DESC:FIELD OF INVENTION
[0001] The present invention relates to a handlebar mounting bracket for two-wheeled vehicles, welded along the circumferential surface to improve strength, clearance, and durability. This design reduces interference with adjacent components and enhances manufacturing efficiency.
BACKGROUND OF THE INVENTION
[0002] Two-wheeled vehicles, such as motorcycles, scooters, and bicycles, play a crucial role in personal and commercial transportation. Among these, electric two-wheelers have seen widespread adoption due to their environmental benefits, cost-effectiveness, and ease of use in urban settings. A key structural component of these vehicles is the handlebar assembly, which serves as the primary interface between the rider and the vehicle. The handlebar not only enables steering and control but also supports essential mounted components such as the throttle, brake levers, instrument cluster, and headlamp cover. These components must be securely attached using mounting brackets that ensure proper positioning, structural stability, and long-term durability.
[0003] Traditionally, these brackets are welded along the length of the handlebar to provide an attachment point for essential components. While this method is widely used, it presents several engineering and manufacturing challenges that impact both the performance and efficiency of the vehicle. One of the primary issues is the trade-off between weld length and clearance with adjacent components. Given the limited space available on the handlebar, the bracket must be positioned in a way that avoids interference with other components such as the throttle, grips, and brake levers. This often results in a compromise on weld length, which directly affects the strength and stability of the bracket attachment.
[0004] When the weld length is reduced to accommodate space constraints, the bracket may lack the necessary structural integrity to withstand vibrations, external forces, and prolonged usage. In two-wheeled vehicles, the handlebar is subjected to continuous mechanical stress, making a weak weld prone to failure over time. If the bracket becomes loose or detaches, it could cause misalignment of mounted components such as the instrument cluster or headlamp cover, potentially affecting vehicle operation and rider safety.
[0005] Another significant issue is interference and fouling between the bracket and adjacent handlebar-mounted components. Due to the accumulation of dimensional tolerances across various parts, there is a risk that the bracket may come into contact with the throttle or brake levers in worst-case scenarios. If the bracket obstructs the throttle, it can restrict smooth acceleration, while interference with the brake levers may result in improper braking response, both of which can compromise rider safety.
[0006] Additionally, manufacturing and assembly challenges arise due to inconsistencies in bracket placement and welding precision. In a mass production environment, even minor variations in tolerances can lead to misalignment between the bracket and adjacent parts, increasing handlebar rejection rates during quality control. These higher rejection rates lead to increased production costs, material wastage, and inefficiencies in the manufacturing process. Moreover, design constraints force engineers to make difficult trade-offs between bracket positioning, weld strength, and clearance allowances, which often result in suboptimal designs that are neither structurally ideal nor manufacturing-friendly.
[0007] Given these challenges, there is a clear need for an improved bracket design and welding approach that eliminates the trade-off between weld length and clearance, ensures better structural integrity, and enhances manufacturing efficiency. The current methods do not effectively address interference issues, durability concerns, or production inefficiencies, leaving a gap in the field that requires a more optimized solution.

