DESC:FIELD OF THE INVENTION
The invention relates to Adjustable Lever Holder Assembly for 2/3-wheelers which provides comfort of option to rider by adjusting distance of lever from the handlebar.

The invention relates to Adjustable Lever Holder Assembly having “Lead Screw-and-carrier” mechanism which in turn is a nut-bolt mechanism used to adjust the distance of lever from the handlebar. The invention has 5 different positions of lever up to which rider can adjust as per his/her comfort requirement. The invention provides an adjusting feel to the rider when he/she adjusts the lever from one position to the another.

BACKGROUND OF THE INVENTION

Conventionally, in two wheelers the lever holder assembly comprises of holder, stud lever screw, nyloc nut and a lever. In conventional lever holder assembly lever is a single solid part. In this case, the distance of the lever from the handlebar is fixed and the rider has no option to adjust the lever distance as per his comfort. The palm and finger size of different riders are not same. For the people with smaller palm and finger size it becomes difficult for them to operate the lever and same is the case with people having larger palm and finger size. Both cases result in rider discomfort in operating the lever. Hence an improvement is needed to facilitate the rider to adjust the distance of the lever from the handlebar close to as per individual requirement/preference.

There are already few inventions available for adjustable lever.

Kawaguchi (1988) (US 4779482) disclosed a hand-operated lever for operating a control member, such as the master cylinder of the braking system for a motorcycle, is mounted on the handle grip thereof in a manner to permit adjustment of the lever with respect to the handle grip. The lever is resiliently biased with respect to the control member in order to eliminate "dead travel" from lever operation and to prevent dislodgement of the lever from its adjusted position due to vibration or jarring of the motorcycle. Kawaguchi claimed “For use with a motorcycle having a handle grip and a master cylinder containing an input end fixed with respect to said handle grip, the combination comprising: a lever having an operating portion at one end and a protruding portion at its other end; pivot means intermediate the ends of said lever for pivotally connecting said lever with respect to said master cylinder; a moving body connected intermediate its ends by said pivot means for coaxial pivotal movement with respect to said lever and to said master cylinder, said moving body having an acting portion at one end for operably engaging said master cylinder input end and means forming a base at its other end disposed in facing relation to said lever protruding portion; means interconnecting the operating portion of said lever and the acting portion of said moving body for adjusting the angular position there-between; and means disposed between said moving body base and said lever protruding portion for resiliently biasing said lever operating portion toward said moving body acting portion.

