Abstract:
A motorcycle headlight assembly that has simplified structure that cost less to manufacture and assemble than a conventional headlight. The headlight assembly may enhance the rigidity of the headlight assembly and decrease the number of components. The headlight assembly can include a headlight, a right indicator, left indicator and a bodywork cover. The bodywork cover is connected to the headlight cap and configured to overlay the front part of the vehicle.

Description:
PRIORITY INFORMATION 
   The present application is based on and claims priority under 35 U.S.C. § 119(a-d) to Taiwanese Patent Application No. 093128715, filed on Sep. 22, 2004, the entire contents of which is expressly incorporated by reference herein. 
   BACKGROUND OF THE INVENTIONS 
   1. Field of the Inventions 
   The inventions relate to a headlight assembly structure for motorcycles, especially to a headlight assembly structure for scooter-type motorcycles. 
   1. Description of the Related Art 
   Scooter-type motorcycles are often used for transportation. These motorcycles can easily maneuver in high traffic areas and are convenient to park. Motorcycles typically have headlights for increasing the motorcycle driver&#39;s visibility and/or for alerting other people to the presence of the motorcycle. Turn indicators of the motorcycle can be used to inform other drivers that the motorcycle is going to change lanes, make a turn, and the like. 
     FIGS. 1 and 2  illustrate a conventional headlight assembly for scooter motorcycles. A headlight cap covering  80  is formed by matching and mounting several covers, such as a headlight cap  81 , a pair of indicator-mounting covers on the two sides of the cap  81 , and a bodywork cover  83 .  FIG. 2  illustrates an indicator-mounting cover  82  assembled with a corresponding indicator  84 . Although not illustrated, another indicator-mounting cover  82  and indicator  84  can be positioned on the other side of the cap  81 . The indicator-mounting covers and corresponding indicators are then matched with the headlight cap  81  and bodywork cover  83  and fixed by screw(s), thereby forming a headlight cap assembly. 
   With continued reference to  FIG. 2 , a bracket  85  is used hold the pair of indicators. To couple the indicators (e.g., the indicator  84 ) to the bracket  85 , the locking part  86  can be passed through a hole  87  of the bracket  85 . Nuts  88  can be threadably coupled to the locking part  86  to securely attach the indicator  84  to the bracket  85 . A power wire  89  can extend inwardly from each locking part, such as the locking part  86 . The wires  89   a ,  89   b  can converge and meet at the middle of the bracket  85  and are used to provide power from a power supply to the indicators. 
   Unfortunately, the illustrated headlight cap covering  80  is assembled by matching and mounting the headlight cap  81 , the pair of indicator-mounting covers on the two sides of the headlight, the bodywork cover  83 , etc. Therefore, the headlight assembly is a complex assembly with many components and, thus, may be difficult and extremely time-consuming to assemble. Additionally, gaps may be formed between components of the headlight assembly due to manufacturing tolerances and/or inappropriate component arrangement and assembly. Furthermore, some regulatory schemes for motorcycle fixtures may require that the indicators be separated by a relatively large distance, resulting in relatively large moments being applied to the headlight cap covering  80 . After extended use, the jointed components may become loose, and the indicators may sway, therefore adversely influencing the overall rigidity of the headlight assembly. Additionally, conventional headlight assemblies may have an unsuitable appearance and may not be waterproof. 
   Additionally, the indicators of conventional headlight assemblies are often fixed by an elongated member, such as the bracket  85 . The pair of indicators and the bracket  85  may be moved rearwardly to avoid contacting the headlight  90 . However, this increases the longitudinal length of the headlight cap and the overall size of the headlight cap covering  80 . 
   Furthermore, as shown in  FIG. 2 , the power wires  89   a ,  89   b  of the pair of indicators may be bent near the middle of the bracket  85 . The bent portions of the power wires  89   a ,  89   b  may be vulnerable and be prone to damaged. For example, the power wires  89   a ,  89   b  may become worn during the manufacturing process and/or aftermarket maintenance. 
   SUMMARY OF THE INVENTION 
   An aspect of the present invention includes a headlight assembly structure that is a portion of a motorcycle. The headlight assembly structure can have a relatively low number of components, improved rigidity, and/or improved overall strength. The headlight assembly structure can have a relatively low cost and simple structure. 
   In accordance with one aspect of the present invention, a scooter-type motorcycle has a headlight assembly structure. The headlight assembly structure comprises a headlight, a pair of indicators, a bodywork cover, and a forward cowling. The forward cowling defines a headlight cap which covers the headlight and is connected to the bodywork. The forward cowling and the bodywork cover are configured to overlay a front part of the motorcycle. The headlight and the pair of indicators are directly coupled to the headlight cap. 