SUMMARY OF THE INVENTION
[0008] In light of the disadvantages mentioned in the previous section, the following summary is provided to facilitate an understanding of some of the innovative features unique to the present invention and is not intended to be a full description. A full appreciation of the various aspects of the invention can be gained by taking the entire specification and drawings as a whole.
[0009] The present invention addresses the limitations of traditional handlebar bracket designs by introducing a mounting bracket that is welded along the circumferential surface of the handlebar, rather than along its length. This novel welding approach eliminates the trade-off between weld strength and clearance, ensuring a secure attachment without interfering with adjacent components such as the throttle, brake levers, and grips.
[0010] The bracket comprises a base, at least one pair of arms, and a mounting extension, configured to provide structural stability and optimized spacing for handlebar-mounted accessories. By utilizing circumferential welding, the invention enhances bracket strength, durability, and vibration resistance, preventing loosening or detachment over time. Additionally, this design reduces manufacturing rejection rates, leading to improved production efficiency and cost savings.
[0011] The invention is adaptable to various handlebar geometries and two-wheeled vehicle types, including electric scooters, motorcycles, and bicycles. It provides enhanced mechanical integrity, better part clearance, and an overall more reliable handlebar assembly, improving both vehicle performance and rider safety.
[0012] This summary is provided merely for purposes of summarizing some example embodiments, so as to provide a basic understanding of some aspects of the subject matter described herein. Accordingly, it will be appreciated that the above-described features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way.
BRIEF DESCRIPTION OF THE DRAWING
[0013] FIG. 1 is an exemplary top view of the handlebar of a two-wheeled vehicle illustrating various components according to the embodiments of the present disclosure.
[0014] FIG. 2 is an exemplary perspective view illustrating all the internal components of the handlebar according to the embodiments of the present disclosure.
[0015] FIG. 3 is another exemplary side perspective view of the handlebar according to the embodiments of the present disclosure.
[0016] FIG. 4 is an illustrative view of the handlebar showing various components and their arrangements according to the embodiments of the present disclosure.
[0017] FIG. 5 is an exemplary side view of the handlebar illustrating its structural configuration according to the embodiments of the present disclosure.
[0018] FIG. 6 is a close-up illustration of Part A, as highlighted in FIG. 4, showing detailed structural features according to the embodiments of the present disclosure.
[0019] FIG. 7 is a close-up illustration of Part B, as highlighted in FIG. 4, showing detailed structural features according to the embodiments of the present disclosure.
DETAILED DESCRIPTION
[0020] For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the disclosure as would normally occur to those skilled in the art are to be construed as being within the scope of the present disclosure.
[0021] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures, or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0022] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this disclosure belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0023] Handlebar assemblies in two-wheeled vehicles play a crucial role in supporting and securing various functional components such as the throttle, brake levers, instrument cluster, and headlamp cover. Traditionally, these components are mounted using brackets that are welded along the length of the handlebar. However, this approach presents significant design and manufacturing challenges. One of the primary issues is the inherent trade-off between weld length and clearance between the bracket and adjacent handlebar-mounted components. Since handlebars have limited space and multiple components need to be accommodated, designers often have to compromise on the length of the weld to ensure there is sufficient clearance for proper assembly and function. This results in a weaker bracket attachment, which may affect the durability and reliability of the mounting over time. In some cases, the reduced weld length can lead to mechanical failure due to vibrations and continuous stress exerted on the handlebar during vehicle operation.
[0024] Another major problem associated with traditional bracket welding methods is interference with nearby components. Due to cumulative part tolerances and variations in assembly, there is a risk that the bracket may come into contact with the throttle or brake levers, potentially causing functional obstructions. If the bracket is too close to the throttle, it may restrict smooth acceleration, while interference with the brake levers could impact braking efficiency. These issues not only affect the overall riding experience but also pose safety concerns. Additionally, misalignment due to minor variations in component placement can lead to higher rejection rates in mass production, increasing manufacturing costs and material wastage. As a result, there is a need for an improved bracket design and welding approach that eliminates these drawbacks while ensuring optimal structural integrity, sufficient clearance, and ease of manufacturing.
[0025] The present invention provides an improved handlebar assembly (100) with a bracket (600) that is welded along the circumferential surface of the handlebar (100) rather than along its length. This configuration allows for increased weld length without compromising clearance, ensuring a stronger and more secure attachment. The bracket (600) comprises a base (606), at least one pair of arms (602A, 602B), and a mounting extension (604). The base (606) serves as the primary attachment point and is welded directly to the circumferential surface of the handlebar (100), ensuring even load distribution and enhanced mechanical stability. This welding approach prevents the structural weaknesses that arise from traditional axial welding, which often limits weld length due to space constraints. By securing the bracket (600) around the circumference, the design maximizes the strength of the attachment while maintaining optimal clearance from adjacent handlebar-mounted components such as the throttle (110), grip (102), and brake levers (104, 108).
