Abstract:
An aesthetically pleasing and functional axle nut cover assembly for a motorcycle using minimal threaded fasteners and taking advantage of elastic deformation between multiple portions of a mounting bracket to bias the mounting bracket and a cover member to a motorcycle swingarm to reduce vibration and noise. Separate deformations in the mounting bracket occur during assembly of the mounting bracket to the swingarm and during assembly of the cover member to the mounting bracket. Spring portions of the mounting bracket are maintained in deformed conditions when the axle nut cover assembly is assembled.

Description:
BACKGROUND 
       [0001]    The present invention relates to an apparatus and method for covering an axle nut on a motorcycle. 
       SUMMARY 
       [0002]    In one embodiment, the invention provides an axle nut cover assembly for a motorcycle having a swingarm, an axle, and an axle nut coupling the axle to the swingarm. The axle nut cover assembly includes a mounting bracket including a first portion configured to couple to the swingarm, a second portion disposed a distance from the first portion, and a spring portion between the first and second portions. The spring portion has a natural condition defining a first configuration of the first portion relative to the second portion and a deflected condition defining a second configuration of the first portion relative to the second portion, the second configuration being different from the first configuration. The spring portion is configured to be in the deflected condition when the first portion is coupled to the swingarm such that the second portion is biased toward the swingarm. A third portion of the mounting bracket is disposed a distance from the second portion, and a second spring portion is between the second portion and the third portion. The second spring portion has a natural condition defining a first configuration of the third portion relative to the second portion and a deflected condition defining a second configuration of the third portion relative to the second portion. The second configuration of the third portion is different from the first configuration of the third portion. A cover member is coupled to the third portion of the mounting bracket and configured to cover the axle nut. The cover member displaces the third portion relative to the second portion when coupled to the mounting bracket such that the second spring portion is in its deflected condition. The second spring portion is configured to bias the cover member toward the swingarm. 
         [0003]    In another embodiment, the invention provides a motorcycle including a frame and a swingarm movably coupled to the frame, the swingarm having an outboard side. An axle couples the rear wheel and the swingarm and defines an axis of rotation of the rear wheel relative to the swingarm. An axle nut is coupled to the axle to restrict movement of the axle relative to the swingarm. An axle nut cover assembly is configured to at least partially conceal the axle nut. The axle nut cover assembly includes a mounting bracket having a first portion coupled to the outboard side of the swingarm, a second portion disposed a distance from the first portion, and a spring portion between the first and second portions. The spring portion has a natural condition defining a first configuration of the first portion relative to the second portion and a deflected condition defining a second configuration of the first portion relative to the second portion. The second configuration is different from the first configuration. The spring portion is biased toward its natural condition. The spring portion is in the deflected condition when the first portion is coupled to the swingarm such that the second portion is biased toward the swingarm. A cover member is coupled to the mounting bracket and covers the axle nut. 
         [0004]    In yet another embodiment, the invention provides a method of assembling an axle nut cover assembly to a swingarm for covering an axle nut. A mounting bracket is provided having a bracket-mounting portion and a cover-mounting portion. The bracket-mounting portion is coupled to the swingarm. A cover member is coupled to the cover-mounting portion, deflecting the cover-mounting portion into a deflected condition. The cover member is urged toward the swingarm with the cover-mounting portion. 
         [0005]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a side view of a motorcycle including an axle nut cover assembly. 
           [0007]      FIG. 2  is a perspective view of a swingarm of the motorcycle of  FIG. 1  with the axle nut cover assembly of  FIG. 1  removed. 
           [0008]      FIG. 3  is an exploded view of the axle nut cover assembly of  FIG. 1 . 
           [0009]      FIG. 4  is a perspective view of a mounting bracket of the axle nut cover assembly coupled to the swingarm of  FIG. 2 . 
           [0010]      FIG. 5  is a top view of the mounting bracket of  FIGS. 3 and 4  coupled to the swingarm of  FIG. 2 . 
           [0011]      FIG. 6  is a rear view of the mounting bracket of  FIGS. 3 and 4  coupled to the swingarm of  FIG. 2 . 
           [0012]      FIG. 7  is a perspective view of the axle nut cover assembly of  FIGS. 1 and 3 , including a cover member, coupled to the swingarm of  FIG. 2 . 
           [0013]      FIG. 8  is a perspective view of the axle nut cover assembly of  FIG. 7 . 
           [0014]      FIG. 9  is an alternate perspective view of the axle nut cover assembly of  FIG. 8 . 
           [0015]      FIG. 10  is a cross-sectional view of the axle nut cover assembly taken along line  10 - 10  of  FIG. 9 . 
           [0016]      FIG. 11  is a perspective view of the mounting bracket of  FIG. 4 . 
           [0017]      FIG. 12  is a side view of the mounting bracket of  FIG. 11 . 
           [0018]      FIG. 13  is a rear view of the mounting bracket of  FIG. 11 . 