   Another aspect of the present invention includes a motorcycle with a headlight assembly structure comprising a bracket having a right end and a left end. A cowling is configured to overlay a front part of the motorcycle. A headlight is housed within the cowling. The cowling is interposed between a right indicator and the right end of the bracket and between a left indicator and the left end of the bracket. The right indicator is coupled to the right end of the bracket and the left indicator is coupled to the left end of the bracket. 
   In some aspects, a method of producing a scooter-type motorcycle is provided. The method comprises positioning a headlight in a headlight cap. The headlight is secured to the headlight cap with at least one fastener. A bracket with a first hole at one end and a second hole at another end is provided. The bracket is positioned along an inner surface of the headlight cap such that the first and second hole are positioned at opposing sides of the headlight cap. A first indicator having a first locking part and a first power wire and a second indicator having a second locking part and a second power wire are provided. The first locking part and the first power wire are passed through the first hole. The second locking part and the second power wire are passed through the second hole. 
   According to some aspects, the headlight and the pair of indicators are all disposed on the headlight cap. The headlight assembly structure has a reduced number of components and can be easily installed. Thus, the headlight assembly structure does not have to be assembled on a production line for the motorcyles. Instead, the headlight assembly structure may be sub-assembled before being sent to the motorcycle production line, thus the delay along the motorcycle production line will be reduced. In addition, the headlight assembly structure may be assembled in a relatively short production time, because its components can be accurately matched and assembled. Additionally, when the headlight assembly structure is assembled, few or no gaps may be formed between its components. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other features, aspects and advantages of the present invention will now be described with reference to drawings that show a presently preferred arrangement that is intended to illustrate and not to limit the present invention and in which drawings: 
       FIG. 1  is a side view of a conventional scooter-type motorcycle having a headlight assembly; 
       FIG. 2  is an enlarged exploded perspective view of the conventional headlight assembly of  FIG. 1 ; 
       FIG. 3  is a side view of a scooter-type motorcycle having a headlight assembly structure; and 
       FIG. 4  is an enlarged exploded perspective view of the headlight assembly structure of  FIG. 3 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The following is a detailed description of one embodiment of a motorcycle  7 , with reference to  FIGS. 3 and 4 . As used herein, the term “motorcycle” is a broad term and is used in its ordinary meaning and includes, without limitation, scooters (e.g., scooter-type motorcycles including mopeds), motorbikes, and the like. As used herein, the terms “motorcycle” and “scooter-type motorcycle” may be used interchangeably. While the headlight assembly structure  1  is illustrated as employed on a scooter-type motorcycle, the headlight assembly structure can also be used on other types of motorcycles, all-terrain vehicles (“ATV”), snowmobiles, or other transportation vehicles. For the sake of convenience, the described headlight assembly structure  1  is mounted to a scooter-type motorcycle. In the following description, the terms “front,” “rear,” “left,” and “right” are used to describe the motorcycle  7  and its various components as viewed by a rider seated in a normal riding position. 
   As shown in  FIG. 4 , the headlight assembly structure  1  includes a headlight  2 , a pair of indicators  3   a ,  3   b , and a forward cowling  11  defining a headlight cap  4 . A bodywork cover  5  can be connected to the forward cowling  11 . As shown in  FIGS. 3 and 4 , the forward cowling  11  and bodywork cover  5  can cooperate to overlay the front part of the motorcycle  7 . 
   With continued reference to  FIG. 4 , the headlight cap  4  is configured to house one or more headlights  2 . In some embodiments, including the illustrated embodiment, the headlight cap  4  surrounds and houses at least a portion of a single headlight  2 . The headlight  2  may be a projector type headlight or other type of headlight known in the art. The headlight  2  may include a lamp body positioned and extending rearwardly of a forward facing opening  9  of the forward cowling  11 . 
   The headlight cap  4  can comprise a pair of cowling sides  41   a ,  41   b , which preferably extend forwardly from a front face  29  of the forward cowling  11 . The headlight cap  4  may be forwardly tapered and may have a generally circular cross-sectional profile as viewed from the front of the motorcycle  7 . The headlight cap  4  can have any suitable configuration for housing one or more headlights  2 . Additionally, the headlight assembly structure  1  can comprise a plurality of headlight caps  4 , each containing at least one headlight. 
   One or more of the indicators can be spaced from the illustrated headlight cap  4 . The illustrated motorcycle  7  has a pair of indicators  3   a ,  3   b . As used herein, the term “indicator” is a broad term and is used in its ordinary meaning and includes, without limitation, turn/signal indicators and the like. In the illustrated embodiment, the headlight cap  4  is interposed between the indicators  3   a ,  3   b . 
