164R which extend from the headlight-use driver 142 are introduced into the inside of the headlamp assembly 10 through grommet 166L, 166R, and are connected to the printed circuit boards 156, 158.
Reference symbol 170L shown in FIG. 9 indicates a vertical aiming bolt for performing the aiming adjustment of the upper lamp 110L and the lower lamp 112L integrally in the vertical direction, and reference symbol 170R indicates a vertical aiming bolt for performing the aiming adjustment of the upper lamp 110R and the lower lamp 112R integrally in the vertical direction. The vertical aiming bolts 170L, 170R are arranged in the vicinity of the upper edges of the reflectors 116 of the upper lamps 110L, 110R.
Reference symbol 172L indicates a lateral aiming bolt for performing the aiming adjustment of the upper lamp 110L and the lower lamp 112L integrally in the lateral direction, and reference symbol 172R indicates a lateral aiming bolt for performing the aiming adjustment of the upper lamp 110R and the lower lamp 112R integrally in the lateral direction. The lateral aiming bolts 172L, 172R are arranged in the vicinity of the lower edges of the reflectors 120 of the lower lamps 112L, 112R.
Reference symbols 174L, 174R indicate aiming reference positions, and the aiming adjustment in the vertical direction and the aiming adjustment in the lateral direction are performed with reference to the aiming reference positions 174L, 174R. In this case, vertical aiming axes 176L, 176R are lines connecting the aiming reference positions 174L, 174R and the lateral aiming bolts 172L, 172R respectively. Lateral aiming axes 178L, 178R are lines connecting the aiming reference positions 174L, 174R and the vertical aiming bolts 170L, 170R respectively.
The vertical aiming axes 176L, 176R are arranged in the vicinity of the flange portions 152L, 152R, and are arranged below the lower edges of the reflectors 116 (see FIG. 6). Reference symbol 180 indicates an air permeable waterproof material which allows air to pass therethrough but prevents water, dusts and the like from passing therethrough (for example, GORE-TEX (trademark)).
As described above, the flange portions 152L, 152R which extend downwardly from the lower edges of the reflectors 116 are formed on the reflectors 116 of the upper lamps 110L, 110R and hence, when the headlamp assembly 10 is viewed from a front side or a front upper side over the outer lens 102, the gaps 154 formed between the reflectors 116 of the upper lamps 110L, 110R and the reflectors 120 of the lower lamps 112L, 112R become hard to see, light-emitting areas of the upper lamps 110L, 110R can be ensured whereby the degree of freedom in design is enhanced.
To make the gaps 154 formed between the reflectors 116 and the reflectors 120 hard to see, it is necessary to arrange the lower edges of the reflectors 116 and the extension members 126L, 126R close to each other (it is necessary to make the gaps 155 small).
In this embodiment, the aiming axes of the upper lamps 110L, 110R and the lower lamps 112L, 112R which are subjected to the aiming adjustment in the vertical direction integrally are arranged in the vicinity of the flange portions 152L, 152R and hence, it is possible to prevent the reflectors 116 from largely moving in the longitudinal direction with respect to the extension members 126L, 126R due to the aiming adjustment whereby the gaps 155 can be easily set thus making the designing of the flange portions 152L, 152R easy.
The lower lamps 112L, 112R are provided for reflecting light which is irradiated downwardly from the light source 118 forwardly by the reflectors 120 and hence, upper portions of the lower lamps 112L, 112R (upper portion of the reflector 120) become dark compared to lower portions of the lower lamps 112L, 112R. Accordingly, even when the flange portions 152L, 152R extend downwardly from the lower edges of the reflectors 116 of the upper lamps 110L, 110R, the flange portions 152L, 152R hardly influence the light-emitting areas and the external appearance of the headlamp assembly 10.
The flange portions 152L, 152R extend downwardly to an extent that at least the concave surface portions 121a of the reflectors 120 are not visible through the gaps 155. Accordingly, the concave surface portions 121a are not visible through the gaps 155 and hence, the external appearance of the headlamp assembly 10 can be enhanced.
The signal-lamp driver 140 and the headlight-use driver 142 are arranged between the reflectors 116 of the upper lamps 110L, 110R and the reflectors 120 of the lower lamps 112L, 112R and behind and in the vicinity of the reflectors 116, 120 and hence, the degree of freedom in designing arrangement positions of the signal-lamp driver 140 and the headlight-use driver 142 can be enhanced. Further, the reflectors 116, 120 respectively include the inclined surfaces 119, 123 whose rear surfaces extend in the direction separating from each other as the reflectors 116, 120 extend rearward and hence, the signal-lamp driver 140 and the headlight-use driver 142 which are arranged between the left and right upper lamps 110L, 110R and the left and right lower lamps 112L, 112R respectively can be arranged on a more forwardly side whereby the headlamp assembly 10 can be miniaturized.
