Claims:WE CLAIM:
1. A cap assembly (200), comprising:
a cap body (210) having a first outwardly protruding flange (212) configured for receiving a lever (214), and one or more lateral projections (216) provided on an outer surface of the cap body (210);
a cap body cover (220) disposed along the outer surface of the cap body (210), the cap body cover (220) having one or more vertical projections (222) configured to be locked with the one or more lateral projections (216) on the outer surface of the cap body (210); and
a cap unit (230) configured to be disposed on the cap body (210) via the lever (214), the cap unit (230) being openable by means of actuation of the lever (214).

2. The cap assembly (200) as claimed in claim 1, wherein the lever (214) is configured to be actuated by means of a cable and spring (218) arrangement, the cable being operable by means of a key.

3. The cap assembly (200) as claimed in claim 1, wherein the cap body (210) has a substantially rectangular cross section, the cap body (210) comprising a pair of longitudinal faces (210A) and a pair of transverse faces (210B).

4. The cap assembly (200) as claimed in claim 3, wherein the one or more lateral projections (216) are provided on the pair of longitudinal faces (210A) at the outer surface of the cap body (210).

5. The cap assembly (200) as claimed in claim 3, wherein the longitudinal faces (210A) on the cap body comprise one or more slots (208), such that the one or more vertical projections (222) on the cap body cover (220) are accessible through the slots (208).

6. The cap assembly (200) as claimed in claim 3, further comprising a mounting flange (206) disposed on one of the transverse faces (210B) of cap body (210), the mounting flange (206) configured for mounting the cap assembly (200) on to a surface.

7. A saddle type vehicle (10), comprising:
a cap assembly (200) configured to be mounted on the body of the saddle type vehicle (10), the cap assembly (200) having:
a cap body (210) having a first outwardly protruding flange (212) configured for receiving a lever (214), and one or more lateral projections (216) provided on an outer surface of the cap body (210);
a cap body cover (220) disposed along the outer surface of the cap body (210), the cap body cover (220) having one or more vertical projections (222) configured to be locked with the one or more lateral projections (216) on the outer surface of the cap body (210); and
a cap unit (230) configured to be disposed on the cap body (210) via the lever (214), the cap unit (230) being openable by means of actuation of the lever (214).

8. The saddle type vehicle (10) as claimed in claim 7, the lever (214) is configured to be actuated by means of a cable and spring (218) arrangement, the cable being operable by means of an ignition key of the saddle type vehicle (10).

9. The saddle type vehicle (10) as claimed in claim 7, further comprising a fuel tank assembly, the cap assembly (200) being configured to be mounted on an inlet of the fuel tank assembly.

10. The saddle type vehicle (10) as claimed in claim 9, wherein the cap assembly (200) comprises a mounting flange (206) for mounting the cap assembly (200) to the fuel tank assembly.

11. The saddle type vehicle (10) as claimed in claim 7, further comprising a battery pack assembly, the cap assembly (200) being configured to be mounted on a charging socket of the battery pack assembly.

12. A method (300) of assembling a cap assembly (200) for a saddle type vehicle (10), comprising the steps of:
disposing a cap unit (230) on a cap body (210), by means of a lever (214), the lever (214) being received on an outwardly protruding flange (212) the cap body (210);
mounting the cap body (210) on to the saddle type vehicle (10) by means of a mounting flange (206) on the cap body (210);
snap fitting one or more vertical projections (222) on a cap body cover (220) on one or more lateral projections (216) on an outer surface of the cap body (210) such that cap body cover (220) disposed along the outer surface of the cap body (210).

, Description:FIELD OF THE INVENTION
[001] The present invention relates to a cap assembly.