   The indicators  3   a ,  3   b  can be generally similar to each other and, accordingly, the following description of one of the indicators applies equally to the other, unless indicated otherwise. The indicator  3   a  has an elongated arm  18   a  extending between an indicator signal  19   a  and a locking part  31   a . The indicator signal  19   a  may comprise a light source used for signaling. The light source can be positioned within and protected by an indicator housing. 
   The headlight assembly structure  1  can include one or more forward brackets or bosses  39   a ,  39   b  each configured to receive and engage a corresponding indicator  3   a ,  3   b . In the illustrated embodiment, each bracket  39   a ,  39   b  is positioned between the headlight cap  4  and an edge of the forward cowling  11 . For example, the bracket  39   a  is interposed between the left side cowling  41   a  and a left edge  26  of the forward cowling  11 . The bracket  39   b  is interposed between the right side cowling  41   b  and a right edge  27  of the forward cowling  11 . The brackets  39   a ,  39   b  can be attached to the headlight cap  4  and/or the front face  29  of the forward cowling  11 . For example, the brackets  39   a ,  39   b  can be connected to and extend laterally from a corresponding side  41   a ,  41   b  of the headlight cap  4 . The brackets  39   a ,  39   b  can be any suitable mounting structure for engaging an indicator. 
   The forward brackets  39   a ,  39   b  can be removably or permanently attached to the forward cowling  11 . The forward cowling  11  and forward brackets  39   a ,  39   b  can have a one-piece construction. In some embodiments, the forward brackets  39   a ,  39   b  and the forward cowling  11  form a unity or monolithic body. Alternatively, the forward cowling  11  and the forward brackets  39   a ,  39   b  can have a multi-piece construction. For example, the forward brackets  39   a ,  39   b  can be mounted to the forward cowling  11  by screw(s), nut and bolt assemblies, and the like. 
   The pair of indicators  3   a ,  3   b  is coupled to the headlight cap  4  via the brackets  39   a ,  39   b , respectively. The brackets  39   a ,  39   b  can have one or more structures for engaging the indicators. In some aspects, each of the forward brackets  39   a ,  39   b  comprises one or more holes  42  that preferably extend through the associated bracket  39   a ,  39   b  and the forward cowling  11 . The illustrated brackets  39   a ,  39   b  each comprise a single hole  42 . The indicators  3   a ,  3   b  can be fixed relative to the headlight cap  4 . Any suitable attachment system or device can be used to couple the indicators  3   a ,  3   b  to the forward brackets  39   a ,  39   b , respectively. The indicator  3   a  can be mounted to the forward bracket  39   a  by inserting the locking part  31   a and the associated power wire  32   a  through the hole  42   a . The locking part  31   a  can comprise an externally threaded member sized to pass conveniently through the corresponding hole  42   a  and engage a nut. The nut can secure the locking part  31   a  to the forward cowling  11 . The indicator  3   b  can be mounted to the bracket  39   b  in a similar manner. 
   A bracket  6  is preferably configured to be positioned between the headlight cap  4  and at least a portion of the headlight  2 , preferably within the headlight cap  4 . The bracket  6  can be configured to extend between the locking parts  31   a ,  31   b  when the indicators  3   a ,  3   b  are attached to the forward cowling  11 . As shown in  FIG. 4 , the bracket  6  in the illustrated embodiment includes an elongated curved body shaped to pass along the inner surface of the headlight cap  4 . The illustrated bracket  6  has a somewhat U-shape. Alternatively, the bracket  6  can have a curved shape (e.g., semi-circular), angled shape, and/or other suitable shape. In some aspects, the bracket  6  is formed by bending or molding a material into a desired shape. 
   Each side of the bracket  6  has a hole for receiving the corresponding locking part and the power wire extending therefrom. For example, the illustrated bracket  6  has a hole  61  that receives the locking part  31   a  and the power wire  32   a . Each of the locking parts  31   a ,  31   b  is preferably locked to the bracket  6  by a nut  62   a ,  62   b , respectively. The connection between the indicators  3   a ,  3   b  and the forward cowling  11  results in enhanced rigidity, overall strength, and/or the absorption of vibrations from the pair of indicators  3   a ,  3   b . The design can also reduce and/or prevent cracking or damage of the forward cowling  11  and enhance the appearance around joined parts. 
   In addition, when replacing a bulb of the headlight  2 , or during aftermarket repairs, there is no need to dismount the bracket  6  or the indicators  3   a ,  3   b . The headlight  2  can be replaced or repaired while the bracket  6  remains along the inner surface of the headlight cap  4 , thus significantly enhancing the convenience of maintaining the headlight  2 . 