The signal-lamp driver 140 and the headlight-use driver 142 are supported on the rear surface wall 100a of the housing 100 and hence, the signal-lamp driver 140 and the headlight-use driver 142 which are arranged behind and in the vicinity of the reflectors 116, 120 can be easily supported.
Although the headlight-use driver 142 has a waterproof function, the headlight-use driver 142 is supported on an outer side of the rear surface wall 100a of the housing 100 and hence, the heat radiation performance of the headlight-use driver 142 can be easily ensured.
The headlight-use driver 142 is arranged in the recessed portion 144 indented forwardly which is formed on the rear surface wall 100a of the housing 100 and hence, the power lines 164L, 164R which connect the headlight-use driver 142 and the light sources 114, 118 to each other can be shortened.
The signal-lamp driver 140 is arranged inside of the housing 100, such that the rear surface wall 100a of the housing 100 is sandwiched between the signal-lamp driver 140 and the headlight-use driver 142. Accordingly, it is possible to protect the signal-lamp driver 140 from water and/or dust. Further, the signal-lamp driver 140 is mounted by making use of a flat surface, that is, the mounting surface 101 of the rear surface wall 100a provided for mounting the headlight-use driver 142. Accordingly, it is unnecessary to additionally provide mounting surfaces 101 for mounting the respective drivers 140, 142 thus eventually making the headlamp assembly 10 compact.
FIG. 10 is a bottom plan view of the license lamp 48, FIG. 11 is a front view of the license lamp 48, FIG. 12 is a cross-sectional view as viewed in the direction indicated by an arrow XII-XII in FIG. 11, FIG. 13 is a cross-sectional view as viewed in the direction indicated by an arrow XIII-XIII in FIG. 11, and FIG. 14 is a cross-sectional view as viewed in the direction indicated by an arrow XIV-XIV in FIG. 10.
The license lamp 48 includes: a light source 202 which is a light-emitting element such as an LED mounted on the printed circuit board 200; a case member 204 which stores the printed circuit board 200 and the light source 202, and a lens 206 which is mounted on a lower side of the case member 204 and allows light irradiated from the light source 202 to pass therethrough.
The case member 204 includes a base portion 208 which holds the light source 202 thereon and is mounted on the rear fender 44, and a cover portion 210 which is mounted on the base portion 208 by ultrasonic welding or the like so as to cover the light source 202 from behind. The lens 206 is mounted on lower sides of the base portion 208 and the cover portion 210 using an adhesive agent or the like.
As shown in FIG. 11, an inner side of the base portion 208 is recessed rearward as viewed in a front view thus forming a recessed portion 212, and nut portions 216 which are threadedly engaged with bolts 214 for mounting the base portion 208 on the rear fender 44 are formed on left and right sides of the recessed portion 212 (see FIG. 12). A grommet 218 is provided at the center of the recessed portion 212. A power line 220 is introduced into the inside of the license lamp 48 through the grommet 218 and is connected to the printed circuit board 200 (see FIG. 13).
The printed circuit board 200 is fixed to the case member 204 in such a manner that one end of the printed circuit board 200 is inserted into a recessed portion 222 which is formed on the cover portion 210, and a screw 224 which is inserted into a hole 200a formed in the other end of the printed circuit board 200 is threadedly engaged with a nut portion 226 of the base portion 208 (see FIG. 14). The nut portion 226 is formed in the inside of the license lamp 48 and is arranged in the recessed portion 222 of the base portion 208.
Although the invention has been explained in conjunction with the preferred embodiment heretofore, the technical scope of the invention is not limited to the scope described in the above-mentioned embodiment. It is apparent to those who are skilled in the art that various modifications and improvements may be added to the above-mentioned embodiment. It is also apparent from the description of the Scope of Claims that embodiments to which such modifications and improvements are added also fall within the technical scope of the invention. Further, symbols with parenthesis described in the Scope of Claims are added in conformity with symbols in the attached drawings for facilitating the understanding of the invention and hence, it should not be construed that the invention is limited to elements to which symbols are given.
DESCRIPTION OF REFERENCE NUMERALS AND SIGNS


