Claims:We Claim:
1. A lever assembly (100) for a vehicle, said lever assembly (100) comprising :
a lever (105);
a holder (110);
said lever (105) being attached to said holder (110) through a connecting pin (112),
wherein,
a portion of said connecting pin (112) being covered by a resilient member (120).
2. The lever assembly (100) as claimed in claim 1, wherein said connecting pin (112) includes a head (115) and a shank (117) and said shank (117) includes an upper shank portion (117A) and a lower shank portion (117B), wherein said upper shank portion (117A) is integrally attached with said head (115) on a upper side (X) and said upper shank portion (117A) is integrally attached with said lower shank portion (117B) along a vertical axis (X-X’) of said connecting pin (112).
3. The lever assembly (100) as claimed in claim 2, wherein said lower shank portion (117B) includes an inner recess portion (116).
4. The lever assembly (100) as claimed in claim 3, wherein said inner recess portion (116) covers less than twenty five percent of the total area of the lower shank portion (117B).
5. The lever assembly (100) as claimed in claim 3, wherein said inner recess portion (116) covers less than forty percent of the total area of the lower shank portion (117B).
6. The lever assembly (100) as claimed in claim 3, wherein said inner recess portion (116) covers less than eighty percent of the total area of the lower shank portion (117B).
7. The lever assembly (100) as claimed in claim 3, wherein said resilient member (120) covers said inner recess portion (116).
8. The lever assembly (100) as claimed in claim 2, wherein said upper shank portion (117A) being cylindrical in shape having a first base surface (PP’) and a second base surface (QQ’).
9. The lever assembly (100) as claimed in claim 8, wherein said first base surface (PP’) and said second base surface (QQ’) being circular in shape and parallel to each other.
10. The lever assembly (100) as claimed in claim 8, wherein said first base surface (PP’) being oval in shape whereas the second base surface (QQ’) being oval in shape and parallel to each other.
11. The lever assembly (100) as claimed in claim 8, wherein said first base surface (PP’) being circular in shape whereas said second base surface (QQ’) being oval in shape and parallel to each other.
12. The lever assembly (100) as claimed in claim 8, wherein said first base surface (PP’) and said second base surface (QQ’) being oval in shape and parallel to each other.
13. The lever assembly (100) as claimed in claim 1, wherein said holder (100) includes an upper face (111) and said upper face (111) having an oval opening (111A) for receiving said connecting pin (112).
14. The lever assembly (100) as claimed in claim 1, wherein said resilient member (120) being configured with an elongated semi-circular cross section profile, said resilient member (120) being disposed along a rotation axis (X-X’) of said connecting pin (112).
15. The lever assembly (100) as claimed in claim 1, wherein said resilient member (120) being configured with a crescent shaped cross sectional profile, said resilient member (120) being disposed along a rotation axis (X-X’) of said connecting pin (112).
16. The lever assembly (100) as claimed in claim 1, wherein said connecting pin (112) being connected by a regular (121), a head 115 of said connecting pin (112) being covered by said regulator (121) and said connecting pin (112) being rotatable by said regulator (121) for increasing or decreasing a grip of said resilient member (120) to said connecting pin (112) thereby selectively achieving one of a soft and a hard feel of lever actuation as experience by a user , Description:TECHNICAL FIELD
[0001] The present subject matter described herein generally relates to a lever assembly, and particularly but not exclusively relates to a hand lever assembly for a vehicle.
BACKGROUND
[0002] Generally, in two-wheeled vehicles and three wheeled vehicles, a lever assembly is employed for variety of purposes including braking of the wheels and engagement and disengagement of the clutch assembly. The vehicle is provided with a pair of brakes disposed on the front and the rear wheels. Typically, such brakes are operated mechanically or hydraulically and includes drum brakes and disc brakes. In some applications, disc brake is installed on front wheel(s) and in some other application, the disc brake is installed on both front and rear wheels. Typically, determination of whether to use disc brakes is primarily based on the capacity of the vehicle and the maximum load of the vehicle.
[0003] In present times, braking systems that allow simultaneous actuation of a front brake and a rear brake upon application of a single brake have gained widespread popularity across the globe. Such, simultaneous actuation of the front wheel brake and the rear wheel brake is performed by a hand operated lever assembly or a foot operated pedal assembly.
BRIEF DESCRIPTION OF DRAWINGS

[0004] The detailed description of the present subject matter is described with reference to the accompanying figures. Same reference signs are used throughout the drawings to reference like features and components.