BACKGROUND OF THE INVENTION
[002] In conventional motor vehicles, there exist multiple variants of caps and cap assemblies for covering a fuel inlet or charging port. With the introduction of external fuel inlets or external charging ports, the external fuel inlets have become more and more prevalent, especially owing to the convenience and better fit and finish associated with them. An external fuel inlet or charging port requires a cap assembly fitted on to the body of the vehicle or a body cover of the vehicle.
[003] An existing external fuel tank cap assembly includes an assembly in which the body cover is capable of being rotated even when the cap component is in closed condition. In another assembly, the body cover is rotatably attached to the body such that it gets locked in one direction of rotation and unlocked in the opposite direction. In such systems, the cap component and the cap cover are provided as two different serviceable elements, which can be removed easily for servicing. However, such provision leaves a chance of actuating the cap cover to open the cap component externally or actuating the cable to open to open the cap cover, which means that the cap cover can be opened without operating the key, thereby making the assembly theft prone.
[004] Provision of conventional external fuel tank cap assemblies thus are susceptible not only for theft of body parts of fuel tank cap assembly such as the cap cover or the cap component, but also fuel from the fuel tank, especially during servicing.
[005] Thus, there is a need in the art for a cap assembly for a saddle-type vehicle which addresses at least the aforementioned problems.

SUMMARY OF THE INVENTION
[006] In one aspect, the present invention is directed towards a cap assembly. The cap assembly has a cap body having a first outwardly protruding flange configured for receiving a lever, and one or more lateral projections provided on an outer surface of the cap body. The cap assembly further has a cap body cover disposed along the outer surface of the cap body. The cap body cover has one or more vertical projections that are configured to be locked with the one or more lateral projections on the outer surface of the cap body. A cap unit is configured to be disposed on the cap body via the lever and the cap unit being openable by means of actuation of the lever.
[007] In an embodiment of the invention, the lever is configured to be actuated by means of a cable and spring arrangement and the cable is operable by means of a key.
[008] In another embodiment of the invention, the cap body has a substantially rectangular cross section and the cap body has a pair of longitudinal faces and a pair of transverse faces. In an embodiment, the one or more lateral projections are provided on the pair of longitudinal faces at the outer surface of the cap body.
[009] In another embodiment of the invention, the longitudinal faces on the cap body have one or more slots, such that the one or more vertical projections on the cap body cover are accessible through the slots.
[010] In another embodiment of the invention, the cap assembly further has a mounting flange disposed on one of the transverse faces of cap body and the mounting flange is configured for mounting the cap assembly on to a surface.
[011] In another aspect, the present invention relates to a saddle type vehicle having a cap assembly. The cap assembly is configured to be mounted on the body of the saddle type vehicle. The cap assembly has a cap body having a first outwardly protruding flange configured for receiving a lever, and one or more lateral projections provided on an outer surface of the cap body. The cap assembly further has a cap body cover disposed along the outer surface of the cap body. The cap body cover has one or more vertical projections that are configured to be locked with the one or more lateral projections on the outer surface of the cap body. A cap unit is configured to be disposed on the cap body via the lever and the cap unit being openable by means of actuation of the lever.
[012] In an embodiment of the invention, the lever is configured to be actuated by means of a cable and spring arrangement, the cable being operable by means of an ignition key of the saddle type vehicle.
[013] In a further embodiment of the invention, the saddle type vehicle has a fuel tank assembly and the cap assembly is configured to be mounted on an inlet of the fuel tank assembly. In an embodiment, the cap assembly has a mounting flange for mounting the cap assembly to the fuel tank assembly.
[014] In a further embodiment of the invention, the saddle type vehicle has a battery pack assembly and the cap assembly is configured to be mounted on a charging socket of the battery pack assembly.
[015] In another aspect, the present invention relates to a method of assembling a cap assembly for a saddle type vehicle. The method steps are disposing a cap unit on a cap body, by means of a lever, the lever being received on an outwardly protruding flange the cap body; mounting the cap body on to the saddle type vehicle by means of a mounting flange on the cap body; snap fitting one or more vertical projections on a cap body cover on one or more lateral projections on an outer surface of the cap body such that cap body cover disposed along the outer surface of the cap body.