Romano (1990) (US 4,945,785) disclosed a control device adapted to be mounted on a handlebar of a bicycle includes a support body having a first element adapted to be rigidly connected to the handlebar and a second element pivotally mounted on the first element for rotation about an axis relative to the first element. A projection on the second element extends radially with respect to the axis into a recess in the first element and a pair of screw members engage the projection on opposite sides thereof to adjust the position of the second element relative to the first element and to secure the second element in the adjusted position. A control lever is pivoted on the support body and is adapted to operate a control cable.
Romano claimed a control device adapted to be mounted on a handlebar of a bicycle comprising a support body having a control lever pivoted thereon and against which a sheath of a control wire adapted to be operated by the control lever abuts, said support body including a first element adapted to be connected to the handlebar and a second element pivotally mounted on said first element for rotation about an axis, said control lever being pivoted on said second element and adjustable abutment means interposed between said first and second elements for varying the angular position of the second element relative to the first and for making the second element fast with the first element.
Brainard (2003) disclosed a brake lever is adjustably positionable relative to a handlebar of a motorcycle. The lever includes a base, a lever, and an adjustment mechanism. The base is adapted to be pivotally coupled to a master cylinder coupled to the handlebar, and the lever is pivotally coupled to the base. The adjustment mechanism controllably positions the lever relative to the base to control spacing between the lever and the handlebar. The adjustment mechanism includes a cylinder and a pin. The cylinder is rotatable about a longitudinal axis, is coupled to one of the base and the lever, and has a first and second bore hole extending radially therein for first and second preselected distances, respectively. The pin is coupled to the other of the base and the lever, is substantially perpendicular to the longitudinal axis of the cylinder, and is alternately engageable with the first and second bore holes.
Brainard claimed a control lever, comprising: a base; a lever pivotally coupled to said base; and an adjustment mechanism for controllably positioning said lever relative to said base, said adjustment mechanism including: a cylinder rotatable about a longitudinal axis and coupled to one of said base and said lever and having a first and second bore hole extending radially therein for first and second preselected distances, respectively, and a pin coupled to the other of said base and said lever and being substantially perpendicular to the longitudinal axis of said cylinder and alternately engageable with said first and second bore holes.
Brainard also claimed a control lever, comprising: a base; a lever pivotally coupled to said base; a spring extending between said base and said lever and urging said lever in a first direction toward a first operating position; and an adjustment mechanism extending between said base and said lever for controllably positioning said lever relative to said base, said adjustment mechanism being disengaged and free for adjustment in response to movement of said lever in a second direction opposite to said first direction, said adjustment mechanism comprising: a cylinder rotatable about a longitudinal axis and coupled to one of said base and said lever and having a first and second bore hole extending axially therein for first and second preselected distances, respectively, and a pin coupled to the other of said base and said lever and being substantially perpendicular to the longitudinal axis of said cylinder and alternately engageable with said first and second bore holes.
Brainard also claimed a brake lever positionable relative to a handlebar of a motorcycle, the brake lever comprising: a base adapted to be pivotally coupled to a master cylinder coupled to said handlebar; a lever pivotally coupled to said base; and an adjustment mechanism for controllably positioning said lever relative to said base to control spacing between said lever and said handlebar, said adjustment mechanism including: a cylinder rotatable about a longitudinal axis and coupled to one of said base and said lever and having a first and a second bore hole extending radially therein for first and second preselected distances, respectively, and a pin coupled to the other of said base and said lever and being substantially perpendicular to the longitudinal axis of said cylinder and alternately engageable with said first and second bore holes.
Owyang (2013) (US 2013/0047777) disclosed a lever positioner assembly that is coupled to a handlebar of a vehicle comprises a lever, a lever holder, and a lever positioner. The lever moves relative to the handlebar between a released position and an engaged position. The lever holder holds the lever. Additionally, the lever holder is coupled to and movable relative to the handlebar. The lever positioner is coupled to the lever and is positioned on the opposite side of the lever from the handlebar. Additionally, the lever positioner can include an adjuster screw that is selectively rotated to adjust the released position of the lever relative to the lever holder and the handlebar. The lever and the lever holder can move as a unitary structure during movement of the lever between the released position and the engaged position.
Owyang has claimed a lever positioner assembly that is coupled to a handlebar of a vehicle, the lever positioner assembly comprising: a lever that moves relative to the handlebar between a released position and an engaged position; a lever holder that is coupled to the lever, the lever holder being coupled to and movable relative to the handlebar; a lever positioner that is coupled to the lever and that adjusts the released position of the lever relative to the lever holder and the handlebar, the lever positioner is positioned on the opposite side of the lever from the handlebar; and wherein the lever and the lever holder move as a unitary structure during movement of the lever between the released position and the engaged position.
Owyang has also claimed A vehicle including a handlebar, the lever positioner assembly of claim 1 that is coupled to the handlebar, and an actuator that is secured to the lever holder, the actuator selectively actuating a device, and the lever positioner adjusting the released position of the lever without moving the actuator relative to the lever holder.