[0005] Fig.1 illustrates a perspective view of a lever assembly in accordance with an embodiment of the present subject matter.
[0006] Fig.2 illustrates a perspective view of a holder of a lever assembly in accordance with an embodiment of the present subject matter.
[0007] Fig.3 illustrates a side view of a connecting pin in accordance with the present subject matter.
[0008] Fig.4 illustrates a perspective view of a connecting pin in accordance with the present subject matter.
[0009] Fig.5 illustrates a top view of a lever assembly in accordance with an embodiment of the present subject matter.
[00010] Fig.6 illustrates a top view of a lever assembly in accordance with an embodiment of the present subject matter.
[00011] Fig.7 illustrates a top view of a lever assembly in accordance with an embodiment of the present subject matter.
[00012] Fig.8 illustrates a top view of a lever assembly in accordance with an embodiment of the present subject matter.
[00013] Fig.9 illustrates a sectional view of a holder of a lever assembly in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION OF THE INVENTION
[00014] Automobile sector has witnessed a huge technological growth in the past few decades in terms of improving the safety and the comfort of the rider and the passengers. In light of the same, manufactures of two wheeled vehicles and three wheeled vehicles have introduced several braking technologies to improve rider safety and provide the rider a comfortable riding experience. Some of the braking technologies are anti-lock braking system (ABS), Electronic Brake-Force distribution system (EBD) and Synchronised Braking System (SBS). Among these large number of passenger vehicles are equipped with at least the SBS technology.
[00015] Under the Synchronised Braking System or other forms of integrated braking systems or linked braking systems, the vehicle uses a reaction relay mechanism though which the front brakes are applied automatically in a quick succession when the rider applies the rear brake. Such a mechanism also ensures a smooth transition of brake force distribution from the rear bake to the front brake. This mechanism ensures an efficient braking with less braking distance. However, the end customer often faces difficulties in adapting towards such technologies. Conventionally, a customer who have been riding two wheeled or three wheeled vehicles from a long duration of time continues to have the same muscle memory and habit of applying the front brake and the rear brake separately. Conventionally, in two wheeled vehicles the front brake was actuated through a hand lever whereas the rear brake is actuated through a foot pedal.
[00016] Also, with the implementation of SBS technology effectiveness of the brake system for front brakes was reduced at an optimised level. This system ensures additional force is not applied to the front brakes. If additional force is applied to the front brakes the front wheel may experience premature wheel locking and this results in vehicle instability or rear wheel lifting. Such a situation often arise when the rider separately applies the front brakes through a front brake lever in an emergency situation. In such situations often the additional force is transmitted to the front wheel.
[00017] Keeping the safety of the rider in mind, the manufacturers provide a hard front brake lever by pre-setting a lever ratio of the hand operated front brake lever. In addition to the same, the manufacturer provides a synchronised braking system or any other linked braking system (LBS) or an integrated braking system (IBS) in which the front brakes and the rear brakes are linked together so that with depressing or application of one brake lever, a required vehicle braking is achieved in combination of all brakes. The required braking is determined by a proportional control valve which proportionally distributes the input actuation force to each wheel based on preset criteria. In this manner safety related problems are resolved. However, riders still face comfort related problems. The riders face problem with a hard brake feel on the hand operated brake lever. Such problem is faced by riders with different experience which includes a rider who have been habituated to press the front brake hand lever, a rider who rides the vehicle in different terrains and wishes to press the front brake lever and also has used the synchronised braking system or any other linked braking system or an integrated braking system.
[00018] As per known art, the lever ratio of the lever assembly is changed thereby resolving the problem of hard lever feel to the rider. The lever ratio is defined as the length of the lever to a pivot point divided by the measurement of the distance of pivot point to a lower arm or actuating point that controls actuation of the rod of the master cylinder. However, any variation in the lever ratio fails the purpose of using a synchronised braking system or any other linked braking system or the integrated braking system or any other braking technology where the front and the rear brakes are actuated by one lever or pedal.
[00019] As per other known arts, a separate master cylinder is provided for the individual lever assembly having an in-built delay mechanism which delays the application of the brakes on actuation of the lever assembly. However, using a separate master cylinder assembly increase the cost of the vehicle and complicates the braking for the rider. Additionally, in case of damage to the additional master cylinder assembly, the problems mentioned above remain unresolved. Thus there is a need to provide simpler, cost-effective and permanent solution to improve the brake feel of the lever assembly without changing the lever ratio of the lever assembly which is determined or fixed by the manufacturer.
