Cover Headlamp Designs for Enhanced Protection

Headlamps are some of the most vulnerable pieces on any bike or car. Sitting at the very front of any vehicle, headlamps receive the beating of stones, dirt and debris, UV exposure, high-pressure washing, and extreme temperatures. A yellowed, cracked or wet headlamp does not only look ugly, it can be downright dangerous in the night. Hence cover headlamps, protective lenses or covers that are attached over the existing OEM headlamp, must be a standard accessory on off-road vehicles, work trucks, and drivers who may encounter rugged conditions on their daily commute.

As manufacturers of LED multifunctional lighting, Danyang Yeya Opto-Electronic Company Limited precision molds cover headlamp designs. The following are four ways today's cover light designs offer enhanced protection.

1. Impact-Resistant Polycarbonate Construction

The most important purpose of a headlamp cover is to absorb impact forces that could break or shatter the built-in lens. Oncoming traffic, branches on trails, and parking lot bumps are all dangers. Untreated or acrylic plastic cover headlamps are vulnerable to cracking or spider-veining when hit.

Danyang Yeya produces cover headlamps with high quality impact modified polycarbonate. This material is the same material used in making bullet proof glazing and safety shields. Does not fracture, has little tendency to crack, and does not break easily when hit hard. Polycarbonate cover headlamps give a protective layer for the costly factory headlamp on off road vehicles, ATVs, UTVs and construction equipment vehicles. Cover can be replaced when scratched and damaged, which is much less expensive than replacing an entire headlamp assembly.

2. UV-Stabilized Coatings to Prevent Yellowing

Plastic headlamp lenses are killed by the sun's rays. Exposing polycarbonate to UV radiation will cause the molecular structure of the material to be altered, resulting in yellowing, hazing and micro-cracking. If a cover headlamp is not UV protected it will soon get cloudy and will not serve its purpose.

All cover headlamps are multi-layer hard coated by Danyang Yeya. This coating contains UV absorbers which prevent more than 98 percent of harmful radiation from reaching the underlying polycarbonate layer. This coating also protects against scratches from car washing, wiping and road impurities. Consequently, our cover headlamps are crystal clear for years and keep protecting as well as optically performing for many years. This UV stability is an essential specification when in sunny areas or where vehicles are kept outside.

3. Sealed Designs with Moisture Prevention

A frequent failure mode of headlamps is moisture ingress. The condensation within the lamp causes light scattering, output loss and is a possibility of corrosion on reflectors or LED boards. Rain, pressure washers and humidity should not be able to get under cover headlamps, or between the cover and the factory lens.

Danyang Yeya designs the headlamps features precisely molded gasket channels and optionally breather vents. A closed-cell foam gasket or silicone gasket forms a water-tight seal with the headlamp bezel or housing, but permits thermal expansion. We supply fully potted covers for extreme applications such as forklifts, trailers and marine applications where openings are not needed. The quality control process comprises water ingress testing to ensure IP65/67 rating. Cover head lamps that will prevent moisture from entering in all types of weather conditions are provided for customers.

4. Custom Fitments for OEM and Aftermarket Applications

Most so called “universal” cover headlamps are of a generic size and may not fit your helmet properly which can cause dirt to get trapped inside or make the headlamp appear not to fit. The correct curving, mounting and outer dimensions of a specific vehicle model must be matched by a proper cover headlamp. This is especially critical for sleeker, more sophisticated car headlamp designs.

In our OEM / ODM service, we provide custom cover headlamp designs based on the uniqueness of the customer's products. We make covers that snap, clip or bolt to factory headlamps of popular models, such as BMW, Toyota, Ford, Honda, Porsche, Vespa, Yamaha, etc., without modification. Our professional engineers create new tooling if needed, for new models or unique applications, using a 3D scan or dimensions supplied by the customer. The characteristics of quick delivery, reasonable pricing and strict quality control from raw material to product are common.

Summary

The key characteristics of cover headlamp designs for providing higher level of protection are as follows: Impact-resistant polycarbonate construction, UV-stabilized coating, sealed moisture-prevention system, and custom-fitments for specific vehicles. Danyang Yeya Opto-Electronic Company Limited has merged the innovative engineering, quality first production and quick response OEM/ODM support to make cover headlamps that maintain the factory's light performance and appearance. For off road vehicles, vehicles used daily, or heavy equipment, please call us to talk about your needs and get samples!