Patent Document

BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates to front suspension forks of motorcycles. More particularly, the present invention relates to a cosmetic shroud, which may be installed on a motorcycle front suspension fork to alter the appearance of the motorcycle fork for aesthetic purposes.  
           [0002]    In general, a motorcycle suspension fork comprises a pair of generally parallel fork blades and an attachment or securing member, which connects the fork blades to one another at or near their respective upper ends. Lower ends of the fork blades connect to and support an axle for a front wheel of the motorcycle. The attachment member pivotally connects the fork blades to the frame of the motorcycle and pivots relative to the frame to permit steering of the front wheel. Typically, each of the fork blades includes first and second support members that are telescopically engaged with one another for reciprocating movement relative to one another along an axis. Such fork blades also typically include one or more springs, which bias the support members toward a particular orientation relative to one another, and dampers which minimize oscillation. The reciprocating movement of the support members of each fork blade, together with their associated springs and dampers, provides suspension, which allows the fork to absorb shock and thereby provide a smooth ride as the motorcycle travels.  
           [0003]    In general, there are two configurations of telescoping fork blades for motorcycles in wide usage. In the first configuration, the upper support member has an upper portion that is rigidly attached to the securing member of the fork and a lower end margin that is telescopically received within an upper end margin of the lower support member, and the lower portion of the lower support member is connected to the axle of the front wheel. In the second configuration, the telescoping relationship of the upper and lower support members is opposite the first configuration in that an upper end margin of the lower support member is telescopically received within a lower end margin of the upper support member.  
           [0004]    The first fork blade configuration (wherein the lower end margin of the upper support member is telescopically received within an upper end margin of the lower support member) has advantages in that it tends to be less expensive and easier to produce and assemble than the second fork blade configuration (wherein the upper end margin of the lower support member is telescopically received within the lower end margin of the upper support member). Generally speaking, the second fork blade configuration tends to be associated with superior or high performance forks.  
           [0005]    Motorcycle enthusiasts tend to prefer superior or high performance motorcycles and parts, so generally speaking, the second fork blade configuration tends to be the preferred configuration. However, not all motorcycle enthusiasts are not willing or able to pay the higher price typically attached to premium components such as these high performance motorcycle forks, yet many motorcycle enthusiasts would still prefer to at least give the appearance of having premium components such as high performance forks with the second fork blade configuration, is simply like the look of a fork blade wherein the upper support member is larger in diameter than the lower support member. Thus, there is a need for a manner of providing the “look” of forks having the second fork blade configuration, yet having the structure and function of the first fork blade configuration, which tends to be less expensive.  
         SUMMARY OF THE INVENTION  
         [0006]    The present invention pertains to a cosmetic shroud that disguises a portion of a fork blade, thereby giving the fork blade the appearance of having a different structural configuration.  
           [0007]    In one aspect of the invention, a motorcycle fork is adapted to be pivotally attached to a motorcycle frame and comprises a fork blade and a shroud. The fork blade has an upper support member and a lower support member and each of the upper and lower support members has upper and lower end margins. The lower end margin of the lower support member is adapted to be secured to a wheel axle and the lower end margin of the upper support member is telescopically received within the upper end margin of the lower support member. This connection is such that the upper support member is movable in a reciprocating manner along an axis relative to the lower support member but is also such that bending moment perpendicular the axis is transmittable from the lower support member to the upper support member. In other words, the upper support member is held in alignment with the lower support member by nature of the telescopic connection therebetween. The shroud is attached to the fork blade and has upper and lower portions. The upper portion of the shroud is fixedly attached to the upper end margin of the upper support member and the upper end margin of the lower support member is telescopically received in the lower portion of the shroud.  
           [0008]    In another aspect of the invention, a method comprises the steps of providing a motorcycle fork, providing a shroud, and disguising the motorcycle fork by attaching the shroud to the motorcycle fork. The step of providing of the motorcycle fork is performed in a manner such that the motorcycle fork comprises a fork blade having first and second support members. The first support member is telescopically received in the second support member in a manner such that the first support member is slidably engaged with the second support member. The step of disguising the motorcycle fork by attaching the shroud is performed in a manner such that the shroud conceals the first support member and provides a false appearance that the second support member is slidably engaged with the shroud.  