[00020] In view of the above, the objective of the present subject matter is to improve the brake feel of the lever assembly without changing the lever ratio of the lever assembly determined by the manufacturer. Another objective of the present subject matter is to provide the lever assembly on which the rider is able to change the level of lever hardness as per his comfort without affecting the functioning of any other braking technology being used or without affecting the lever ratio. Additionally, another objective of the present subject matter is to prevent premature wheel locking upon pressing the lever and thereby enhance safety of the rider.
[00021] As per an aspect of the present subject matter, the lever assembly comprises: a lever and a holder. The lever is integrated to the holder through a connecting pin and a portion of said connecting pin being covered by a resilient member. The resilient member provides a cushioning support to the connecting pin. The resilient member prevents the force applied by the rider on the lever to be transmitted through the lever assembly to the brakes. The resilient member act as primary receiver of the force applied by the rider on the lever and restrict the movement of the lever assembly. Also, the resilient member ensures that connecting pin is adjusted as per the preference of the rider thereby the complaint associated with the hard brake lever feel is resolved without changing the lever ratio.
[00022] As per an aspect of the present subject matter, the connecting pin includes a shank. The shank includes an upper shank portion and a lower shank portion. The lower shank portion includes an inner recess portion and the resilient member covers the inner recess portion. The advantage of such a covering of the resilient member to the inner recess portion is that the hard feel of the lever is reduced as per rider preference which does not affect the lever ratio of the lever assembly. Therefore, when such a lever assembly is used as a brake lever assembly, the wheel locking is prevented due to application of force on lever. In such scenario despite application of load on the lever, the force is not transmitted to the brakes on the wheel. The resilient member absorbs the force applied by the rider on the lever and minimise the force transmitted through the lever assembly to the brakes. Ultimately, when the present invention implemented in vehicles with integrated braking technology or linked braking technology or synchronised braking technology or any other braking technology whereby front brakes and rear brakes are applied by single actuation, in such vehicles, the rider complaint of hard brake feel is checked as well as ensuring the safety of the rider and the passenger.
[00023] Summary provided above explains the basic features of the invention and does not limit the scope of the invention. The nature and further characteristic features of the present subject matter will be made clearer from the following descriptions made with reference to the accompanying drawings.
[00024] Exemplary embodiments detailing features of the lever assembly and its construction, in accordance with the present subject matter will be described hereunder with reference to the accompanying drawings. Various aspects of different embodiments of the present subject matter will become discernible from the following description set out hereunder. Rather, the following description provides a convenient illustration for implementing exemplary embodiments of the present subject matter. Further, it is to be noted that terms “upper”, “lower”, “right”, “left”, “front”, “forward”, “rearward”, “downward”, “upward”, “top”, “bottom” and like terms are used herein based on the illustrated state of the lever assembly. Furthermore, a vertical axis refers to a top to bottom axis relative to the lever assembly, defining a vertical direction; while a lateral axis refers to a side to side, or left to right axis relative to the lever assembly, defining a lateral direction. Further, a longitudinal axis refers to a front to rear axis relative to the lever assembly, defining the in a longitudinal direction. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
[00025] The present subject matter along with all the accompanying embodiments and their other advantages would be described in greater detail in conjunction with the figures in the following paragraphs.
[00026] With reference to Fig.1, a description is made of an entire schematic structure of a lever assembly 100. The lever assembly 100 includes a lever 105, a holder 110, a one or more actuation cables 107, a master cylinder assembly 108, a first handlebar holding portion 114 and a second handlebar holding portion 113. The lever 105 includes a first lever portion 105A and a second lever portion 105B.The first lever portion 105A receives force from the rider whereas the second lever portion 105B provides integration of the lever assembly 105 with a holder 110. The second lever portion 105B also includes a gap portion 106 which ensures integration of the second lever portion 105B with the holder 110. A connecting pin 112 also passes through the gap portion 106. As per the illustrated embodiment, the connecting pin 112 having a head 115 is accommodated in the holder 110 from the upper face 111 of the holder 110. Further, a master cylinder assembly 108 is integrated to the holder 110. Also, the first handlebar holding portion 114 and the second handlebar holding portion 113 integrates the holder 110 to a handlebar (not shown). The first handlebar holding portion 114 is provided on the holder 110 such that the first handlebar holding portion 114 is having a first opening portion 114A. Also, the second handlebar holding portion 113 is provided with a second opening portion 113A corresponding to the first opening portion 114A of the first holding portion 114 such that when the first opening portion 114A and the second opening portion 113A are integrated they enclose and grip a portion of the handlebar from opposite sides.
