Bicycle suspension fork assembly

A suspension fork assembly is mounted to the front part of a bicycle frame and includes a fork column, a fork shoulder unit, a pair of suspension assemblies, a connector and a lamp mounting unit. The fork column is rotatably mounted to the front part of the frame. The fork shoulder unit is secured at the center thereof to the bottom end of the fork column and extends laterally there from in either direction. Each suspension assembly is secured to a respective end of the fork shoulder unit. The shaft of the front wheel is mounted to the bottom ends of the suspension assemblies. The connector has an arch-like configuration and connects and reinforces the suspension assemblies while avoiding contact with the front wheel. The lamp mounting unit is disposed on a top surface of the connector and a front lamp can be mounted thereto.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to Japanese Patent Application No. 2004-331679. The entire disclosure of Japanese Patent Application No. 2004-331679 is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention generally relates to a bicycle suspension fork assembly. More specifically, the present invention relates to a bicycle suspension fork assembly that is mounted to the front part of the frame of a bicycle.

2. Background Information

Bicycling is becoming an increasingly more popular form of recreation as well as a means of transportation. Moreover, bicycling has become a very popular competitive sport for both amateurs and professionals. Whether the bicycle is used for recreation, transportation or competition, the bicycle industry is constantly improving the various components of the bicycle. One component that has been extensively redesigned is the bicycle suspension fork.

Suspension forks are widely used in bicycle front forks in recent years. When the bicycle travels on a path having rough surfaces, the suspension fork prevents vibrations from being transmitted to the rider thereby enabling a comfortable ride. A mud guard and an illumination device, such as a front lamp, may be mounted to the front fork. However, because a suspension fork does not have dedicated mounting units the mounting of devices such as a mud guard or illumination device is difficult.

Accordingly, a suspension fork to which a mud guard and an illumination device can be easily mounted has been developed (Japanese Patent Laid-Open Publication No. 2002-193166). The conventional suspension fork to which a mud guard and an illumination device can be easily mounted includes a fork column that is rotatably mounted to the head tube in the front part of the frame, a fork shoulder unit, a pair of suspension assemblies and a horseshoe-shaped connector called a ‘brace’ that connects the suspension assemblies. The fork shoulder unit extends laterally in either direction from the center of the bottom end of the fork column, and the top end of each suspension assembly is secured to either end of the shoulder unit. The front wheel is rotatably mounted to the bottom ends of the suspension assemblies. Each suspension assembly has a cylinder and a rod that moves forward and backward relative to the cylinder. Upright-type suspension assemblies in which the rods are mounted to the fork shoulder unit and the front wheel is mounted to the cylinders are generally used. The connector is formed in an arch shape and connects and reinforces the suspension assemblies while avoiding contact with the wheel. The connector is integrally formed with the cylinders. In the conventional suspension fork, separate members comprising multi-purpose mounting members are mounted to the connector in order to enable mounting of a mud guard and an illumination device.

In the conventional suspension fork, multi-purpose mounting members are mounted to the connector. As a result, component parts that are mounted around the suspension fork, such as a front lamp and a mud guard, can be efficiently mounted. However, because multi-purpose mounting members are used, the number of component parts increase, leading to an increase in weight. In addition, because multi-purpose mounting members must be mounted, the mounting of the mud guard or illumination device is a cumbersome operation.

In view of the above, it will be apparent to those skilled in the art from this disclosure that there exists a need for an improved bicycle suspension fork assembly that is light weight and easily mounted. This invention addresses this need in the art as well as other needs, which will become apparent to those skilled in the art from this disclosure.

SUMMARY OF THE INVENTION

An object of the present invention is to enable mounting of an illumination device on a bicycle suspension fork assembly without an increase in the number of component parts.

In accordance with a first aspect of the present invention, a bicycle suspension fork assembly is provided that includes a fork column, a fork shoulder unit, first and second suspension assemblies, a connector and an illumination device mounting unit. The fork column is configured and arranged to be rotatably mounted to a front part of a frame of a bicycle. The fork shoulder unit has a center portion with a bottom end of the fork column secured thereto and has first and second arms extending laterally in opposite directions from the center portion. The first and second suspension assemblies are secured to end portions of the first and second arms of the fork shoulder unit, respectively. The arch shaped connector is configured and dimensioned to connect the first and second suspension assemblies. The illumination device mounting unit is disposed on a top surface of the connector for mounting an illumination device. The illumination device mounting unit has a concave mounting area across a cross-sectional width of the illumination device mounting unit.

