Private Label Bicycle Front Light with Horn

This device integrates a forward‑facing LED illumination module and a piezoelectric horn into a single housing suitable for mounting on bicycle handlebars. The design targets OEMs that require a configurable front‑lighting and audible‑warning unit for private‑label distribution.

Optical Performance

The LED array delivers a typical luminous flux of 150 lm at a nominal drive current of 350 mA. Beam concentration is defined by a TIR lens producing a full‑width‑half‑maximum angle of 12°, suitable for illuminating the road ahead without excessive glare to on‑coming traffic. Colour temperature is set at 6000 K (±300 K) to provide a white output comparable to daylight.

Audible Signal Characteristics

The horn element is a sealed piezo transducer driven by a square‑wave signal at 2.8 kHz. Measured sound pressure level at 1 m distance is 95 dB (A) with a tolerance of ±3 dB. The horn can be activated independently of the light via a separate switch contact or wired in parallel for simultaneous operation.

Power Supply and Electrical Interface

Operating voltage range is 6 V DC to 16 V DC, accommodating common bicycle dynamo outputs and battery packs. Typical current draw is 120 mA for the LED at full brightness and 20 mA for the horn during activation. Electrical connection is made through a 2‑pin JST‑PH connector rated for 2 A, with pin‑out defined as V+ (pin 1) and GND (pin 2).

Environmental Protection

The assembly meets IP65 rating per IEC 60529, providing protection against dust ingress and low‑pressure water jets from any direction. Operating temperature range is –20 °C to +50 °C, and the unit survives storage temperatures from –40 °C to +85 °C. Shock resistance complies with IEC 60068‑2‑27 (30 g, 11 ms half‑sine).

Mechanical Design and Mounting

Overall dimensions are 45 mm × 30 mm × 22 mm (L × W × H) excluding the mounting bracket. Mass is 28 g. The housing is constructed from UV‑stabilized polycarbonate with a silicone gasket for sealing. Mounting options include a stainless‑steel strap clamp (fits bar diameters 22–32 mm) and a proprietary quick‑release adapter.

• Strap clamp with nylon liner to prevent bar surface damage
• Quick‑release adapter for tool‑free installation
• Optional rubber spacer for oversized handlebars

Private‑Label Customization

OEMs can specify housing colour (Pantone‑matched polycarbonate), lens shape (flat, domed, or asymmetric), and firmware parameters such as LED brightness levels, horn pulse pattern, and low‑voltage cutoff. Branding can be applied via pad‑printing on the housing surface or laser etching on the lens.

• Housing colour: black, white, silver, or custom Pantone
• Lens geometry: flat (standard), domed (increased diffusion), asymmetric (offset beam)
• Firmware: steady, flashing (1 Hz), or horn‑only mode
• Branding: pad‑print (up to 2 colours) or laser etch

Typical Applications

Urban commuting cyclists benefit from the combined illumination and audible warning to increase visibility at intersections. Off‑road riders use the focused beam to identify trail obstacles while the horn alerts wildlife or other trail users. Fleet operators and bike‑sharing services select the unit for its low maintenance, standardized interface, and ability to display corporate branding.

Quality Control and Testing

Each production lot undergoes luminous flux measurement using an integrating sphere calibrated to CIE 127. Horn output is verified with a Class 1 sound level meter at 1 m. IP compliance is confirmed by spraying water at 3 kPa from a nozzle per IEC 60529. Functional testing includes 500 cycles of horn activation and 1000 hours of LED aging at elevated temperature.

Comparison of Standard and Custom Options

Frequently Asked Questions

For technical datasheets, sample requests, or to discuss a private‑label project, please contact our engineering team.