Owyang has further claimed a lever positioner assembly that is coupled to a handlebar of a vehicle, the vehicle including a device, the lever positioner assembly comprising: a lever that moves relative to the handlebar between a released position and an engaged position; a lever holder that holds the lever, the lever holder being coupled to and movable relative to the handlebar; a lever positioner that is coupled to the lever and that adjusts the released position of the lever relative to the lever holder and the handlebar, the lever positioner is positioned on the opposite side of the lever from the handlebar; and an actuator that is secured to lever holder, the actuator actuating the device when the lever moves from the released position to the engaged position; wherein the lever positioner adjusts the released position of the lever without moving the actuator relative to the lever holder.
Owyang has still further claimed a vehicle including a handlebar, a device, and the lever positioner assembly of claim 10 that is coupled to the handlebar, wherein the actuator actuates the device when the lever moves from the released position to the engaged position.
Lavezzi et al. 2011 disclosed an adjustable lever assembly for a motorcycle master cylinder includes a first element pivotally connected to the master cylinder, and a manually operable second element pivotally connected to the first element. An adjuster rotatably mounted on the second element can be turned to adjust the angular rest position between the first and second elements.
Lavezzi et al. have claimed an adjustment device for motorcycle master cylinders, said device comprising first operating means pivotally associable to a cylinder-piston unit of a motorcycle master cylinder, so as to impart an actuation movement to said cylinder-piston unit, said first operating means comprising coupling counter-means; second operating means pivotally connected to said first operating means and suitable for imparting a thrust movement to said first operating means for carrying out said actuation means of said first operating means, said second operating means further comprising a first end, two side surfaces protruding from said first end and arranged in position substantially parallel to one another, said two side surfaces delimiting a seat recessed between said two side surfaces; said device further comprising adjustment means, arranged between said first operating means and said second operating means, said adjustment means being coupled with said second operating means and being pivotally housed into said seat, said adjustment means further being suitable for adjusting the relative angular position between said second operating means and said first operating means, said adjustment means further having a side skirt comprising coupling means suitable for geometrically and selectively coupling with said coupling counter-means of said first operating means for defining at least one angular rest position between said first operating means and said second operating means for imparting said thrust movement from said second operating means to said first operating means, operating portions comprising thrust surfaces accessible by an operator for a rotation of said adjustment means, said rotation being suitable for selecting the coupling between one of said coupling means and said coupling counter-means; and wherein, moreover, said coupling means and said operating portions are comprised between planes defined by said side surfaces of said seat wherein said adjustment means have a rotation hole and a first rotation pin, axially housed in said hole and cooperating with said first end, for holding said adjustment means in said seat and for allowing rotation of said adjustment means about said first pin, when said coupling means are uncoupled from said coupling counter-means and said thrust movement of said second operating means to said first operating means is actuated along an angular actuation stroke and said second operating means are also actuable along an angular adjustment stroke, opposed to said angular actuation stroke, for releasing said coupling means from said coupling counter-means and allowing rotation of said adjustment means, and further comprising elastic means substantially housed into said seat and axially associated with said adjustment means by said first pin, said elastic means biasing said second operating means toward said angular rest position when said second operating means are actuated along said angular adjustment stroke.
Holland and Gorsline (2014)(EP 2 778 033) disclosed a hand control assembly (18) comprising a base (20), an actuating mechanism (52) movable relative to the base (20), a hub (40) pivotally coupled to the base (20) and positioned to move the actuating mechanism (52, a lever arm (42) pivotally movable relative to the hub (40) for movement about a pivot axis (58), and an adjusting mechanism (44) positioned between the lever arm (42) and the hub (40) and adapted to adjust a space between the lever arm (42) and a handlebar (16). The adjusting mechanism (44) includes a dial (70) mounted for rotation about an adjusting axis (74) angled relative to the pivot axis (58). The dial (70) and the lever arm (42) cooperatively define a dimension corresponding with the dial (70) protruding from the lever arm (42), and it is preferred that this dimension does not change when the dial (70) is rotated from a short-reach position to a long-reach position. The dial (70) can be mounted for rotation about the adjusting axis (74) that is offset from an engaging member (54).
Holland and Gorsline have claimed a hand control assembly comprising: a base; an actuating mechanism movable relative to the base; a hub pivotally coupled to the base and positioned to move the actuating mechanism; a lever arm pivotally movable relative to the hub for movement about a pivot axis; and an adjusting mechanism positioned between the lever arm and the hub and adapted to adjust a space between the lever arm and the hub to thereby adjust the position of the lever arm relative to the base, the adjusting mechanism including a dial mounted for rotation about an adjusting axis angled relative to the pivot axis.
Holland and Gorsline have also claimed a vehicle comprising: a wheel; a seat supported by the wheel; a handlebar supported by the wheel; and a hand control assembly mounted in the handlebar and comprising: a base; an actuating mechanism movable relative to the base; a hub pivotally coupled to the base and positioned to move the actuating mechanism; a lever arm pivotally movable relative to the hub for movement about a pivot axis; and an adjusting mechanism positioned between the lever arm and the hub and adapted to adjust a space between the lever arm and the handlebar, the adjusting mechanism including a dial mounted for rotation about an adjusting axis angled relative to the pivot axis.

