DESC:FIELD OF THE DISCLOSURE

The present disclosure relates to a metallic insert with plastic thread moulding design for an assembly in a two-wheeler.

BACKGROUND

Generally, vehicles such as two-wheelers are equipped with various assemblies such as clamps. Each clamp may include at least two components adapted to be assembled by using at least one fastener. An insert is disposed in a body of one of the components, and the at least one fastener is tightened in the metallic insert by applying a tightening force.

However, a problem associated with the conventional insert is that an additional amount of the tightening force may cause rotation of the insert with respect to the body. This results in an unnecessary movement of the insert and lowers the performance of the clamp. Further, the conventional insert requires more space to accommodate the body of the clamp. Moreover, the conventional insert is made of brass material, which is expensive and increases the overall cost of the insert.

Accordingly, there is a need to develop an insert that overcomes one or more problems of the existing art.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify essential inventive concepts of the invention nor is it intended for determining the scope of the invention.

The present disclosure relates to a clamp assembly adapted to be mounted on a handlebar of a two-wheeler. The clamp assembly includes a first portion, a second portion adapted to lock with the first portion, and a lock assembly adapted to secure the first portion with the second portion. The handlebar is sandwiched between the first portion and the second portion. The lock assembly includes one or more cavities extending inside the first portion, one or more cavities extending inside the second portion and aligned with the one or more cavities of the first portion, and an insert adapted to be received inside each of the one or more cavities of the first portion. The one or more cavities of the first portion include a plurality of threads. The inserts include a slot having a plurality of threads aligned with the plurality of threads of each of the cavities of the first portion. A fastener is threaded partially in the insert and partially in the each of the cavities.

The clamp assembly facilitates the clamping of the first portion and the second portion thereby enabling a secure coupling of the two portions. In addition, partial threading of the fastener with the inserts and the cavities of the first portion prevents any slippage of the fasteners. In addition, the inserts prevent any slippage within the cavities due to their rectangular shape configuration. The insert in the present disclosure achieves high tightening torque for clamping the second portion with the first portion. In this manner, the clamp assembly may be used in a plurality of applications such as but not limited to machines, mountings, fixtures, flanges, couplings, shafts, or any other application requiring clamping of the two portions.

The insert disclosed herein achieves high tightening torque for the second portion and the first portion and facilitates an improved mounting of the clamp assembly on the handlebar of the two-wheeler. The insert is constrained within each of the cavities of the first portion and prevents the rotation or shifting of the insert from the position during the tightening/screwing of the fastener. Further, the insert is of compact size, so it requires less space to accommodate in the first portion. Moreover, the insert is formed of a material including carbon steel with zinc plating, or any plastic or polymeric material known in the art. The usage of such material reduces the overall cost of the metallic insert and provides a better quality. In this manner, a high tightening torque is achieved for the clamp assembly and prevents any failure of the clamp assembly arising due to the spinning or twisting of the insert within the clamp assembly.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates an exploded view of a clamp assembly, according to an embodiment of the present disclosure;
Figure 2 illustrates an assembled view of the clamp assembly, according to an embodiment of the present disclosure;
Figure 3 illustrates a top view of a first portion of the clamp assembly, according to an embodiment of the present disclosure;
Figure 4 illustrates a sectional view of the first portion of the clamp assembly, according to an embodiment of the present disclosure;
Figure 5 illustrates a top-perspective view of an insert adapted to rest inside the clamp assembly, according to an embodiment of the present disclosure; and
Figure 6 illustrates a sectional view of the insert of the clamp assembly, according to an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present disclosure. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

While the embodiments in the disclosure are subject to various modifications and alternative forms, the specific embodiment thereof has been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

It is to be noted that a person skilled in the art would be motivated from the present disclosure to modify a metallic insert with plastic thread moulding design for an assembly as disclosed herein. However, such modifications should be construed to be within the scope of the disclosure. Accordingly, the drawings show only those specific details that are pertinent to understand the embodiments of the present disclosure, so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.

Referring to Figure 1 and Figure 2, a clamp assembly 100 adapted to be mounted on a handlebar (not shown) of a two-wheeler (not shown) is shown. Specifically, Figure 1 illustrates an exploded view of the clamp assembly 100. Figure 2 illustrates an assembled view of the clamp assembly 100. Figure 3 illustrates a top view of a first portion 102 of the clamp assembly 100. Figure 4 illustrates a sectional view of the first portion 102 of the clamp assembly 100. The clamp assembly 100 may be a part of a switch box of a two-wheeler, a bar switch lever assembly, a switch assembly, or any module adapted to be mounted on the handlebar of the two-wheeler.