BRIEF DESCRIPTION OF THE DRAWINGS
[016] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a right side view of an exemplary saddle-type vehicle, in accordance with an embodiment of the invention.
Figure 2 illustrates a perspective view of a cap assembly, in accordance with an alternative embodiment of the invention.
Figure 3 illustrates a perspective view of a cap body of the cap assembly, in accordance with an embodiment of the invention.
Figure 4 illustrates an exploded view of the cap assembly, in accordance with an embodiment of the invention.
Figure 5 illustrates a perspective view of a cap body cover mounted on the cap body, in accordance with an embodiment of the invention.
Figure 6 illustrates a method for assembling a cap assembly for a saddle type vehicle, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[017] The present invention relates to a cap assembly. More particularly, the present invention relates to a cap assembly for a saddle-type vehicle.
[018] Figure 1 illustrates a right-side view of an exemplary saddle-type vehicle 10, in accordance with an embodiment of the present subject matter. The vehicle 10 comprises a frame 105. The frame 105 comprises a head tube 105A, and a portion of a main tube 105B extending rearwardly downward from the head tube 105A to a floorboard 155. One or more front suspensions 110 connect a front wheel 115 to a handlebar 190, which forms a steering assembly of the vehicle 10. The steering assembly is rotatably disposed about the head tube 105A. The main tube 105B further includes a portion extending horizontally and rearwardly from the frame 105. Further, the frame 105 includes one or more rear tubes 105C extending inclinedly rearward from a rear portion of the main tube 105B towards a rear portion of the vehicle 10.
[019] The vehicle 10 includes a power unit comprising at least one of an internal combustion (IC) engine 125 or a traction motor (not shown). The power unit is coupled to the rear wheel 145. In one embodiment, the power unit is swingably connected to the frame assembly 105. In one embodiment, the power unit is mounted to the swing arm (not shown) and the swing arm is swingably connected to the frame 105. Further, the vehicle 10 includes a transmission means (not shown) coupling the rear wheel 145 to the power unit. The transmission means includes a continuously variable transmission, an automatic transmission, or a fixed ratio transmission. A seat assembly 151 is disposed above the power unit and is supported by the rear tubes 105C of the 105. The seat assembly 151 is hingedly openable. The frame 105 defines a step-through portion ahead of the seat assembly 151. The floorboard 155 is disposed at the step-through portion, wherein a rider can operate the vehicle 10 in a seated position by resting feet on the floorboard 155. Further, the floorboard 155 is capable of carrying loads.
[020] Further, the frame 105 is covered by plurality of body panels including a front panel 160 having a front face 160A and a rear face 160B, an under-seat cover 162, and a left and a right-side panel 163 disposed on the frame 105 and covering the frame 105 and parts mounted thereof.
[021] In addition, a front fender 165 is covering at least a portion of the front wheel 115. A utility box is disposed below the seat assembly 151 and is supported by the frame 105. A rear fender 175 is covering at least a portion of the rear wheel 145 and is positioned upwardly of the rear wheel 145. One or more suspension(s) (not shown) are provided in the rear portion of the vehicle 10 for connecting the swing arm and the rear wheel 145 to the frame 105 for damping the forces from the rear wheel 145 and the power unit from reaching the frame 105.
[022] Furthermore, the vehicle 10 comprises of plurality of electrical and electronic components including a headlight 185A, a taillight 185B, a transistor-controlled ignition (TCI) unit (not shown), and an alternator (not shown), a starter motor (not shown).
[023] Figure 2 illustrates a cap assembly 200 in accordance with an embodiment of the invention. The cap assembly 200 has a cap body 210. In an embodiment, the cap body 210 is substantially a tubular member with a rectangular cross section. The cap body 210 has a first outwardly protruding flange 212. The first outwardly protruding flange 212 is configured for receiving a lever 214. In an embodiment, the lever 214 is configured to be actuated by means of a cable and spring 218 arrangement. The cable is operable by means of a key. In that, one end of the cable, which is an operable end is connected to the lever 214 by means of the cable and spring 218 arrangement, and the other end of the cable is connected to an assembly operable by a key. Turning of the key results in movement of the cable, thereby causing actuation of the lever 214.
[024] Figure 3 illustrates a perspective view of the cap body 210 in accordance with an embodiment of the invention. As illustrated in Figure 3, the cap body 210 further comprises one or more lateral projections 216 that are provided on an outer surface of the cap body 210. In the embodiment wherein the cap body 210 has a rectangular cross section, the cap body 210 has a pair of longitudinal faces 210A and a pair of transverse faces 210B. In this embodiment, the one or more lateral projections 216 are provided on the pair of longitudinal faces 210A on the outer surface of the cap body 210.