[0026] The bracket (600) is designed to provide reinforced structural stability through its arms (602A, 602B), which extend from the base (606) and partially wrap around the handlebar (100). These arms (602A, 602B) act as additional supports, ensuring that the bracket (600) remains rigid and stable under operational forces. The welding of these arms (602A, 602B) is carried out at multiple circumferential contact points, distributing stress evenly across the bracket (600) and handlebar (100). This arrangement significantly reduces the likelihood of weld failure or structural fatigue over time. Furthermore, the internal welding of the base (606) and arms (602A, 602B) minimizes external protrusions, ensuring that the bracket (600) does not interfere with the rider’s control of the vehicle.
[0027] In addition to improved welding and structural reinforcement, the bracket (600) includes a mounting extension (604) that provides a secure attachment point for components such as an instrument cluster cover or headlamp cover (106). The mounting extension (604) extends outward from the bracket (600) and is designed with at least one aperture for fastening additional accessories or functional elements. The position and orientation of this extension (604) allow for flexible mounting configurations, ensuring compatibility with different vehicle models and handlebar designs. This design eliminates the common issue of interference between the mounting bracket (600) and nearby control elements while ensuring easy assembly and accessibility during maintenance.
[0028] The circumferential welding approach also offers significant advantages in manufacturing efficiency and quality control. Since the weld is distributed around the handlebar (100) rather than along its length, there is a lower likelihood of bracket misalignment due to cumulative tolerances. This leads to higher production consistency, reduced rejection rates, and cost savings in large-scale manufacturing. The design also allows manufacturers to adjust the bracket strength based on application requirements without being constrained by weld placement limitations. Additionally, the bracket (600) can be fabricated from various materials such as steel, aluminum, or reinforced composites, allowing for customization based on strength, weight, and durability considerations.
[0029] By addressing the core issues of weld strength, component clearance, and manufacturing efficiency, the present invention offers a robust and practical solution for modern two-wheeled vehicles. The circumferential welding technique, combined with the reinforced structure of the bracket (600) and its optimized mounting extension (604), results in a more reliable, durable, and production-friendly handlebar assembly (100).
[0030] FIG. 1 illustrates a top view of the handlebar (100) of a two-wheeled vehicle, showing various components mounted on it. The handlebar (100) serves as the primary structural component for steering and control, with key elements attached to it for rider operation. The grip (102) is located on either end of the handlebar (100), providing a comfortable and secure area for the rider to hold while steering. Adjacent to the grips (102), the left-hand brake lever assembly (104) and right-hand brake lever assembly (108) are mounted, allowing the rider to control the braking system effectively. The throttle (110) is positioned on the right side of the handlebar (100), enabling acceleration by twisting the grip. Additionally, the headlamp cover (106) is centrally positioned on the handlebar (100), enclosing and protecting the lighting assembly while contributing to the overall aesthetics of the vehicle. This figure provides an overview of how various functional components are integrated onto the handlebar (100) and highlights the space constraints and clearance issues that traditional handlebar bracket designs must address.
[0031] FIG. 2 presents a perspective view of the handlebar (100), illustrating its internal components and structural arrangement. This view provides insight into the mounting positions of different elements, showing how they are secured to the handlebar (100). The internal wiring and fastening mechanisms used for securing the brake lever assemblies (104, 108), throttle (110), and instrument cluster are visible, offering a better understanding of the structural limitations and space constraints that exist when attaching mounting brackets. The perspective representation emphasizes the alignment of the components and the potential interference issues that arise with conventional mounting bracket designs, particularly when brackets are welded along the length of the handlebar (100).
[0032] FIG. 3 provides a side perspective view of the handlebar (100), similar to FIG. 2, but from a different angle to further illustrate the spatial relationship between the mounted components. This view clearly depicts how the throttle (110), brake levers (104, 108), and headlamp cover (106) are positioned relative to each other. The potential interference between the mounting bracket and adjacent components is more apparent in this view, particularly in scenarios where small variations in part tolerances may cause fouling or misalignment. Additionally, the figure shows the attachment points for the bracket (600) and highlights the clearance challenges associated with traditional welding methods.
[0033] FIG. 4 offers another illustrative view of the handlebar (100), showing a detailed arrangement of various components and their mounting positions. This figure provides additional perspective on how each component interacts with the handlebar (100) and demonstrates the limitations of previous bracket attachment methods. The spacing constraints and the trade-off between weld length and clearance are particularly evident in this view. By analyzing this figure, it becomes clear why an improved mounting bracket design is necessary to eliminate interference and ensure a stronger, more reliable attachment.
[0034] FIG. 5 is a side view of the handlebar (100), focusing on the alignment and structural positioning of its mounted components. This figure highlights the relative placement of the brake levers (104, 108), throttle (110), and headlamp cover (106) along the length of the handlebar (100). The side view also demonstrates the mounting challenges faced by conventional brackets, particularly in terms of ensuring sufficient clearance and a secure weld attachment without obstructing adjacent components.