As shown in Figure 1 to Figure 4, the clamp assembly 100 may include the first portion 102 having a central cavity 103a defining a semi-circular cavity extending along a length of the first portion 102. In addition, the clamp assembly 100 includes a second portion 104 adapted to be assembled and locked with the first portion 102 and includes a central cavity 103b defining a semi-circular cavity extending along a length of the second portion 104. The central cavity 103a of the first portion 102 is adapted to align with the central cavity 103b of the second portion 104, such that the handlebar is sandwiched between the central cavity 103a of the first portion 102 and the central cavity 103b of the second portion 104. As shown, the two central cavities 103a, 103b collectively define a cylindrical shape configuration for facilitating the resting of the handlebar of the two-wheeler.

In addition, the clamp assembly 100 includes a lock assembly 105 adapted to secure the first portion 102 with the second portion 104 and facilitate the locking of the first portion 102, the handlebar, and the second portion 104, thereby enabling a secure arrangement of the handlebar with the clamp assembly 100.

In an embodiment, the first portion 102 and the second portion 104 are assembled by using a fastener 106. The fastener 106 may be embodied as at least one screw having a plurality of external threads, or at least one bolt, or at least one stud. In an exemplary embodiment, the fastener 106 includes a head portion 106a adapted to rest inside the second portion 104, a shank portion 106b extending outwardly from the head portion 106a and adapted to rest partially inside the first portion 102 and partially inside the second portion 104. In an example, the head portion 106a may define a binding shape configuration, a button shape configuration, a cheese shape configuration, a fillister shape configuration, a flange shape configuration, a hex shape configuration, a pan shape configuration, a round shape configuration, a socket shape configuration, a low socket shape configuration, a square shape configuration and a truss head shape configuration or any other design or configuration of a head of a fastener known in the art. In another example, the shank portion 106b defines a cylindrical shape configuration. In addition, the shank portion 106b includes a plurality of threads 106c extending along a portion of the shank portion 106b and adapted to rest within the first portion 102. The clamp assembly 100 may include one or more than one screws adapted to rest within the lock assembly 105 and lock the first portion 102 with the second portion 104. In an embodiment, the clamp assembly 100 may include two screws to facilitate the assembly of the first portion 102 and the second portion 104.

As shown, in Figure 1 to Figure 4, the lock assembly 105 for securing the first portion 102 with the second portion 104 of the clamp assembly 100 may include at least one mounting portion 108 adapted to couple with the second portion 104 of the clamp assembly 100. The at least one mounting portion 108 of the lock assembly 105 includes one or more cavities 109 extending inside the first portion 102 to facilitate the resting and coupling of the fasteners 106 inside the each of the cavities 109. As an example, the at least one mounting portion 108 includes a first cavity 109a extending inwardly along an end of the first portion 102 and a second cavity 109b extending inwardly along an opposite end of the first portion 102. In an example, the one or more cavities 109 may define a diamond, a square, a rectangular, and a rhombic shape configuration.

Further, the lock assembly 105 having the one or more cavities 109 of the first portion 102 includes at least one insert 110 adapted to be received and fused inside each of the cavities 109 of the first portion 102 to prevent any slippage, loosening or freeing of the inserts 110 within the cavity. Additionally, the lock assembly 105 of the clamp assembly 100 includes one or more cavities 111 extending inside the second portion 104 and aligned with the one or more cavities 109 of the first portion 102. The one or more cavities 111 of the second portion 104 are adapted to receive the fastener 106 to facilitate the screwing/tightening of the insert 110 disposed within the each of the cavities 109 of the first portion 102. In an example, the one or more cavities 111 of the second portion 104 includes a first cavity 111a extending inwardly from the second portion 104 and disposed proximate to an end of the second portion 104 and a second cavity 111b disposed spaced apart from the first cavity 111a and extending inwardly from the second portion 104 and disposed proximate to an opposite end of the second portion 104. The first cavity 109a of the first portion 102 is aligned with the first cavity 111a of the second portion 104, and the second cavity 109b of the first portion 102 is aligned with the second cavity 111b of the second portion 104 to facilitate the insertion of the fasteners 106 in the two cavities 109, 111 such that the fasteners 106 rest partially in the two cavities 109, 111 and partially in the inserts 110. In an embodiment, the second portion 104 and the first portion 102 may be formed of plastic.