[00027] With reference to Fig 2, a perspective view of the holder 110 is illustrated as per an embodiment of the present subject matter. The holder 110 is having the upper face 111 and a lower face 122. The connecting pin 112 is integrated to the holder 110 passing through either an oval opening 111A (shown in Fig 6) or a circular opening 111B (shown in Fig 7) which is provided on the upper face 111 and the lower face 122. The connecting pin 112 includes the head 115, a shank 117 and a tip 118. Also, a nut 119 is provided on the tip 118 to hold the connecting pin 112 on the holder 110.
[00028] With reference to Fig 3, a side view of the connecting pin 112 is illustrated as per an embodiment of the present invention. In accordance with the illustrated embodiment, the shank 117 includes an upper shank portion 117A, a lower shank portion 117B and a resilient member 120 abuttingly coupled with the lower shank portion 117B. Below the lower shank 117B is disposed the threaded tip 118 which is capable of receiving a nut 119 to lock and secure the connecting pin 112 against the lower surface 122 of the holder 110. The upper shank portion 117A is integrally attached to the head 115 from an upper side X and is integrally attached to the lower shank portion 117B from a lower sider X’ along a vertical axis X-X’ of the connecting pin 112.
[00029] In an embodiment, the upper shank portion 117A is cylindrical in shape having an upper shank length L and a first base surface PP’ and a second base surface QQ’. The first base surface PP’ is having a upper shank diameter D. In an embodiment the first base surface PP’ and the second base surface QQ’ are circular in shape and parallel to each other.
[00030] In another embodiment, the first base surface PP’ is oval in shape whereas the second base surface QQ’ is circular in shape and parallel to each other.
[00031] In another embodiment, the first base surface PP’ is circular in shape whereas the second base surface QQ’ is oval in shape and parallel to each other.
[00032] In an embodiment the first base surface PP’ and the second base surface QQ’ are oval in shape and parallel to each other.
[00033] The presence of a cylindrical shaped upper shank portion 117A with a circular or oval shaped first base surface PP’ ensures that the connecting pin 112 is provided with degree of freedom to rotate when the connecting pin 112 is fitted to the holder 110.
[00034] The presence of a cylindrical shaped upper shank portion 117A with a circular or oval shaped second base surface QQ’ ensures that adequate resting space for a resilient member 120 is provided which does not cause interference of the resilient member 120 with the adjoining parts. Also, an adequate grip is provided at junction of the resilient member 120 and the upper shank portion 117A which improves the cushioning and gripping of the resilient member 120 to the shank 117 of the connecting pin 112.
[00035] In an embodiment, the lower shank portion 117B includes an inner recess portion 116 having a circular or arc shaped cross section profile. In an embodiment, the inner recess portion 116 covers less than forty percent of the total surface area of the lower shank portion 117B.
[00036] In another embodiment, the inner recess portion 116 covers less than sixty percent of the total surface area of the lower shank portion 117B.
[00037] In another embodiment, the inner recess portion 116 covers about eighty percent of the total area of the lower shank portion 117B.
[00038] The resilient member (120) is engaged or abutting only on the limited portion of the shank 117. With an increase in presence of resilient member on the shank 117, more cushioning support is provided to the connecting pin 112. Thus, with presence of inner recess portion 116 at less than twenty five percent of the area of the shank, or less than forty percent of the area of shank, or less than eighty percent area of the shank, the rider is able to adjust the lever hardness as per requirement.
[00039] Further, in the illustrated embodiment, a resilient member 120 being provided to cover the inner recess portion 116. Also, the tip 118 being provided on the lower side of the lower shank portion 117B along the vertical axis X-X’.
[00040] In an embodiment, the resilient member 120 is having an elongated semi-circular cross section profile along the vertical axis X-X’ of the connecting pin 112 capable of coupling with a circular outer profile of the recess portion 116.
[00041] In an embodiment, the resilient member 120 is having crescent shaped profile along the vertical axis X-X’ of the connecting pin 112.
[00042] The presence of resilient member 120 with an elongated semi-circular profile is fitted to the shank 117 without any support or without causing any interference to the adjoining parts. This, enhances the cushioning effect of the resilient member 120 to the lever assembly 100.