           [0009]    In yet another aspect of the invention, a method comprises the steps of providing a motorcycle fork blade assembly, providing first and second motorcycle fork triple trees, providing a shroud, and assembling the shroud and the first and second triple trees to the fork blade assembly. The step of providing of the motorcycle fork blade assembly is performed in a manner such that the fork blade assembly comprises upper and lower support members, with each of the upper and lower support members having upper and lower end margins. The lower end margin of the upper support member is telescopically received within the upper end margin of the lower support member in manner such that the upper support member is movable in a reciprocating manner along an axis relative to the lower support member. The step of providing the first and second motorcycle fork triple trees is performed in manner such that the second triple tree has an engagement portion that engages the upper support member. The step of providing of the shroud is performed in a manner such that the shroud has an internal cavity and has at least first and second openings into the internal cavity. The step of assembling of the shroud and the first and second triple trees to the fork blade assembly is performed by inserting the upper end margin of the upper support member of the fork blade assembly into the internal cavity of the shroud. This is done by passing said upper end margin through the first opening of the shroud. The engagement portion of the second triple tree is inserted into the internal cavity of the shroud by passing the engagement portion through the second opening of the shroud. Thereafter, the first triple tree is fixedly attached to the upper support member and the second triple tree is fixedly attached to the upper support member with the engagement portion thereof being engaged with the upper support member within the internal cavity of the shroud.  
           [0010]    While the principal advantages and features of the invention have been described above, a more complete and thorough understanding of the invention may be attained by referring to the drawings and the detailed description of the preferred embodiments which follow. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a perspective view of a motorcycle suspension fork in accordance with the invention having a cosmetic shroud covering a portion of one of its fork blades.  
         [0012]    [0012]FIG. 2 is a front elevational view of the motorcycle suspension fork shown in FIG. 1 having detailed portions thereof shown in partial cross-section.  
         [0013]    [0013]FIG. 3 is a perspective view of the cosmetic shroud utilized on the suspension fork shown in FIGS. 1 and 2. 
     
    
       [0014]    Reference characters in the written specification indicate corresponding parts throughout the several views of the drawings.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0015]    A preferred embodiment of a motorcycle fork in accordance with the invention is shown in FIGS. 1 and 2, and is generally indicated by the numeral  10 . In general, the fork  10  comprises a frame attachment member  12 , a pair of fork blades  14 , and a pair of shrouds  16  (only one shown). For purposes of describing the invention, one of the fork blades  14  is shown without a shroud  16 . However, it should be appreciated that in practicing the invention, this fork blade would be partially concealed by the second shroud.  
         [0016]    The frame attachment member  12  of the fork  10  preferably comprises a hinge-pin  18  and a pair of triple trees  20 , 22 . The triple trees  20 , 22  and the hinge-pin  18  are preferably formed of metal. The configuration and use of triple trees in conjunction with motorcycle forks are widely known in the motorcycle industry and the triple trees  20 , 22  of the preferred embodiment are generally similar to those of the prior art. The triple trees  20 , 22  each include a hinge-pin opening  24  and a pair of attachment portions  26  that are symmetrically spaced from the hinge-pin opening. Each attachment portion  26  of the upper triple tree  20  comprises a cylindrical through-hole  28  for attachment to one of the fork blades  14  (shown in FIG. 2). Unlike typical prior art triple trees, each of the through-holes  28  of the upper triple tree  20  preferably includes a counterbore  30 . Each of the attachment portions  26  of the lower triple tree  22  includes a slotted through-hole  32 , with each of the slotted through-holes  32  comprising a generally cylindrical portion  34  and a slotted portion  36  extending radially therefrom.  