In these existing adjustable levers described above the parts of their adjustable lever holders/mechanisms are dedicated parts, manufactured through specialized machining process which makes them costlier/expensive than parts which have general use, they are produced in mass production and do not require specialized machining process. Parts which need specialized machining process also increases production time.

SUMMARY
This invention comprises an adjustable lever holder assembly for a vehicle comprising a lever (11) attached to a lever mounting assembly (Figures 4a and 4b), the lever mounting assembly comprising a lever mounting, Lead Screw (5) (Figure 1) and a carrier assembly (15) (Figure 1). The Lead Screw upon rotation provides a linear movement to the carrier, thereby providing an adjustable distance of the lever from handlebar (19) of the vehicle on which the adjustable lever holder assembly is attached.
The carrier, which is like a nut having guiding features (6b) (Figure 3) is in touch with the surface (4c) of lever mounting (Figure 5a), this works as a guiding feature of carrier for restricting its rotational movement and allowing it to move in linear direction only. The carrier has a detent profile feature (4f) of lever mounting (4) (Figure 5), the detent feature consisting of multiple peaks (4g) and valleys (4h) (Figure 6). Alternatively it may have smooth continuous adjustment of lever. The carrier has guiding features (6b) which are in touch with the guiding base (4c) of the lever mounting assembly; this guiding feature of carrier is meant for restricting its rotational movement and allowing it to move only in linear direction. The carrier has its internal threads (6a) engaged with external threads (5a) of the Lead Screw (Figure7); whereupon the Lead Screw engaged with carrier of carrier assembly (15) is rotated, the carrier assembly engaged with the Lead Screw threads, starts moving linearly because of the guiding features (6b) of carrier has restricted the rotational movement, the only direction carrier assembly can move is, in linear direction, along the axis of the Lead Screw when Lead Screw is rotated; the linear up or down movement of carrier assembly, depending upon the direction in which Lead Screw is rotated i.e. clockwise or anticlockwise,
The carrier has a pusher (6c) (Figure 3) which is always in touch with the lever adjusting face (11a) (Figure 8) of the lever, a torsion spring (10) assembled at the hinge between the lever and lever mounting ensuring that the lever surface (11a) being always in contact with the carrier pusher (6c; Figure 3) as the torsion spring is in pre-compressed state in its assembled position, the torsion spring is always exerting force on the lever ensuring it is always in contact with the carrier pusher (6c).
The lever adjusting face (11a) of the adjustable lever holder assembly of this invention is not parallel to the Lead Screw axis along which carrier assembly moves linearly. With the Lead Screw rotating about its axis and the carrier assembly (15) engaged with it moving linearly and the pusher (6c) on carrier pushing the lever adjusting face (11a), the result is changing the lever distance from the handlebar (19) center adjusting the lever distance from the handlebar axis.
The carrier assembly (15) comprises a carrier (6), a spring (7) and a steel ball (8) along with the lever mounting detent profile (4f) providing different positions, The steel ball (8) is initially sandwiched between the spring (7) of carrier assembly (15) and in one of the valleys of detent profile (4h) of the lever mounting (4), representing one of the positions of adjustable lever. As the carrier assembly moves from one valley to another valley adjusting the lever accordingly to another position, the pusher (6c) of carrier pushes the lever adjusting face (11a) of the lever. Multiple valleys in the detent profile represent multiple adjustment positions of the lever. In the example here, illustrated detent profile has five positions. There may be less or more positions. Upon rotating the Lead Screw, the carrier assembly moves from detent profile valley (4h) to detent profile peak (4g) of the lever mounting, spring (7) in the carrier assembly getting compressed. Upon rotating the Lead Screw further, the carrier assembly moving further from peak to next valley of the lever mounting, the compressed spring (7) expands and the steel ball in contact with this spring hitting the valley of the detent profile producing a click sound, providing a sense of feeling for rider upon adjusting the lever from one position to the other new position i.e. from one valley to another valley of detent profile of lever mounting. Alternatively, detent profile may also be provided on head of Lead Screw (Figure16), spring and steel ball being sandwiched between the detent profile of Lead Screw and spring guiding hole of lever mounting; wherein, upon rotating the Lead Screw the spring-loaded steel ball jumps from one detent profile to another causing stepped feeling, the carrier assembled with it starting to move linearly along the Lead Screw axis, the pusher (6c) of carrier pushing the lever adjusting face (11a) of the lever, thereby adjusting the lever with respect to the handlebar. In yet another embodiment of this invention, instead of spring and ball arrangement a plunger and spring assembly may also be used.
The detent profile may be an integral part of lever mounting or a separate sheet metal or plastic part.
The adjustable lever holder assembly could be a brake lever holder assembly or a clutch lever holder assembly.