With this suspension fork assembly, when it is mounted to the frame, an illumination device can be directly mounted to the connector because an illumination device mounting unit is disposed on the top surface of the connector. As a result, an illumination device can be mounted to the suspension fork assembly without using an extra component part such as a multi-purpose mounting member. Here, because an illumination device mounting unit is disposed on the connector of the suspension fork assembly, an illumination device is mounted without an increase in the number of component parts. Furthermore, because the purpose of the connector is to connect and reinforce the suspension assemblies as described above, the connector is formed to have a relatively high rigidity. Therefore, the construction in which an illumination device is directly mounted to the connector has a high rigidity and thereby ensures that the optical axis of the illumination device is not easily affected by the vibrations that occur during the travel of the bicycle.

The bicycle suspension fork assembly pertaining to a second aspect of the present invention comprises the bicycle suspension fork assembly according to the first aspect of the present invention, wherein the suspension assemblies each have a rod that is secured to the fork shoulder unit and a cylinder in which the rod is housed such that it can move axially therein. The wheel axle is mounted to the bottom end of the cylinder and the connector connects the cylinders in front of the rods. Since a connector is essential in an upright type suspension fork with rods mounted to a fork shoulder unit in order to reinforce the cylinders, such a connector is disposed in front of the rods. A front lamp comprising an illumination device that provides forward illumination can be easily mounted without an increase in the number of component parts on the connector disposed in front of the rods.

The bicycle suspension fork assembly pertaining to a third aspect of the present invention comprises the bicycle suspension fork assembly according to the second aspect of the present invention, wherein the connector is integrally formed with the cylinders. In this case, because the connector is integrally formed with the cylinders, the rigidity of the suspension increases.

The bicycle suspension fork assembly pertaining to a fourth aspect of the present invention comprises the bicycle suspension fork assembly according to any of the first through third aspects of the present invention, wherein the illumination device mounting unit has a concave mounting area that forms a depression in the connector.

The bicycle suspension fork assembly pertaining to a fifth aspect of the present invention comprises the bicycle suspension fork assembly according to the fourth aspect of the present invention, wherein the concave mounting area has an arc-shaped curved surface to which an illumination device can be mounted such that it can move around the lateral axis thereof. In this case, the optical axis of the illumination device mounted to the illumination device mounting unit can be adjusted up and down.

The bicycle suspension fork assembly pertaining to a sixth aspect of the present invention comprises the bicycle suspension fork assembly according to the fourth aspect of the present invention, wherein the concave mounting area has a hemispherical recess to which an illumination device can be mounted such that it can move around the lateral and vertical axes thereof. In this case, the optical axis of the illumination device mounted to the illumination device mounting unit can be adjusted not only vertically but also horizontally.

The bicycle suspension fork assembly pertaining to a seventh aspect of the present invention comprises the bicycle suspension fork assembly according to any of the first through sixth aspects of the present invention, wherein the suspension fork assembly further includes a mud guard mounting unit that is disposed on the bottom surface of the connector that faces the illumination device mounting unit. In this case, an illumination device and a mud guard can be mounted simultaneously, which facilitates the mounting of such component parts. In addition, because even if the suspension fork assembly moves up and down, the mud guard similarly moves up and down together with the connector. The distance between the mud guard and the wheel stays constant at all times and the splashing of muddy water or the like can be more effectively controlled.