         [0017]    Each of the fork blades  14  generally comprises an upper support member  38  and a lower support member  40  which are preferably formed of metal. The upper support member  38  of each of the fork blades  14  is generally shaped as a solid cylindrical rod and has axially opposite upper and lower end margins  42 , 44 . The lower support member  40  of each of the fork blades  14  is an elongate member and also has an upper end margin  46  opposite a lower end margin  48 . The upper end margin  46  of the lower support member  40  has a socket that is recessed therein and is adapted for receiving the lower end margin  44  of the upper support member  38  in a telescoping manner as shown. The lower end margin  48  of the lower support member  40  comprises a lug  50  that is adapted to be secured to the axle of a front wheel of a motorcycle. The lower support member  40  further includes a brake mechanism attachment member  52  that is adapted to support the brake mechanism (not shown) of the motorcycle from the lower support member. Although not visible in the drawings, each of the fork blades  14  also comprises one or more helical compression springs that act to bias the upper support member  38  in a particular direction relative to the lower support member  40 . In the preferred embodiment, these helical compression springs are located within the recess of each of the lower support members  40 . It is important to appreciate that the fork blades  14  are conventional prior art suspension fork blades and are fully capable of attaching the front wheel of a motorcycle to the remainder of the motorcycle and of being used in a conventional manner without the shrouds  16  hereinafter described. Thus, a detailed discussion of the configuration and operation of the fork blades  14  in this specification is unnecessary.  
         [0018]    The shrouds  16  are preferably formed of metal and preferably identical to one another. For clarity, one of the shrouds  16  is shown by itself in FIG. 3. Each shroud  16  preferably comprises a thin cylindrical wall  54  and an end cap  56 . The cylindrical wall defines an internal cavity  58  with an opening  60  at the base of the lower portion  62  of the shroud  16 , which permits access to the internal cavity  58  from below. The end cap  56  is generally “washer-shaped,” with a diameter and thickness substantially equal to that of the cylindrical wall  54 , and is preferably welded to the cylindrical wall in a manner such that it partially closes the top of the upper portion  64  of the shroud  16 . Alternatively, the end cap  56  and cylindrical wall  54  may be of a unitary construction. An opening  66  extends through the end cap  56  and communicates with the internal cavity  58  of the shroud  16 . A generally rectangular slot  68  extends through the cylindrical wall  54  and also communicates with the internal cavity  58  of the shroud  16 .  
         [0019]    Having described the various main components of the fork  10 , the method of assembling the various components will now be described. It should be appreciated that the purpose of shrouds  16  is to conceal the nature of the fork blades  14  and that, assuming the fork  10  was already being used on a motorcycle without the shrouds, the fork blades and the triple trees  20 , 22  must first be disassembled from one another and from the motorcycle by reversing the steps of their original assembly, though the upper and lower support members  38 , 40  of each of the fork blades  14  can remain attached to each other.  
         [0020]    Once the fork blades  14  and the triple trees  20 , 22  have been disassembled from one another and from the motorcycle, the counterbores  30  of the attachment portions  26  of the upper triple tree  20  can be formed therein by a machining process or other means. An O-ring  70  (preferably of an elastomeric material) is then slid onto the upper support member  38  of each of the fork blades  14  by passing the upper end margin  42  of the upper support member through the O-ring  70 . Preferably, the appropriate attachment portion  26  of the lower triple tree  22  is then inserted into the internal cavity  58  of one of the shrouds  16  by passing it through the rectangular slot  68  of the cylindrical wall  54  of the shroud. The upper support member  38  of one of the fork blades  14  is then inserted through the opening  60  at the base of the cylindrical wall  54  of the shroud and is slid upwardly into the internal cavity  58  of the shroud. During this procedure, the upper end margin  42  of the upper support member  38  of the fork blade  14  is inserted through the cylindrical portion  34  of attachment portion  26  of the lower triple tree  22 . Once the fork blade  14  is fully inserted into the shroud  16 , the end cap  56  of the shroud will engage the upper support member  38  of the fork blade  14  and thereby prevent further upward movement of the fork blade relative to the shroud. This procedure is then repeated for the other fork blade  14  and the other shroud  16 .  