DETAILED DESCIPTION OF THE INVENTION
The instant invention provides an adjustable lever that overcomes the need of manufacturing of the parts through specialized machining process. In the instant invention, the components used in the invention can be manufactured by conventional mass production manufacturing process based on use of simple nut-bolt mechanism. The instant invention comprises of Lead Screw, also known as “power screw” or translation screw, is a screw used as a linkage in a machine, to translate turning motion into linear motion. Lead Screws are commonly used in linear actuators, machine slides (such as in machine tools), vices, presses, and jacks. Lead Screws are a key component in electric linear actuators.
Lead Screws are manufactured in the same way as other thread forms (they may be rolled, cut, or ground).
The advantages of a Lead Screw are: large load carrying capability, compact, simple to design, easy to manufacture; no specialized machinery is required, large mechanical advantage, precise and accurate linear motion, smooth, quiet, and low maintenance, minimal number of parts required to translate motion.
In short, this is a screw which upon rotation provides a linear movement to the carrier. A Lead Screw is like a bolt and a carrier(carrier is like a nut); and lever mounting part comprises of detent profile feature, which provides five different positions for the rider to which he can adjust as per his comfort.

This said invention can be used also as a brake lever holder assembly or as a clutch lever holder assembly.

Brief description of figures and legends

Descriptions of legends: (1) holder, (2) stud lever screw, (3) nyloc nut, (4) lever mounting,(4a) Lead Screw guiding hole, (4b) Lead Screw guiding hole, (4c) guiding base, (4d) lever mounting hinge hole, (4e) torsion spring leg 2 guide, (4f) detent profile, (4g) detent profile peak, (4h)detent profile valley, (4i) spring guiding hole, (5) Lead Screw, (5a) Lead Screw external threads, (5b) Lead Screw guiding shaft 1, (5c) Lead Screw guiding shaft 2, (5d) Lead Screw flaring shaft (6) carrier, (5e) Lead Screw detent profile,(6a) carrier internal threads, (6b) carrier guiding feature (6c) carrier pusher, (6d) spring guiding hole (7) spring, (8) steel ball, (9) washer, (10) torsion spring,(10a) torsion spring axis, (10b) Torsion spring leg 1, (10c) Torsion spring leg 2, (11) lever,(11a) lever adjusting face, (11b) lever hinge hole, (11c) torsion spring leg 1 guide, (12) hinge bolt, (13) cover, (14a and14b) cover mounting screws, (15) carrier assembly, (16) lever mounting assembly, (16a) spin riveting/ flaring, (17) adjustable lever assembly, (18) adjustable lever holder assembly, handlebar (19).

Figure 1 illustrates exploded view of adjustable lever holder assembly.
Figure 2 illustrates carrier assembly.
Figure 3 illustrates carrier features.
Figure 4 illustrates lever mounting assembly.
Figure 5 illustrates lever mounting features.
Figure 6 illustrates detent profile of lever mounting.
Figure 7 illustrates Lead Screw features.
Figure 8 illustrates lever features.
Figure 9 illustrates Torsion spring features.
Figure 10 illustrates assembly of lever, torsion spring, lever mounting assembly, hinge bolt and nyloc nut.
Figure 11 illustrates adjustable lever assembly.
Figure 12 illustrates adjustable lever holder assembly.
Figure 13 illustrates sectional view of adjustable lever holder assembly.
Figure 14 illustrates adjustable lever holder assembly with handlebar.
Figure 15a illustrates variant 2 of Adjustable lever holder assembly.
Figure 15b illustrates lever mounting features for variant 2 of adjustable lever assembly.
Figure 16 illustrated Lead screw construction to be used for variant 2 of adjustable lever holder assembly.
Figure 17a illustrates Lever mounting construction to be used for variant 2 of adjustable lever holder assembly.
Figure 17b illustrates lever mounting assembly for variant 2 of adjustable lever holder assembly.

Assembly
Spring (7) is assembled inside a spring guiding hole (6d) of carrier (6). A steel ball (8) is then assembled on the spring (7). This assembly of carrier (6), spring (7) and steel ball (8) is called as carrier assembly (15) (Figure 2) (in fig 13).