    10: lighting equipment
    12: motorcycle
    100: housing
    100a: rear surface wall
    102: outer lens
    104: extension cover
    106: inner lens
    110L, 110R: upper lamp
    112L, 112R: lower lamp
    114, 118, 202: light source
    116, 120, 132: reflector
    126L, 126R; extension member
    117a, 121a: concave surface portion
    117b, 121b, forwardly extending portion
    119, 123: inclined surface
    130: turn signal lamp
    140: signal-lamp driver
    142: headlight-use driver
    144: recessed portion
    146L, 146R: eaves portion
    152L, 152R: flange portion
    154, 155: gap
    156, 158, 200: printed circuit board
    160, 162: heat sink
    176L, 176R: vertical aiming axis

## Claims

1. A headlamp assembly for a saddle-type vehicle, the headlamp assembly comprising:
an upper light-emitting portion having a first light source and a first reflector which reflects light from the first light source toward a front side;
a lower light-emitting portion having a second light source and a second reflector which reflects light from the second light source toward the front side, the lower light-emitting portion arranged below the upper light-emitting portion;
a housing which supports the upper light-emitting portion and the lower light-emitting portion therein while covering the upper light-emitting portion and the lower light-emitting portion from behind;
a lens which covers a front side of the upper light-emitting portion and a front side of the lower light-emitting portion, while allowing a light emitted from the upper light-emitting portion and a light emitted from the lower light-emitting portion to pass therethrough;
a heat sink disposed inside of the housing for each light source, each of the heat sinks having an L shape as seen in side view, and configured so as to cover an upper side and a rear side of an adjacent one of the reflectors; and
a printed circuit board for each of the light sources, respectively, where each of the light sources are mounted on a lower surface of a corresponding one of the printed circuit boards, respectively, and an upper surface of each of the printed circuit boards is connected to the one of the heat sinks;
wherein an extension member is provided proximate the first reflector and extending in a substantially horizontal direction, such that the extension member approaches a front end of the first reflector from a front side thereof; and wherein a flange portion is provided extending downwardly from the lower edge of the first reflector.

2. The headlamp assembly for a saddle-type vehicle according to claim 1, wherein: the extension member is fixedly supported on the lens or on the housing, the upper light-emitting portion and the lower light-emitting portion are configured to be vertically adjusted integrally with each other relative to the housing during an aiming adjustment, and vertical aiming axes of the upper light-emitting portion and the lower light-emitting portion are arranged at a position close to the flange portion than an upper edge of the upper light-emitting portion or a lower edge of the lower light-emitting portion as viewed in a front view.

3. The headlamp assembly for a saddle-type vehicle according to claim 2, wherein the second light source comprises an LED, and light irradiated downwardly from the second light source is reflected forwardly by the second reflector.

4. The headlamp assembly for a saddle-type vehicle according to claim 3, wherein the second reflector includes a concave surface portion which reflects light from the second light source frontward, and a forwardly-extending portion extending forwardly from an end portion of the concave surface portion, and the flange portion extends downwardly to an extent that at least the concave surface portion is not visible through a gap.