According to the present invention, because an illumination device mounting unit is disposed on the connector, an illumination device can be mounted without an increase in the number of component parts. Furthermore, because an illumination device can be directly mounted on the connector, which has a relatively high rigidity, the optical axis of the illumination device is not easily affected by vibrations that occur when the bicycle is ridden.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially toFIG. 1, a bicycle5in which one embodiment of the present invention is applied has a frame body12that is bent in a letter ‘V’ shape as well as a frame11having a bicycle suspension fork assembly13comprising one embodiment of the present invention. The bicycle5also has a drive unit14movably mounted to the bottom part of the frame body12, a front wheel16fmounted to the ends of the bicycle suspension fork assembly13, a rear wheel16rmounted to the rear end of the drive unit14and a handle unit15connected on top of the bicycle suspension fork assembly13. The bicycle5also has front and rear disk brake devices8f,8r, a generator hub17on a hub shaft17aand the handle unit15. The generator hub17is mounted in the center of the front wheel16f, and the hub shaft17athereof is detachably secured to the bottom ends of the bicycle suspension fork assembly13. The handle unit15has a handle stem18that is mounted to the bicycle suspension fork assembly13and a handlebar19that is secured to the handle stem18. The frame body12has a head tube12band a hanger unit12athat protrudes downward from a bent area of the frame body12. The drive unit14, having a suspension function, is mounted to the hanger unit12a.

As used herein to describe the present invention, the following directional terms “front, forward, rear, rearward, above, up, downward, down, vertical, horizontal, below, right and left and transverse” as well as any other similar directional terms refer to those directions of a bicycle equipped with the present invention and based on the perspective of the rider of the bicycle. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a bicycle equipped with the present invention and from a viewpoint behind the bicycle.

The suspension fork13is rotatably mounted to the head tube12bin the front part of the frame body12, as shown inFIGS. 2 and 4, and is used to steer the front wheel16f. The bicycle suspension fork assembly13is an upright-type, and is mounted to the head tube12bsuch that it can rotate around an angled axis. The handle stem18is connected to the top of the bicycle suspension fork assembly13, and the hub shaft17aof the front wheel16fis mounted to the bottom thereof. The bicycle suspension fork assembly13has a fork column20that is rotatably mounted to the head tube12b, a fork shoulder unit22that is secured to the bottom end of the fork column20, suspension assemblies24aand24bthat are secured to either end of the fork shoulder unit22, a connector26that connects the suspension assemblies24aand24b, a lamp mounting unit or an illumination device mounting unit28for mounting a front lamp or an illumination device37, and first and second mud guard mounting units29a,29bfor mounting a mud guard38.

The fork column20comprises a metal pipe member, for example, and is rotatably supported by the head tube12b. The handle stem18is secured to the top end of the fork column20. The bottom end of the fork column20is inserted in the center of the fork shoulder unit22and is secured therein using an appropriate means such as press fitting, screw fitting or welding.

The fork shoulder unit22comprises a metal molded member, for example, and has in the center thereof a cylindrical column securing unit22ato which the fork column20is mounted. The fork shoulder unit22also has a pair of arms22bthat extend laterally in either direction from the column securing unit22awhile curving downward, as well as a pair of cylindrical suspension mounting units22cthat are formed at the ends of the arms22b.

The suspension assemblies24aand24beach have a rod34that is secured to one of the suspension mounting units22cdisposed at either end of the fork shoulder unit22, and a cylinder36in which the rod34is housed such that it can axially move therein. Each cylinder36has a dampening mechanism (not shown) comprising a hydraulic system, pneumatic system, coil spring or rubber, or a combination thereof disposed between the rod34and the cylinder36. The dampening mechanism is of a conventional type and will not be detailed herein.

The rods34comprise metal pipe members, the surfaces of which are plated with nickel chrome, for example. The rods34are secured to the suspension mounting units22cat the top ends thereof using bolts, for example. The lower parts of the rods34are inserted in the cylinders36such that they can move axially therein while being supported by the cylinders36.

The cylinders36each comprise a cylindrical member having an opening at the top end thereof, and also have a front claw36aby which to secure the hub shaft17aof the front wheel16fat the bottom end of the cylinder36. The connector26is integrally formed at the front part of the top end of each cylinder36. A caliper mounting unit (not shown) by which to mount the brake caliper60of the front disk brake apparatus8fis disposed on the cylinder36belonging to the left suspension assembly24a.

It will be apparent to one of skill in the art that it is also acceptable if the connector26comprises a separate member and is secured to the cylinders36using bolts or the like, for example. In addition, a brake seat of the brake caliper60can be mounted to the connector26.

The connector or brace26of the bicycle suspension fork assembly13connects and reinforces the cylinders36of the suspension assemblies24aand24b. The connector26further reinforces the bicycle suspension fork assembly13. The connector26has a pair of securing units26aeach disposed on one of the cylinders36and a bridge26bthat connects the securing units26a. The bridge26bis formed such that it is curved in an arch-like horseshoe configuration in order to connect the cylinders36in front of the rods34while avoiding contact with the front wheel16f.