           [0019]      FIG. 14  is a top view of the mounting bracket of  FIG. 11 . 
       
    
    
       [0020]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
       DETAILED DESCRIPTION 
       [0021]      FIG. 1  illustrates a motorcycle  20  including a frame  24 , a steerable front wheel  28 , and a drivable rear wheel  32 . The rear wheel  32  is coupled to the frame  24  with a swingarm  36  and an axle  40 . The swingarm  36  and the axle  40  allow the rear wheel  32  to rotate about an axis and also allow the rear wheel  32  to pivot as necessary relative to the frame  24  (e.g., when encountering a bump in the road, etc.). As shown in  FIG. 2 , the swingarm  36  includes openings  44  through which end portions of the axle  40  extend. The axle  40  is coupled to the swingarm  36  with an axle nut  48  on either end of the axle  40 . The axle nuts  48  are disposed generally on the exposed sides  36 A of the swingarm  36  facing outwardly away from the rear wheel  32 . The openings  44  in the swingarm  36  are extended or slotted in the front-to-rear direction such that the position of the rear wheel  32  relative to the swingarm  36  is adjustable. 
         [0022]    One or two axle nut cover assemblies  52  are coupled to the swingarm  36  to cover one or both ends of the axle  40  and the respective axle nuts  48 . One axle nut cover assembly  52  is shown on the motorcycle  20  in  FIG. 1 . An additional axle nut cover assembly  52  (e.g., a mirror image of the illustrated axle nut cover assembly  52 ) is coupled to the swingarm  36  on the side opposite the illustrated side. Each axle nut cover assembly  52  is configured to substantially conceal the corresponding axle nut  48  in the illustrated embodiment, but the axle nut cover assembly  52  is effective with motorcycles using different types of axles or end hardware coupling an axle to a swingarm for improving the appearance of the axle-to-swingarm connection and protecting the same from contact with the elements. The description below, along with the figures referred to therein, are directed to the illustrated axle nut cover assembly  52  with the understanding that the non-illustrated axle nut cover assembly  52  is substantially identical. As mentioned above, the non-illustrated axle nut cover  52  may be a mirror image of the illustrated axle nut cover assembly  52 . 
         [0023]    As shown in  FIG. 3 , the axle nut cover assembly  52  includes, among other things, a mounting bracket  60 , a cover member  64 , and a plurality of fasteners  68 . The mounting bracket  60  includes a first portion  72  that is coupled to the swingarm  36  with a first fastener  68 A to mount the mounting bracket  60 . The first fastener  68 A is a thread-forming screw that is threaded into an axle adjustment hole  76  ( FIG. 2 ). A second portion  80  of the mounting bracket  60  is spaced apart from the first portion  72  and includes an opening  84 . In the illustrated construction, each of the first and second portions  72 ,  80  are substantially planar, but are not coplanar with each other when the mounting bracket  60  is formed ( FIGS. 11-14 ). The second portion  80  extends rearward of the first portion  72  toward the free end of the swingarm  36 . The opening  84  is sized to allow the axle nut  48  to extend through and be adjusted to various positions relative to the swingarm  36  without moving or adjusting the mounting bracket  60 . The second portion is pressed firmly against the exposed side  36 A of the swingarm  36 , as described in further detail below, without any threaded fasteners between the second portion  80  and the swingarm  36 . 
         [0024]    A spring portion  88  is positioned between the first and second portions  72 ,  80  of the mounting bracket  60 . The spring portion  88  movably couples the first and second portions  72 ,  80  together. The spring portion  88  includes a pair of legs  88 A oriented generally in a V-shape and forming an angle Φ of about 90 degrees therebetween, as shown in  FIG. 14 , to facilitate elastic bending of the mounting bracket  60  between the first and second portions  72 ,  80 . The spring portion  88  has a natural condition defining a first configuration of the first portion  72  relative to the second portion  80  ( FIG. 14 ). The spring portion  88  further has a deflected condition defining a second configuration of the first portion  72  relative to the second portion  80  ( FIG. 5 ). As shown in  FIG. 5 , the spring portion  88  is in the deflected condition when the first portion  72  is coupled to the swingarm  36  such that the second portion  80  is biased toward the swingarm  36  by energy stored in the deflected spring portion  88 . Thus, the second portion  80  is coupled to the swingarm  36  without a conventional fastener. As shown in  FIGS. 9 and 10 , a two-sided adhesive strip  92  may be positioned between an inner, swingarm-facing surface  96  ( FIG. 14 ) of the second portion  80  and the exposed side  36 A of the swingarm  36 . The stored energy in the deflected spring portion  88  compresses the adhesive strip  92  between the second portion  80  and the swingarm  36 . 