Figure 4a shows exploded view of Lever mounting assembly (16) (comprising of lever mounting (4), carrier assembly (15), Lead Screw (5), washer (9), cover (13) and cover mounting screws (14a and 14b). Carrier assembly (15) (Figure 2) is assembled inside the lever mounting (4) (Figure 1 and Figure 4). Carrier (6) of carrier assembly having guiding features (6b) (Figure 3) is in touch with the surface (4c) of lever mounting (Figure 5a). This guiding feature of carrier restricts its rotational movement and allows it to move in linear direction only. The detent profile feature (4f) of lever mounting (4), shown in Figure 5, comprises multiple peaks (4g) and valleys (4h) (Figure 6) which are equally spaced. Steel ball (8) of carrier assembly is sandwiched between the detent profile(4f) of lever mounting(4) and the spring (7) of carrier assembly (Figure 4a) As the carrier (6) of carrier assembly (15) can only have linear movement the spring (7) and steel ball (8) assembled with it will also move linearly along with the carrier. i.e. carrier assembly will have a linear movement.

Lever mounting (4) (Figure 5a) comprises Lead Screw guiding hole (4a) and (4b) in which Lead Screw guiding shaft 1 (5b) and Lead Screw guiding shaft 2 (5c) (Figure 7) is guided. A washer is assembled on the Lead Screw flaring shaft (5d) and spin riveting or flaring (16a) (Figure 4b) is done at the end to ensure Lead Screw’s linear movement is constrained and it can only have rotational movement about its axis. Lead Screw comprising of external threads (5a) (Figure 7) engages with internal threads (6a) (Figure 3 and Figure 2) of carrier (6) of the carrier assembly (15) (Figure 4b).

A cover (13) (Figure 1 and 4a) is assembled on the lever mounting (4) (Figure 4a) with the cover mounting screws (14a and 14b) (Figure 1 and 4a) to avoid direct exposure of Lead Screw (5) and carrier assembly (15) to the environment.

Lever (11) having hinge i.e. a hole feature (11b) (Figure 8) is aligned with hole axis (10a) (Figure 9) of the torsion spring (10). Torsion spring leg 1 (10b) touches with lever torsion spring leg 1 guide (11c). Lever (11) along with the torsion spring (10) is assembled with the lever mounting (4) at the lever mounting hinge hole (4d) (Figure 5a).Torsion spring leg 2 (10c) (Figure 9) touches with lever mounting’s torsion spring leg 2 guide (4e) (Figure 5a). Torsion spring assembly between lever and lever mounting is such that the spring is in pre-compressed state in assembled condition i.e. the torsion spring is always exerting force on the lever and lever mounting in its assembled condition.
A hinge bolt (12) (Figure 10) is passed through these aligned holes of lever mounting, torsion spring and lever. A nyloc nut (3) is then fitted at the other end which is used to hold the lever mounting, torsion spring and lever together at the hinge.

The lever mounting assembly (16) along with torsion spring (10), lever (11), hinge bolt (12) a nyloc nut (3) is called adjustable lever assembly (17) (Figure 11).
Adjustable lever assembly (17) along with holder (1), stud lever screw (2) and nyloc nut (3) is called adjustable lever holder assembly (18). (Figure 12)

Working of the Invention
The Lead Screw which is assembled into the guiding holes (4a) and (4b) of lever mounting can only rotate about its axis. The linear movement of the Lead Screw is restricted by the washer which is assembled on Lead Screw and is riveted at the end. Carrier (6) of carrier assembly having guiding features (6b) is in touch with the guiding base (4c) of lever mounting. This guiding feature of carrier restricts its rotational movement and allows it to move only in linear direction. The external threads (5a) of Lead Screw is engaged with the internal threads (6a) of carrier of carrier assembly (15). When the Lead Screw is rotated, the carrier assembly engaged with the Lead Screw threads, starts moving linearly because of the guiding features (6b) of carrier has restricted the rotational movement. So, the only direction carrier assembly can move is, in linear direction, along the axis of the Lead Screw when Lead Screw is rotated. The linear up or down movement of carrier assembly, depends upon the direction in which Lead Screw is rotated i.e. clockwise or anticlockwise.
Carrier (6) comprises a pusher (6c) (Figure 3) which is always in touch with the lever adjusting face (11a) (Figure 8) of the lever. A torsion spring (10) which is assembled at the hinge between the lever and lever mounting ensures that the lever surface (11a) is always in contact with the carrier pusher (6c; Figure 3) as the torsion spring is in pre-compressed state in its assembled position i.e. the torsion spring is always exerting force on the lever and ensures it is always in contact with the carrier pusher (6c).