         [0021]    Having performed the above-mentioned steps, the fork blades  14  will be connected to each other via the lower triple tree  22 , and the upper triple tree  20  is then attached to the assembly. This is preferably done by inserting the top of the shrouds  16  into the counterbores  30  of the upper triple tree  20  and by inserting bolts  72  downwardly through the through-holes  28  of the upper triple tree. Each of the bolts  72  is configured to threadingly engage the upper support member  38  of the respective fork blade  14  through the opening  66  in the end cap  56  of the respective shroud  16  and to thereby clamp the end cap of the shroud between the upper support member and the upper triple tree. The attachment portions  26  of the lower triple tree  22  are also locked securely to the upper support members  20  by tightening bolts (not shown) that thereby reduce the width of the slotted portions  36  of the slotted through-holes  32  so as to create a clamping action.  
         [0022]    The fork  10  assembly can be reattached to the motorcycle by passing the hinge pin  18  of the frame attachment member  12  through the hinge pin openings  24  of the triple trees  20 , 22  and through the corresponding portion (not shown) of the motorcycle frame in a conventional manner. Finally, if removed during any portion of the assembly procedure, the front wheel of the motorcycle can be reattached to the lugs  50  of the fork  10 .  
         [0023]    It should be appreciated that the above-described assembly steps could be performed in a different order. For example, the upper support member  38  of the fork blades  14  can be slid upwardly partially into the internal cavity  58  of the shroud  16  prior to the insertion of the attachment portion  26  of the lower triple tree  22  into the internal cavity. As an additional example, the assembly of one fork blade  14  to the triple trees  20 , 22  could be entirely or only partially completed prior to the assembly of the other fork blade.  
         [0024]    As assembled, the shrouds  16  conceal the upper support members  38  of the fork blades  14  and provide the false appearance of being structural members themselves. To facilitate this false appearance, the rectangular slot  68  through the cylindrical wall  54  of each shroud  16  is preferably dimensioned only large enough to allow the attachment portion  26  of the lower triple tree  22  to extend therethrough. Additionally, as shown in the drawing figures, the lower portions  62  of the shrouds overlap the upper end margins  46  of the lower support members  40  slightly such that the lower support members are each telescopically received in the internal cavity  58  of one of the shrouds through the opening  60  at the base of the respective shroud. Preferably, the diameter of each of the O-rings  70  is slightly larger than the inner diameter of the cylindrical wall  54  of the shroud  16  in a manner so that it is radially compressed between the upper support member  38  and the cylindrical wall and thereby maintains the lower portion  62  of the shroud in alignment with the upper support member. Additionally, the diameter of the cylindrical wall  54  of each shroud  16  is configured to be only slightly larger than the diameter of the upper end margin  46  of the lower support member  40  to provide the false appearance of the lower support member being slideably engaged with the shroud. However, it should be appreciated that the lower support members  40  remain slideably engaged with the upper support members  38  and that it is the upper support members  38  that actually transmit loads between the motorcycle and its front wheel in a manner independent of the shrouds  16 .  
         [0025]    In view of the foregoing, it should be apparent and appreciated the shrouds provide an economical means for disguising the type of front suspension on a motorcycle. Additionally, it should be appreciated that the shrouds do not interfere in any way with the operation of the structural components of the suspension system.  
         [0026]    In view of the above, it can be seen that the present invention overcomes problems associated with the prior art and achieves other advantageous results. As various changes could be made without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings be interpreted as illustrative and not limiting. It should be understood that other configurations of the present invention could be constructed, and different uses could be made, without departing from the scope of the invention as set forth in the following claims.  
         [0027]    Furthermore, it should be understood that when introducing elements of the present invention in the claims or in the above description of the preferred embodiment of the invention, the terms “comprising,” “including,” and “having” are intended to be open-ended and mean that there may be additional elements other than the listed elements.

Technology Category: b