   One or more fasteners  63  can be connected to the bracket  6  and configured to hold one or more wires. The illustrated fastener  63  has an elongated shape and may be formed on the sides of the bracket  6  to fasten and guide an associated power wire  32   a  along the side of the bracket  6 . Each of the wires  32   a ,  32   b  extends from the respectively locking part  31   a ,  31   b  and can converge centrally and is connected to a power supply. Therefore, the headlight assembly structure allows for power wires  32   a ,  32   b  without hindering the configuration of other components. Furthermore, damage to the power wires during mounting, installation, and/or dismounting for maintenance can be reduced or avoided. 
   In addition, although the illustrated bracket  6  is preferably configured to be positioned in the space between the headlight cap  4  and above the headlight  2 , the bracket  6  can be in other locations. For example, the bracket  6  may also be configured for positioning in the space between the headlight cap  4  and below the headlight  2 , or any place between the headlight cap  4  and the headlight  2 . 
   With continued reference to  FIG. 4 , the brackets  39   a ,  39   b  can include one or more positioning protrusions (e.g., the protrusion  45 ). The bracket  39   a  has a pair of protrusions  45 . Each protrusion  45  can be spaced from, but preferably proximate to, a corresponding hole  42 . The protrusions  45  can be used to position the indicators  3   a ,  3   b . The brackets  39   a ,  39   b  each have a pair of protrusions  45 . However, any suitable number of protrusions  54  can be used. 
   One embodiment of assembling the headlight assembly structure  1  is described below. During mounting, the headlight  2  is first placed in the headlight cap  4  and adjusted to an appropriate position. After positioning, the headlight  2  is locked to the headlight cap  4  with bolts. After that, the bracket  6  can be positioned, preferably keyed, on the inner surface of headlight cap  4  and adjusted to an appropriate position according to the mounting position of the locking parts  31   a ,  31   b  and other components. Each locking part  31   a ,  31   b  and associated power wire  32   a ,  32   b  is passed through the hole of the corresponding bracket  39   a ,  39   b . The illustrated locking part  3 l a  and power wire  32   a  are passed through the hole  42  and the hole  61  of the bracket  6 . The locking parts  31   a ,  31   b  are secured to the bracket  6  by nuts  62   a ,  62   b . Each power wire  32   a ,  32   b  is configured to extend along the surface of the bracket  6  and is preferably connected to a power supply. The power wire  32   a  is held to the bracket  6  by an optional fastener  63 . 
   A headlight mounting structure  43  preferably is formed by the headlight cap  4  to facilitate the assembly process. The mounting structure  43  can be a gimbal system (e.g., a rim pivot gimbal) formed on the inner surface of the headlight cap  4  to locate the headlight  2 , preferably temporarily. Thus, during mounting, the headlight  2  may be positioned relative to the headlight mounting structure  43  to locate the headlight  2 , whereby the headlight  2  may swing fore and aft slightly, or move along a circular path so as to adjust the position of the bracket  6 . The headlight mounting structure  43  can be any suitable structure for positioning the headlight  2 . After positioning, the headlight  2  is locked to the headlight cap  4  with fasteners (e.g., one or more nut and bolt assemblies, set screws, etc.) or other mounting structure or devices. Thus, convenience and accuracy during mounting and positioning are improved by the headlight mounting structure  43 . 
   In addition, one or more bracket stoppers  44  are optionally formed on the inner surface of the headlight cap  4  to locate bracket  6 , preferably temporarily. During mounting, the bracket  6  may engage the bracket stopper  44  to locate bracket  6 . The stopper  44  can be a recess or protrusion along the interior surface of the headlight cap  4 . The bracket  6  can have structure (e.g., a recess, protrusion, etc.) configured to mate with the stopper  44 . The bracket  6  can be rigidly mounted to the forward cowling  11 . In other embodiments, there can be play between the bracket  6  and the forward cowling  11  to allow some movement of the bracket  6 . After being adjusted to a desired position in accordance with the mounting position of the locking parts  31   a ,  31   b  and other components, the locking parts  31   a ,  31   b  are locked to the bracket  6 . Thus, convenience and accuracy during mounting and positioning are enhanced by using the bracket stopper  44 . 
   In addition, the headlight  2  and the pair of indicators  3   a ,  3   b  are preferably approximately horizontally positioned relative to the ground. Therefore, visual identification of the vehicle&#39;s light signals is improved. In other embodiments, the indicators  3   a ,  3   b  are vertically offset from the headlight  2 . In view of the present disclosure, a skilled artisan can select the desired position of the headlight  2  and the indicators  3   a ,  3   b.    
   Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.