The lever adjusting face (11a) is not parallel to the Lead Screw axis along which carrier assembly is linearly moving. Thus, when Lead Screw is rotated about its axis the carrier assembly (15) engaged with it moves linearly and the pusher (6c) on carrier pushes the lever adjusting face (11a).This changes the lever distance from the handlebar (19) center and thus the lever distance from handlebar axis is adjusted.

The said invention provides different positions up to which the rider can adjust according to the rider’s comfort requirement. Positions up to five are illustrated in the example here. This invention also illustrated a continuously variable positions where finer adjustment is also possible.

The carrier assembly (15) comprises carrier (6), spring (7) and steel ball (8) along with the lever mounting detent profile (4f) enables providing different positions or in absence of a detent profile, continuously variable position is also provided. In the example of the detent profile illustrated here, 5 different positions are provided.
In the example where detent profile is provided, the steel ball (8) initially is sandwiched between the spring (7) of carrier assembly (15) and valley of detent profile (4h) of the lever mounting (4). When the carrier assembly is in one of the valleys of the detent profile it represents one of the positions of adjustable lever. When carrier assembly moves from one valley to another valley the lever is adjusted accordingly to another position as the pusher (6c) of carrier pushes the lever adjusting face (11a) of the lever. There are 5 valleys representing 5 adjustment positions of the lever.

When Lead Screw is rotated, in the example where detent profile is provided, the carrier assembly moves from detent profile valley (4h) to detent profile peak (4g) of the lever mounting. The spring (7) in the carrier assembly gets compressed. When Lead Screw is further rotated, the carrier assembly moves further from peak to the next valley of the lever mounting. The spring (7) which was compressed, now expands and thus the steel ball which is in contact with this spring hits the valley of the detent profile producing a click sound. This spring-loaded steel ball in carrier assembly along with the detent profile in lever mounting produces a sense of feeling for rider when he adjusts the lever from one position to the other new position i.e. from one valley to another valley of detent profile of lever mounting.

In the said invention a plunger and spring assembly can also be used instead of spring and steel ball assembly. The peaks and valleys of detent profile can be equally or unequally spaced depending upon whether the adjustment steps of the lever required is equal or unequal. Also, the detent profile provided can be an integral part of lever mounting or it can be a separate sheet metal or plastic part based on part manufacturing feasibility, dimensional accuracy, cost or any other special requirements.

For, the ease of operation, the threads on Lead Screw and carrier used can have increased pitch than usual standard pitch as in metric threads or it can use multi start threads as well.

The said invention can also have smooth continuous adjustment of lever i.e. not stepped adjustment as mentioned earlier. This can be achieved when the detent profile (4f), steel ball (8) and spring (7) is removed from the design and rest parts are assembled as it (Figure 15a and Figure 15b). Here, the lever can have very fine adjustment as well.