The lamp mounting unit28is disposed on the top center surface of the connector26, as shown inFIGS. 3 and 4. The lamp mounting unit28is located essentially in the lateral center of the bicycle5. The lamp mounting unit28has a concave mounting area40that forms a depression in the center of the lamp mounting unit28. However, while the lamp mounting unit28comprised a concave mounting area in the embodiment described above, it will be apparent to one of skill in the art that the lamp mounting unit28may comprise a protrusion.

The bicycle suspension fork assembly13further includes the front lamp37and the mud guard38. The concave mounting area40has an arc-shaped curved surface40ato which the front lamp37can be mounted such that it can move around a lateral axis of the concave mounting area40. In other words, the arc shaped curved surface40ais configured and arranged to change a vertical position of beam of light from the front lamp37when the front lamp37is mounted on the concave mounting area40. The curved surface40ais curved so as to be recessed downward.

A bolt through-hole44in which a securing bolt42is inserted in order to mount the front lamp37is formed in the lamp mounting unit28such that it runs vertically through the connector26. The bolt through-hole44has some allowance relative to the bolt42for the vertical adjustment of the optical axis of the front lamp37. Specifically, the bolt thorough-hole44is formed in a configuration that is slightly oval from front to back rather than in a perfect circle. This bolt through-hole44is preferably formed such that the opening thereof is positioned in the concave mounting area40. Such a construction enables the securing bolt42to be hidden from external view and improves the design of the area around the connector26.

Referring now toFIGS. 2–4, the first and second mud guard mounting units29a,29bof the bicycle suspension fork assembly13will now be discussed. The first mud guard mounting unit29ais disposed on the bottom center surface of the connector26that faces the lamp mounting unit28. The first mud guard mounting unit29aincludes a curved mounting surface29cand protrusions29d. The curved mounting surface29cis formed in the first mud guard mounting unit29asuch that it engages with the curved top surface of the mud guard38. In addition, the protrusions29dthat can provisionally position the mud guard38in a flexible fashion are formed on either or both sides of the first mud guard mounting unit29a.

The second mud guard mounting units29bare integrally formed on the rear surfaces of the cylinders36. The second mud guard mounting units29beach have a stay mounting unit29fby which to secure the mud guard stay38a.

The front lamp37for mounting to the lamp mounting unit28operates using the electric power from the generator hub17or a built-in battery, for example. As shown inFIGS. 3–5, the front lamp37has a lamp unit46that houses a light-emitting element such as a light bulb or LED and a mounting unit47by which to mount the lamp unit46to the lamp mounting unit28. The front lamp37includes a detachable cover member50that covers the mounting unit47, a clear lens46a, a crevice unit46band a through-hole46c. The clear lens46ais mounted to the front of the lamp unit46. A crevice unit46bfor mounting a bracket48of the mounting unit47is formed behind the lamp unit46. A through-hole46cthrough which is inserted a mounting bolt52is formed in the crevice unit46b. The mounting unit47has a bracket48to which the lamp unit46is mounted such that it can move around the lateral axis thereof.

The bracket48of the mounting unit47is formed by press-molding a metal plate, for example. The bracket48includes a mounting unit48ahaving an arc-shaped member configured such that it travels along the curved surface40aof the concave mounting area40of the lamp mounting unit28. The bracket48further includes a standing unit48bthat extends upward from the mounting unit48a, and a pair of right and left fork end units48cthat extend rearward from either end of the top end of the standing unit48b. There is a gap between the fork end units48cin which the crevice unit46bof the lamp unit46can be grasped. The bracket48also has a mounting hole48d, a nut unit48eand a through-hole48f. The mounting hole48dthrough which the mounting bolt52can be inserted is formed on one fork end unit48c(the left one inFIG. 4), while the nut unit48ewith which the mounting bolt52engages is formed on the other fork end unit48c(the right one inFIG. 4). The through-hole48fthrough which the securing bolt42is inserted is formed in the mounting unit48a. A nut56, which engages the securing bolt42, is secured on the top surface of the mounting unit48asuch that it is coaxial with the through-hole48f.