         [0025]    As shown in  FIGS. 2 and 5 , the exposed side  36 A of the swingarm  36  is generally planar in the area in which the mounting bracket  60  resides, and the first and second portions  72 ,  80  of the mounting bracket  60  assume a generally coplanar orientation when coupled thereto. However, the spring portion  88  is operable to accommodate irregularity in the swingarm  36 , such as forward and rearward portions of the exposed side  36 A being non-planar. To force the spring portion  88  to assume the deflected condition upon coupling the first portion  72  to the swingarm  36 , the second portion  80  is formed to be non-planar with the first portion  72  when the spring portion  88  is in the natural condition. As shown in  FIG. 14  with the spring portion  88  in the natural condition, the first and second portions  72 ,  80  define an interior angle θ of slightly less than 180 degrees. The angle θ is greater than about 170 degrees and less than 180 degrees. The illustrated angle θ is between about 174 degrees and about 177 degrees. By the same principles, the mounting bracket  60  may have a different angle θ between the first and second portions  72 ,  80  (with the spring portion  88  in the natural condition) if the exposed side  36 A of the swingarm  36  is non-planar in the area around the axle nut  48 . 
         [0026]    The mounting bracket  60  includes a third portion  100 , which is spaced a distance from both the first and second portions  72 ,  80 . The cover member  64  is configured to be mounted on the third portion  100  as described below. In the illustrated construction, the third portion  100  includes two coplanar flanges or tabs at a lower end of the mounting bracket  60  that extend from the second portion  80  and away from the swingarm  36 . A second spring portion  104  is positioned between the second portion  80  and each of the tabs of the third portion  100 . Similar to the first spring portion  88 , the second spring portion  100  movably couples the second and third portions  80 ,  100  together. The second spring portion  104  facilitates elastic bending of the mounting bracket  60  between the second and third portions  80 ,  100 . The second spring portion  104  has a natural condition defining a first configuration of the third portion  100  relative to the second portion  80  (FIGS.  6  and  11 - 13 ). The second spring portion  104  further has a deflected condition defining a second configuration of the third portion  100  relative to the second portion  80  ( FIGS. 9 and 10 ). 
         [0027]    The second spring portion  104  is in the deflected condition when the mounting bracket  60  is coupled to the swingarm  36  and the cover member  64  is coupled to the third portion  100  such that the cover member  64  is biased toward the swingarm  36  by energy stored in the deflected second spring portion  104 . Thus, an upper portion  108  of the cover member  64  is urged securely into contact with the mounting bracket  60  and/or the swingarm  36  without a conventional fastener. Effectively, the cover member  64  is cantilevered from a lower portion  112  thereof. As illustrated in  FIGS. 9 and 10 , the cover member  64  includes a flange portion  110  that is biased towards an upper edge  80 A of the second portion  80  of the mounting bracket  60 . The flange portion  110  extends along the upper portion  108  and around the rear end of the cover member  64  to the lower portion  112 . Fasteners  68 B, such as threaded bolts, extend through openings  116  in the lower portion  112  of the cover member  64  and through openings  120  in the third portion  100  of the mounting bracket  60 . Retainers  124 , such as threaded nuts, retain the fasteners  68 B in position ( FIGS. 9 and 10 ). The fasteners  68 B that couple the cover member  64  to the mounting bracket  60  are inserted in an upward direction from below the cover member  64 . Therefore, the fasteners  68 B are substantially concealed from view by the cover member  64  from normal viewing angles (i.e., from elevations above the axle nut cover assembly  52 ). The lack of visible fasteners improves the appearance of the axle nut cover assembly  52  and the appearance of the motorcycle  20 . 
         [0028]    As shown in  FIG. 13 , the third portion  100  is formed at an angle α with the second portion  80 . The angle α is not equal to 90 degrees (the approximate angle between the lower portion  112  of the cover member  64  and the exposed side  36 A of the swingarm  36  when the axle nut cover assembly  52  is mounted) in order to force the second spring portion  104  to assume the deflected condition upon coupling the cover member  64  to the mounted mounting bracket  60 . As shown in  FIG. 13 , with the second spring portion  104  in the natural condition, the second and third portions  80 ,  100  define an interior angle α of slightly less than 90 degrees. The angle α is greater than about 80 degrees and less than 90 degrees. The illustrated angle α is between about 83 degrees and about 85 degrees. By the same principles, the mounting bracket  60  may have a different angle α between the second and third portions  80 ,  100  (with the second spring portion  104  in the natural condition) depending upon the shapes of and/or interfaces between the exposed side  36 A of the swingarm  36 , the third portion  100 , and the lower portion  112  of the cover member  64 . 
         [0029]    Thus, the invention provides, among other things, an aesthetically pleasing and functional axle nut cover assembly  52  for a motorcycle  20  using minimal threaded fasteners  68  and taking advantage of elastic deformation between multiple portions  72 ,  80 ,  100  of a mounting bracket  60  to promote tight fitting of both the mounting bracket  60  and a cover member  64  to a motorcycle swingarm  36  and to reduce vibration and noise in the axle nut cover assembly  52 . Various features and advantages of the invention are set forth in the following claims.