[025] Figure 4 illustrates an exploded view of the cap assembly 200 in accordance with an embodiment of the invention. As illustrated in Figure 4, the cap assembly 200 further comprises of a cap body cover 220. The cap body cover 220 is disposed along the outer surface of the cap body 210. The cap body cover 220 has one or more vertical projections 222 such that the one or more vertical projections 222 are configured to be locked with the one or more lateral projections 216 on the outer surface of the cap body 210, thereby fixing the cap body cover 220 on to the cap body 210. In an embodiment, the one or more vertical projections 222 on the cap body cover 220 are configured to be locked with the one or more lateral projections 216 on the outer surface of the cap body 210 in a snap fit manner.
[026] As further illustrated in Figure 4 and referenced in Figure 2, the cap assembly 200 further comprises a cap unit 230 that is configured to be disposed on the cap body 210 via the lever 214. The cap unit 230 is openable by means of actuation of the lever 214, such that actuation of the lever 214 causes the cap unit 230 to move pivotally along the cap body 210.
[027] Reference is made to Figure 3 and Figure 5 wherein as illustrated, in an embodiment, the longitudinal faces 210A on the cap body 210 comprise one or more slots 208, such that the one or more vertical projections 222 on the cap body cover 220 are accessible through the slots 208. Such a disposition ensures that the snap fit of the one or more vertical projections 222 on to the one or more lateral projections 216 is only accessible through the slot 208 by a tool when the cap unit 230 is opened by actuating the lever 214 by the key.
[028] In addition, the rectangular cross section of the cap body 210 and the snap fit of the one or more vertical projections 222 on to the one or more lateral projections 216 ensure that the cap body 210 and the cap body cover 220 cannot be rotated with respect to each other, thereby ensuring that the cap body 210 and the cap body cover 220 cannot be separated from each other without authorized access by key to open the cap unit 230, making the cap assembly 200 theft proof.
[029] In an embodiment of the invention, the cap assembly 200 further comprises a mounting flange 206 that is disposed on one of the transverse faces 210B of cap body 210. In that, the mounting flange 206 has one or more through holes for allowing a fastener to pass through, and hence is configured for mounting the cap assembly 200 on to a surface.
[030] In another aspect, the present invention relates to a saddle type vehicle 10 that comprises the cap assembly 200 mounted on the body of the vehicle 10 as explained hereinabove. In an embodiment, the cap assembly 200 is mounted on the body of the vehicle such that the cap unit 230 is flush with the body of the vehicle 10.
[031] In an embodiment, the lever 214 is configured to be actuated by means of a cable and spring 218 arrangement, wherein the cable is operable by means of an ignition key of the saddle type vehicle 10.
[032] In an embodiment, wherein the saddle type vehicle 10 is a vehicle with the IC engine 125, the saddle type vehicle 10 comprises of a fuel tank assembly (not shown) and the cap assembly 200 is configured to be mounted on an inlet of the fuel tank assembly, thereby covering the inlet of the fuel tank assembly. In this embodiment, the mounting flange 206 mounts the cap assembly 200 to the fuel tank assembly.
[033] In an alternative embodiment, wherein the saddle type vehicle 10 is an electrically powered vehicle, the saddle type vehicle 10 comprises of a battery pack assembly (not shown) and the cap assembly 200 is configured to be mounted on a charging socket of the battery pack assembly, thereby covering the charging socket of the battery pack assembly.
[034] In another aspect the present invention relates to a method 300 of assembling a cap assembly 200 for a saddle type vehicle 10. The method steps involved in the method are illustrated in Figure 6. At step 3A, a cap unit 230 is disposed on a cap body 210, by means of a lever 214. The lever 214 is received on an outwardly protruding flange 212 the cap body 210. At step 3B, the cap body 210 is fitted on to the saddle type vehicle 10 by means of a mounting flange 206 on the cap body 210. At step 3C, one or more vertical projections 222 on a cap body cover 220 are snap fitted on one or more lateral projections 216 on an outer surface of the cap body 210 such that cap body cover 220 disposed along the outer surface of the cap body 210.
[035] Advantageously, the present invention provides a cap assembly which is theft proof while maintaining the aesthetics and the serviceability of the cap assembly on the saddle type vehicle, especially since the cap unit is flush with the body of the vehicle. The cap assembly can only be disassembled and serviced when the cap unit is opened by means of the vehicle key, and the cap body and the cap body cover cannot be rotated with respect to each other, making the assembly theft proof.
[036] Further, the cap assembly of the present invention, due to fewer movable parts is easier to manufacture and assemble.
[037] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.