Referring to Figure 5 and Figure 6, the insert 110 is shown. Specifically, Figure 5 illustrates a top-perspective view of the insert 110 adapted to rest inside the clamp assembly 100. Figure 6 illustrates a side-sectional view of the insert 110 adapted to rest inside the clamp assembly 100. As shown, the insert 110 includes a slot 112 disposed centrally and extending from a first surface 113a to a second surface 113b of the insert 110. In an example, the slot 112 extending from the first surface 113a to the second surface 113b of the insert 110 thereby defining a cylindrical shape configuration. In addition, the slot 112 includes a plurality of threads 114 disposed internally to the insert 110 and extending along a sidewall of the slot 112 to facilitate the screwing of the fastener 106. In an example, the plurality of threads 114 extends along the cylindrical shape configuration of the slot 112. In an embodiment, the insert 110 is moulded into the first portion 102, so that the material of the first portion 102 rests around the insert 110. In an example, the threads 114 of the slot 112 of the insert 110 are adapted to receive the fastener 106 such as the screw. In an embodiment, the size of the slot 112 is corresponding to the size of the fastener 106. In an embodiment, the insert 110 is made of a material including carbon steel with zinc plating. In an embodiment, the threads 114 includes at least one of a metallic thread and a plastic thread. In another embodiment, the insert 110 may define a cuboidal shape configuration having a square shape of the first surface 113a and the second surface 113b having the slot 112 along a central portion. In an embodiment, the insert 110 is of small size, having a height of 5mm. In an embodiment, the insert 110 may have at least one of a cuboidal shaped configuration, a diamond shaped configuration, a square shaped configuration, a rectangular shaped configuration, and a rhombic shaped configuration having a slot along a central portion. The cuboidal shape may prevent the rotation and the linear movement of the insert 110 during the tightening of the fastener 106. Moreover, the carbon steel with zinc plating is less expensive, and this reduces the overall cost of the insert 110.

As shown in Figures 1 to Figure 4. The cavities 109 of the first portion 102 include a plurality of threads 118 extending internally and in line with the threads 114 of the slot 112 of the insert 110. In an embodiment, the threads 114 of the each of the inserts 110 is in line with the threads 118 of each of the cavities 109 of the first portion 102. The threads 118 are additional threads which may also be referred to as plastic threads. In an example, the threads 118 may include a first thread 118a extending inside the first cavity 109a of the first portion 102, and a second thread 118b extending inside the second cavity 109b of the first portion 102. In an exemplary embodiment, the first thread 118a extending inside the first cavity 109a and is aligned with the threads 114 of the insert 110 disposed inside the first cavity 109a, and the second thread 118b extends inside the second cavity 109b of the first portion 102 and are aligned with the threads 114 of the insert 110 disposed inside the second cavity 109b.

The threads 118 in the first portion 102 of the at least one mounting portion 108 may avoid the pull-out, while a torque is applied during the assembling process of the first portion 102 and the second portion 104. In an embodiment, the insert 110 may be moulded in the first portion 102 of the at least one mounting portion 108. In another embodiment, the insert 110 may be fitted in the first portion 102.

Further, the fastener 106 having the external threads 106c is adapted to be partially threaded with the threads 114 of the insert 110 resting inside the first cavity 109a of the first portion 102 and partially threaded with the first threads 118a of the first cavity 109a. Similarly, the fastener 106 having the external threads 106c is adapted to be partially threaded with the threads 114 of the insert 110 resting inside the second cavity 109b of the first portion 102 and partially threaded with the second threads 118b of the second cavity 109b. In an embodiment, the fastener 106 is partially threaded with the threads 114 of the each of the insert 110 resting in the each of the cavities 109 and partially threaded with the threads 118 of each of the cavity 109. Further, during the moulding process, the first thread 118a and the second thread 118b are formed to provide more tightening torque and strength. The threads 118 of the cavity 109 of the first portion 102 provide additional plastic threads for achieving the high torque, while the fastening of the fasteners 106.

The application and the working of the clamp assembly 100 are now explained. Initially, the insert 110 having the threads 114 defined as the internal threads, is moulded in the first portion 102 via a moulding process. The material of the first portion 102 rests around the insert 110, and the inserts 110 are fused within the cavities 109 of the first portion 102. Additionally, the threads 118 are formed in the cavities 109 of the first portion 102 via the moulding process. Further, the second portion 104 is placed on the first portion 102 by aligning the cavities 109 of the first portion 102 with the cavities 111 of the second portion 104 and accommodating the insert 110 within the cavities 109 of the first portion 102.