[00043] In an embodiment, the tip 118 is having a threaded portion and a non-threaded portion. Whereas, in another embodiment, the tip 118 is completely threaded. In another embodiment, the tip 118 being completely non-threaded.
[00044] With reference to Fig 4, a perspective view of the connecting pin 112 is illustrated as per an embodiment of the present invention. As per the illustrated embodiment, the resilient member 120 covers the inner recess portion 116. The resilient member 120 is having a first thickness T’.
[00045] With reference to Fig 5 and Fig 6, a top view of the lever assembly 100 is illustrated as per another embodiment of the present invention. As per the illustrated embodiment, the oval opening 111A is provided on the upper face 111 of the holder 110. The oval opening 111A accommodate the connecting pin 112 with abutting the oval first base surface PP’ of the upper shank portion 117A of the shank 117. Also, the oval opening 111A accommodate the connecting pin 112 with abutting the oval second base surface QQ’ of the upper shank portion 117A of the shank 117.
[00046] With reference to Fig 7, a top view of the lever assembly 100 is illustrated in another embodiment of the present invention. As per the illustrated embodiment, the circular first base surface PP’ of the upper shank portion 117A being accommodated in a circular opening 111B of the upper face 111 of the holder 110.
[00047] With reference to Fig 8, a top view of the lever assembly 100 is illustrated in another embodiment of the present invention. As per the illustrated embodiment, a regulator 121 is provided on the upper face 111 of the holder 110. The regulator 121 is attached to the head 115 of the connecting pin 112 so as to enable rotating the connecting pin 112 by a user. The resilient member 120 by its virtue of being abutted against the inner recess portion 116 of the lower shank 117B, tends to elastically compress within the space available on the outer diameter of the connecting pin and the inner diameter of the holder 110. Rotation of the regulator causes a desired thickness of the resilient member 120 to be available for transferring and / or absorbing a rider lever input force through its elastic compression. Thus, when a peak thickness i.e. first thickness T of the resilient member 120 is being compressed, the resilient member 120 elastically deforms and absorbs maximum permissible force by the rider and a partial value is transferred for performing the braking functions thereby eliminating excess force being transferred and giving a soft feel to the user. Extreme end low thickness is engaged to be compressed towards an axis of rotation X-X’ of the connecting pin, then minimum force is absorbed by the resilient member 120 leading to a harder feel for the user applying brake actuation force. The regulator along with the connecting pin is thus used to adjust grip of the resilient member 120 as per rider convenience and thereby altering the hard and soft feel of the brake lever. The regulator 121 covers the connecting pin 112 from the top and the regulator 121 is rotatable to increase or decrease the grip of the resilient member such that with decreasing of the grip the hardness of the lever assembly is reduced an ultimately the hard feel of the lever is reduced.
[00048] With reference to Fig 9, a sectional view of the holder 110 is illustrated in another embodiment of the present invention. As per the illustrated embodiment, the resilient member 120 is coupled to the shank 117 of the connecting pin 112 such that the resilient member covers the inner recess portion 116 completely.
[00049] Also in an embodiment, damper bushes are provided in parallel to the master cylinder piston in the master cylinder assembly 108 which restricts the input force during braking and regulate the force rate which further reduces the undesired wheel locking.
[00050] Many modifications and variations of the present subject matter are possible in the light of above disclosure. Therefore, within the scope of claims of the present subject matter, the present disclosure may be practiced other than as specifically described.
 
LIST OF REFERENCE SIGNS

100: Lever Assembly
105: Lever
105A: Second Lever Portion
105B: First Lever Portion
106: Gap Portion
107: Actuation Cables
108: Master cylinder Assembly
110: Holder
111: Upper Face
111A:Oval Opening
111B: Circular Opening
112: Connecting Pin
113: Second Handlebar Holding Portion
113A: Second Opening Portion
114: First Handlebar Holding Portion
114A: First Opening Portion
115: Head
116: Inner Recess Portion
117: Shank
117A: Upper Shank Portion
117B: Lower Shank Portion
118: Tip
119: Nut
120: Resilient Member
121: Regulator
122: Lower Face
D: Upper Shank Diameter
L: Upper Shank Length
PP’: First Base
QQ’: Second Base
T’: First Thickness
X: Upper Side
X’: Lower Side
X-X’: Vertical Axis