[0035] FIG. 6 is a close-up illustration of Part A, as highlighted in FIG. 4, showing a detailed view of the bracket (600) and its welding configuration. This figure provides a closer examination of how the bracket base (606) is secured to the handlebar (100) along the circumferential surface, ensuring a stronger weld with increased durability. The arms (602A, 602B) extending from the base (606) wrap partially around the handlebar (100), reinforcing the bracket's stability. The circumferential welding approach is clearly depicted in this figure, emphasizing its advantage over traditional axial welding methods in terms of improved weld strength and clearance optimization.
[0036] FIG. 7 is a close-up illustration of Part B, as highlighted in FIG. 4, focusing on the mounting extension (604) of the bracket (600). This figure details how the mounting extension (604) extends outward from the bracket (600) and provides attachment points for additional components, such as the headlamp cover (106). The mounting extension (604) is designed to accommodate different accessory configurations, ensuring flexibility in component mounting without interfering with the throttle (110) or brake levers (104, 108). The positioning of the extension (604) in relation to other handlebar-mounted elements is also depicted, showcasing how the design ensures optimized clearance, structural reinforcement, and ease of assembly.
[0037] The present invention offers numerous advantages over conventional handlebar bracket designs, addressing key issues related to weld strength, structural stability, component clearance, and manufacturing efficiency. One of the most significant advantages is the improved welding configuration, where the bracket (600) is welded along the circumferential surface of the handlebar (100) rather than along its length. This ensures a stronger and more durable attachment, eliminating the need for compromising weld length to maintain clearance. By distributing the weld around the circumference of the handlebar (100), stress is more evenly spread, reducing the likelihood of structural fatigue, mechanical failure, or detachment due to vibrations and road-induced forces. This is particularly beneficial for electric two-wheelers, motorcycles, and other high-performance vehicles, where handlebar stability directly impacts rider safety and vehicle longevity.
[0038] Another key advantage is the optimized clearance between the bracket (600) and adjacent handlebar-mounted components such as the throttle (110), brake levers (104, 108), and grips (102). Unlike traditional brackets that may obstruct or interfere with these elements, the present invention ensures sufficient spacing, reducing the risk of throttle restriction, brake lever fouling, or improper component alignment. This improvement enhances ergonomics, ease of use, and safety, as all handlebar-mounted elements can function without obstruction. Additionally, this bracket design helps in reducing handlebar rejection rates during mass production, since tolerance variations in component placement are less likely to cause interference issues. This results in lower production costs, improved assembly efficiency, and better quality control, making the design particularly suitable for large-scale manufacturing applications.
[0039] The invention is also highly adaptable to different handlebar geometries, vehicle types, and accessory configurations. The bracket (600) can be fabricated from various materials, including steel, aluminum, reinforced polymers, or composite materials, depending on the specific strength, weight, and cost requirements of the application. This makes it suitable for a wide range of vehicles, including electric scooters, bicycles, motorcycles, mopeds, and even specialized vehicles such as delivery bikes, off-road motorcycles, and high-speed electric bikes. The mounting extension (604) of the bracket (600) is designed to support various accessories such as instrument clusters, headlamp covers, mirrors, or additional electronic modules, allowing for customization and modular component integration.
[0040] Beyond its primary application in two-wheeled vehicles, this bracket design and welding approach can be extended to other transportation and mechanical systems. For instance, it can be used in three-wheeled electric rickshaws, all-terrain vehicles (ATVs), and personal mobility devices, where handlebar-mounted accessories require secure, vibration-resistant attachment. The circumferential welding method can also be beneficial in industrial machinery, robotic arms, and control panels, where components must be firmly secured while maintaining sufficient clearance.
[0041] Additionally, the bracket (600) can be adapted to incorporate adjustable or modular features, such as swappable mounting extensions, pivoting brackets, or vibration-damping materials. This would allow for enhanced customization, enabling users to reposition or replace components without needing to modify the entire handlebar structure. Such adaptability would be particularly useful in racing motorcycles, modular e-bikes, and smart mobility devices, where components may need to be frequently adjusted or upgraded.
[0042] Overall, the invention provides a versatile, structurally superior, and production-efficient solution for mounting accessories on handlebars, with applications extending beyond traditional two-wheelers. By enhancing weld strength, improving clearance, and allowing for modular component attachment, this invention ensures long-term durability, reduced maintenance, and enhanced usability, making it a valuable improvement for a wide range of vehicle and mechanical applications.
[0043] Examples described herein can also be used in various other scenarios and for various purposes. It may be noted that the above-described examples of the present solution are for the purpose of illustration only. Although the solution has been described in conjunction with a specific embodiment thereof, numerous modifications/versions may be possible without materially departing from the instructions and advantages of the subject matter described herein. Other substitutions, modifications, and changes may be made without departing from the spirit of the present solution. All of the features disclosed in this specification (including any accompanying claims, abstract, and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any arrangement, except combinations where at least some of such features and/or steps are mutually exclusive.
[0044] The present description has been shown and described with reference to the foregoing examples. It is understood, however, that other forms, details, and examples can be made without departing from the spirit and scope of the present subject matter.
,CLAIMS:We Claim:

1. A handlebar assembly for a two-wheeled vehicle, comprising:
a handlebar (100) having a circumferential surface; and
a bracket (600) mounted on the handlebar (100), the bracket (600) comprising:
a base (606) configured to be secured to the circumferential surface of the handlebar (100) via welding;
at least one pair of arms (602A, 602B) extending from the base (606) and engaging the circumferential surface of the handlebar (100) to provide structural stability; and
a mounting extension (604) configured to support one or more components, including an instrument cluster cover and a headlamp cover (106);
wherein the bracket (600) is welded along the circumferential surface of the handlebar (100), thereby improving weld length and clearances with adjacent components.

2. The handlebar assembly of claim 1, wherein the bracket (600) is secured to the handlebar (100) at multiple circumferential contact points to enhance load distribution and mechanical integrity.

3. The handlebar assembly of claim 1, wherein the base (606) of the bracket (600) is welded internally along the circumference of the handlebar (100) to minimize external obstructions.

4. The handlebar assembly of claim 1, wherein the arms (602A, 602B) of the bracket (600) are configured to increase mechanical stability and prevent unwanted movement during vehicle operation.

5. The handlebar assembly of claim 1, wherein the bracket (600) is designed to provide optimized clearance between the handlebar-mounted components and other vehicle parts, minimizing interference with a throttle (110), grip (102), and brake levers (104, 108).

6. The handlebar assembly of claim 1, wherein the mounting extension (604) includes at least one aperture for securing additional vehicle components.

7. The handlebar assembly of claim 1, wherein the bracket (600) is designed to reduce rejection rates in mass production by ensuring uniform clearance between the handlebar (100) and surrounding components.

8. The handlebar assembly of claim 1, wherein the bracket (600) is constructed from a material selected from steel, aluminum, or a reinforced composite to enhance strength and vibration resistance.

9. A method for manufacturing a handlebar assembly for a two-wheeled vehicle, comprising:
providing a handlebar (100) with a circumferential surface;
b. forming a bracket (600) with a base (606), at least one pair of arms (602A, 602B), and a mounting extension (604);
c. securing the bracket (600) to the handlebar (100) by welding the base (606) along the circumferential surface of the handlebar (100); and
d. ensuring that the arms (602A, 602B) of the bracket (600) provide structural reinforcement while maintaining clearance with adjacent components.

10. The method of claim 9, wherein the bracket (600) is welded internally to optimize clearance and prevent interference with control elements such as a throttle (110) and brake levers (104, 108).