The said invention can also have another variant. In this variant (4f) detent profile from lever mounting (4) is removed and (5e) detent profile is provided on head of Lead Screw (Figure 16). Spring and steel ball are sandwiched between the detent profile of Lead Screw (5e) and spring guiding hole of lever mounting (4i) (Figure 17a and 17b). Remaining parts are assembled as it is. Now, when Lead Screw is rotated the spring-loaded steel ball jumps from one detent profile of Lead Screw to another detent profile of Lead Screw causing stepped feeling. When the Lead Screw is rotated, the carrier assembled with it starts to move linearly along the Lead Screw axis. The pusher (6c) of carrier pushes the lever adjusting face (11a) of the lever. Thus, lever can be adjusted with respect to the handlebar.
,CLAIMS:
1. An adjustable lever holder assembly for a vehicle comprising a lever (11) attached to a lever mounting assembly (Figures 4a and 4b), the lever mounting assembly comprising a lever mounting, Lead Screw (5) (Figure 1) and a carrier assembly (15) (Figure 1).
2. The adjustable lever holder assembly according to clam 1, wherein the Lead Screw upon rotation providing a linear movement to the carrier, thereby providing an adjustable distance of the lever from handlebar (19) of the vehicle on which the adjustable lever holder assembly is attached.
3. The adjustable lever holder assembly according to claim 1, wherein the carrier, which is like a nut:
a. having guiding features (6b) (Figure 3) is in touch with the surface (4c) of lever mounting (Figure 5a), this guiding feature of carrier for restricting its rotational movement and allowing it to move in linear direction only,
b. having:
i. a detent profile feature (4f) of lever mounting (4) (Figure 5), the detent feature consisting of multiple peaks (4g) and valleys (4h) (Figure 6), or
ii. have smooth continuous adjustment of lever
c. having guiding features (6b) which are in touch with the guiding base (4c) of the lever mounting assembly; this guiding feature of carrier being for restricting its rotational movement and allowing it to move only in linear direction,
d. having its internal threads (6a) engaged with external threads (5a) of the Lead Screw (Figure7); whereupon the Lead Screw engaged of carrier of carrier assembly (15) is rotated, the carrier assembly engaged with the Lead Screw threads, starts moving linearly because of the guiding features (6b) of carrier has restricted the rotational movement, the only direction carrier assembly can move is, in linear direction, along the axis of the Lead Screw when Lead Screw is rotated; the linear up or down movement of carrier assembly, depending upon the direction in which Lead Screw is rotated i.e. clockwise or anticlockwise,
e. having a pusher (6c) (Figure 3) being always in touch with the lever adjusting face (11a) (Figure 8) of the lever; a torsion spring (10) assembled at the hinge between the lever and lever mounting ensuring that the lever surface (11a) being always in contact with the carrier pusher (6c; Figure 3) as the torsion spring being in pre-compressed state in its assembled position, the torsion spring being always exerting force on the lever ensuring it is always in contact with the carrier pusher (6c).
4. The adjustable lever holder assembly according to claim 1, wherein lever adjusting face (11a) being not parallel to the Lead Screw axis along which carrier assembly moving linearly, the Lead Screw rotating about its axis and the carrier assembly (15) engaged with it moving linearly and the pusher (6c) on carrier pushing the lever adjusting face (11a), the result beings change in the lever distance from the handlebar (19) center adjusting the lever distance from the handlebar axis.
5. The adjustable lever holder assembly according to claim 1 wherein the carrier assembly (15) comprising:
a. carrier (6), and
b. spring (7)and
c. steel ball (8) along with the lever mounting detent profile (4f) providing different positions,
i. the steel ball (8) initially being sandwiched between the spring (7) of carrier assembly (15) and in one of the valleys of detent profile (4h) of the lever mounting (4), representing one of the positions of adjustable lever,
ii. the carrier assembly moving from one valley to another valley adjusting the lever accordingly to another position, the pusher (6c) of carrier pushing the lever adjusting face (11a) of the lever
iii. multiple valleys representing multiple adjustment positions of the lever,
iv. upon rotating Lead Screw the carrier assembly moving from detent profile valley (4h) to detent profile peak (4g) of the lever mounting, spring (7) in the carrier assembly getting compressed,
1. upon rotating the Lead Screw further, the carrier assembly moving further from peak to next valley of the lever mounting,
2. the compressed spring (7) expands and the steel ball in contact with this spring hitting the valley of the detent profile producing a click sound, providing a sense of feeling for rider upon adjusting the lever from one position to the other new position i.e. from one valley to another valley of detent profile of lever mounting,
Or
d. detent profile being provided on head of Lead Screw (5e) (Figure16), spring and steel ball being sandwiched between the detent profile of Lead Screw and spring guiding hole of lever mounting; wherein,
i. upon rotating the Lead Screw the spring-loaded steel ball jumps from one detent profile to another causing stepped feeling,
ii. the carrier assembled with it starting to move linearly along the Lead Screw axis,
iii. the pusher (6c) of carrier pushing the lever adjusting face (11a) of the lever,
iv. thereby adjusting the lever with respect to the handlebar.
Or
e. a plunger and spring assembly being used instead of spring and steel ball assembly in sub-claims a. and b.
6. The adjustable lever holder assembly according to claim 5, wherein the detent profile provided in claim 5 sub-claims a. and b. comprise:
a. an integral part of lever mounting or
b. a separate sheet metal or plastic part.
7. The adjustable lever holder assembly according to claim 1 being a brake lever holder assembly or a clutch lever holder assembly.