Headlamp Installation Structure With Elastic Gap Sealing

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Solution Overview

Problem

Existing headlamp designs in straddle-type vehicles suffer from light leakage and compromised appearance due to large gaps between the headlamp and the lamp cover, which can impair the rider's field of vision and deteriorate the vehicle's aesthetics.

Innovation Solution

An installation structure for the headlamp that includes a lens, a lamp cover with an opening, and an elastic cover to close the gap between the headlamp and the lamp cover, allowing the headlamp to move relative to the lamp cover for optical axis adjustment while the elastic cover seals the gap, preventing light leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the opening of the lamp cover is made larger to allow headlamp movement for optical axis adjustment, then the headlamp can be adjusted independently, but the gap between the headlamp and the opening increases causing light leakage and appearance deterioration

Engineering Contradiction:

Improveoptical axis adjustment capabilityVSAvoidlight leakage

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies a flexible black sheet material that can deform and adapt to the gap between the headlamp and lamp cover opening. This flexible film closes the gap effectively while allowing the headlamp to move for optical axis adjustment, preventing light leakage without restricting the adjustment capability.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If the opening of the lamp cover is made larger to allow headlamp movement for optical axis adjustment, then the headlamp can be adjusted independently, but the appearance of the vehicle is deteriorated

Engineering Contradiction:

Improveoptical axis adjustment capabilityVSAvoidappearance

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The flexible black sheet material not only closes the gap to prevent light leakage but also improves the appearance by providing a clean, finished look. The black color and flexible nature allow it to conform to the gap area aesthetically while the headlamp moves for adjustment.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible black sheet acts as an intermediary element between the headlamp and the lamp cover opening. It mediates the conflict between allowing headlamp movement and maintaining appearance by filling the visual gap created by the larger opening.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If a rigid seal is used to close the gap between the headlamp and the opening, then light leakage is prevented, but the headlamp cannot be moved for optical axis adjustment

Engineering Contradiction:

Improvelight leakage preventionVSAvoidoptical axis adjustment capability

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The patent specifically uses a flexible black sheet material that provides sealing functionality while maintaining flexibility. This allows the headlamp to move for optical axis adjustment while the flexible sheet continuously closes the gap to prevent light leakage, unlike rigid sealants or gaskets.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible black sheet dynamically adapts to the changing gap as the headlamp moves for optical axis adjustment. Rather than being a fixed rigid seal, the flexible material can deform and reposition itself to maintain the seal during adjustment movements.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution maintains the optical axis adjustment functionality while enhancing the vehicle's appearance and preventing light leakage, thereby ensuring clear visibility for the rider.

Implementation Method 1

an elastic cover configured to close a gap between the headlamp and the opening of the lamp cover

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20260015055A1Installation structure for headlamp

Publication Date: 2026.01.15 SUZUKI MOTOR CORP

AI summary

An installation structure for a headlamp includes a headlamp including a lens configured to emit irradiation light toward a front of a vehicle, a lamp cover having an opening through which the lens is exposed, and an elastic cover configured to close a gap between the headlamp and the opening of the lamp cover. The headlamp is configured to be moved with respect to the lamp cover to adjust an optical axis. The elastic cover closes the gap between the headlamp and the opening of the lamp cover regardless of a direction of the optical axis of the headlamp.