5. The headlamp assembly for a saddle-type vehicle according to claim 2, wherein the second reflector includes a concave surface portion which reflects light from the second light source frontward, and a forwardly-extending portion extending forwardly from an end portion of the concave surface portion, and the flange portion extends downwardly to an extent that at least the concave surface portion is not visible through a gap.

6. The headlight assembly for a saddle-type vehicle according to claim 1, wherein the second light source comprises an LED, and light irradiated downwardly from the second light source is reflected forwardly by the second reflector.

7. The headlamp assembly for a saddle-type vehicle according to claim 6, wherein the second reflector includes a concave surface portion which reflects light from the second light source frontward, and a forwardly-extending portion extending forwardly from an end portion of the concave surface portion, and the flange portion extends downwardly to an extent that at least the concave surface portion is not visible through a gap.

8. The headlamp assembly for a saddle-type vehicle according to claim 1, wherein the second reflector includes a concave surface portion which reflects light from the second light source frontward, and a forwardly-extending portion extending forwardly from an end portion of the concave surface portion, and the flange portion extends downwardly to an extent that at least the concave surface portion is not visible through a gap.

9. The headlamp assembly for a saddle-type vehicle according to claim 1, further comprising an extension cover arranged in front of the upper and lower lamps, the extension cover configured to cover outer edge portions of each of the lamps, wherein the extension member is formed as a part of the extension cover.

10. The headlamp assembly for a saddle-type vehicle according to claim 1, wherein each of the first and second light sources respectively comprises an LED, and light irradiated downwardly from each light source is reflected forwardly by its associated reflector.

11. A headlamp assembly for a saddle-type vehicle, the headlamp assembly comprising:
an upper light-emitting portion having a first light source and a first reflector which reflects light from the first light source toward a front side;
a lower light-emitting portion having a second light source and a second reflector which reflects light from the second light source toward the front side, the lower light-emitting portion arranged below the upper light-emitting portion; a housing which supports the upper light-emitting portion and the lower light-emitting portion therein while covering the upper light-emitting portion and the lower light-emitting portion from behind;
a lens which covers a front side of the upper light-emitting portion and a front side of the lower light-emitting portion, while allowing a light emitted from the upper light-emitting portion and a light emitted from the lower light-emitting portion to pass therethrough;
a heat sink disposed inside of the housing for each light source, each of the heat sinks having an L shape as seen in side view, and configured so as to cover an upper side and a rear side of an adjacent one of the reflectors; and
a printed circuit board for each of the light sources, respectively, where each of the light sources are mounted on a lower surface of a corresponding one of the printed circuit boards, respectively, and an upper surface of each of the printed circuit boards is connected to the one of the heat sinks; and
an extension cover arranged in front of the upper and lower lamps, the extension cover configured to cover outer edge portions of each of the lamps, wherein the extension cover comprises an extension member situated proximate the first reflector and extending in a substantially horizontal direction, such that the extension member approaches a front end of the first reflector from a front side thereof; and wherein a flange portion is provided extending downwardly from the lower edge of the first reflector.

12. The headlamp assembly for a saddle-type vehicle according to claim 11, wherein: the extension cover is fixedly supported on the lens or on the housing, the upper light-emitting portion and the lower light-emitting portion are configured to be vertically adjusted integrally with each other relative to the housing during an aiming adjustment, and vertical aiming axes of the upper light-emitting portion and the lower light-emitting portion are arranged at a position close to the flange portion than an upper edge of the upper light-emitting portion or a lower edge of the lower light-emitting portion as viewed in a front view.

13. The headlamp assembly for a saddle-type vehicle according to claim 11, wherein the second reflector includes a concave surface portion which reflects light from the second light source frontward, and a forwardly-extending portion extending forwardly from an end portion of the concave surface portion, and the flange portion extends downwardly to an extent that at least the concave surface portion is not visible through a gap.