Then, the fastener 106 such as the screw is inserted in the cavities 111 of the second portion 104 and passes through the cavities 109 of the first portion 102 via the slot 112 defined in the inserts 110. The threads 114 of the inserts 110 and the threads 118 of the cavities 109 of the first portion 102 are tightened. The tightening of the fastener 106 is done partly with the threads 114 of the inserts 110 and the threads 118 of the cavities 109 of the first portion 102. Thus, the tightening force is partly applied to the insert 110 and partly applied to the threads 118 in the cavities 109 of the first portion 102. This may prevent the rotation of the insert 110 in the first portion 102. The second portion 104 and the first portion 102 are assembled by tightening the fasteners 106. Herein, a portion of the fastener 106 is threaded to the first portion 102, and another portion of the fastener 106 is threaded to the insert 110. This helps to achieve the high strength of the clamp assembly 100.

The advantages of the clamp assembly 100 are now explained. The clamp assembly 100 facilitates the clamping of the first portion 102 and the second portion 104 thereby enabling a secure coupling of the two portions 102, 104. In addition, partial threading of the fastener 106 with the inserts 110 and the cavities 109 of the first portion 102 prevents any slippage of the fasteners 106. In addition, the inserts 110 prevent any slippage within the cavities 109 due to their rectangular shape configuration. The insert 110 in the present disclosure achieves high tightening torque for clamping the second portion 104 with the first portion 102. In this manner, the clamp assembly 100 may be used in a plurality of applications such as but not limited to machines, mountings, fixtures, flanges, couplings, shafts, or any other application requiring clamping of the two portions.

In addition, the clamp assembly 100 facilitates the clamping on the handlebar of the two-wheeler. The insert 110 is constrained within the cavities 109 of the first portion 102 and prevents the rotation or shifting of the insert 110 from the position during the tightening/screwing of the fastener 106. Further, the insert 110 is of compact size, so it requires less space to accommodate in the first portion 102. Moreover, the insert 110 is formed of the material including carbon steel with zinc plating, or any plastic or polymeric material known in the art. The usage of such material reduces the overall cost of the insert 110 and provides a better quality. In this manner, a high tightening torque is achieved for the clamp assembly 100 and prevents any failure of the clamp assembly 100 arising due to the spinning or twisting of the insert within the clamp assembly 100.

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims. ,CLAIMS:We claim:

1. A clamp assembly (100) adapted to be mounted on a handlebar of a two-wheeler, the clamp assembly (100) comprising:
a first portion (102);
a second portion (104) adapted to lock with the first portion (102), wherein the handlebar is sandwiched between the first portion (102) and the second portion (104); and
a lock assembly (105) adapted to secure the first portion (102) with the second portion (104), the lock assembly (105) comprising:
one or more cavities (109) extending inside the first portion (102), wherein the first portion (102) defining the one or more cavities (109) includes a plurality of threads (118);
one or more cavities (111) extending inside the second portion (104) and aligned with the one or more cavities (109) of the first portion (102); and
an insert (110) adapted to be received and fused inside each of the one or more cavities (109) of the first portion (102) to prevent slippage,
wherein the insert (110) includes a slot (112) having a plurality of threads (114) aligned with the plurality of threads (118) of each of the cavities (109) of the first portion (102), and wherein a fastener (106) is partially threaded with the threads (114) of each of the insert (110) resting in the each of the one or more cavities (109) and partially threaded with the threads (118) of each of the one or more cavities (109).

2. The clamp assembly (100) as claimed in claim 1, wherein the threads (114) of each of the inserts (110) is in line with the threads (118) of each of the cavities (109) of the first portion (102).

3. The clamp assembly (100) as claimed in claim 1, wherein the first portion (102) includes a central cavity (103a) and the second portion (104) includes a central cavity (103b) aligned with the central cavity (103a) of the first portion (102) to facilitate the resting of the handlebar within the two central cavities (103a, 103b).

4. The clamp assembly (100) as claimed in claim 3, wherein the two central cavities (103a, 103b) collectively define a cylindrical shape configuration for accommodating the handlebar.

5. The clamp assembly (100) as claimed in claim 1, wherein the insert (110) defines a cuboidal shape configuration to prevent any slipping or rotation of the insert (110) within the each of the cavity (109) of the first portion (102).

6. The clamp assembly (100) as claimed in claim 1, wherein the insert (110) defines at least one of a diamond shaped configuration, a square shaped configuration, a rectangular shaped configuration, and a rhombic shaped configuration.

7. The clamp assembly (100) as claimed in claim 1, wherein the insert (110) is fused in the each of the cavity (109) of the first portion (102).

8. The clamp assembly (100) as claimed in claim 1, wherein the insert (110) is made of at least one of a metal and a polymeric material.

9. The clamp assembly (100) as claimed in claim 8, wherein the insert (110) is made of a carbon steel material plated with zinc.

10. The clamp assembly (100) as claimed in claim 1, wherein the first portion (102) and the second portion (104) are moulded parts.