The cover member50of the front lamp37contains a space in which the bracket48of the mounting unit47can be housed. The cover member50can be split laterally, such that it can cover the bracket48after the bracket48is mounted to the lamp mounting unit28. The cover member50includes a white reflector plate49that is mounted to the front surface of the cover member50.

It will be apparent to one of skill in the art that rather than providing the concave mounting area40of the lamp mounting unit28, which includes the arc-shaped curved surface40ain order to enable vertical adjustment of the optical axis around the lateral axis of the front lamp37, the optical adjustment need not occur using the lamp mounting unit28. For example, in the above embodiment, the bracket48may be designed to permit optical axis adjustment of the bracket48on the mounting unit28. In this case, a gap that can absorb the optical axis adjustment may be disposed between the cover member50and the lamp unit46.

The mud guard38is disposed around the front wheel16fwith a slight gap therebetween such that it covers the front wheel16f, as shown inFIGS. 2–4. The mud guard38is a member made of synthetic resin, for example, and has mud guard stays38athat extend toward the second mud guard mounting units29bof the bicycle suspension fork assembly13. The mud guard38is mounted to the bicycle suspension fork assembly13via the first and second mud guard mounting units29a,29b. A through-hole38bthrough which the securing bolt42is inserted is formed in the mud guard38at a position facing the first mud guard mounting unit29a. In addition, a sunken seat area38cin which the head of the securing bolt42is housed is formed around the through-hole38b.

In a bicycle having this construction, when the front lamp37is to be mounted, while the front wheel16fis removed, the mud guard38is provisionally mounted to the first mud guard mounting unit29ausing the protrusions29d. The front lamp37is then placed on the lamp mounting unit28, as shown inFIG. 3. The securing bolt42is then inserted from the bottom surface of the mud guard and screwed into the nut56. The securing bolt42is provisionally tightened to the nut56, and after adjustment of the optical axis around the lateral axis of the front lamp37as shown inFIG. 6, the securing bolt42is further tightened. Finally, the cover member50is placed around the bracket48, whereupon the mounting of the front lamp37is completed.

In this embodiment, because the lamp mounting unit28is disposed on the connector26of the bicycle suspension fork assembly13, an illumination device such as the front lamp37can be easily mounted around the suspension fork13without an increase in the number of component parts. Furthermore, because the front lamp37and mud guard38can be mounted simultaneously, mounting thereof is easy. In addition, because the mud guard38moves up and down together with the connector26, the distance between the mud guard38and the front wheel16fstays constant at all times, and the splashing of muddy water or the like can be more effectively controlled even if the cylinders36of the suspension fork13move up and down.

Moreover, as described above, because the purpose of the connector26is to connect and reinforce the suspension assemblies24aand24b, the connector26is formed with a relatively high rigidity. Therefore, the construction in which an illumination device, such as the front lamp37, can be directly mounted to the connector26with a high rigidity ensures that the optical axis of the post-adjustment illumination device is not easily affected by the vibrations that occur when the bicycle is ridden.

Second Embodiment

The lamp mounting unit128is essentially the same as in the first embodiment except that the concave mounting area140of the lamp mounting unit128comprises a hemispherical recess140a. The lamp unit146is essentially the same as in the first embodiment except that the lamp unit146of the front lamp137is integrally formed including a part similar to the cover member50of the previous embodiment. The mounting unit147comprises a screw member148secured to the lamp unit146. The bolt through-hole144is formed in the concave mounting area140such that it widens gradually along the front-back direction as it travels downward. The width of the through-hole144along the lateral direction remains constant. A through-hole138bthrough which a screw member148is inserted is formed in the mud guard138at a position facing the first mud guard mounting unit129a. A round protrusion138cto facilitate the screwing of the nut156that engages with the screw member148is formed around the through-hole138b. In this embodiment, optical axis adjustment can be performed not only around the lateral axis of the front lamp137but also around the vertical axis thereof. In other words, the hemispherical recess140ais configured and arranged to change horizontal and vertical positions of beam of light from the front lamp137when the front lamp137is mounted on the concave mounting area140.

While the lamp mounting unit128comprised a concave mounting area140ain the embodiment described above, it will be apparent to one of skill in the art that the lamp mounting unit128may comprise a protrusion.