AN IMPROVED CONTROL LEVER FOR MOTOR VEHICLES
FIELD OF THE INVENTION
The present invention relates to a control lever mounted on handle bar of a motor vehicle.
More specifically, the present invention relates to a control lever made of polymer,
whereby the said polymer is molded with a metal plate as a reinforcing member therein.
BACKGROUND AND PRIOR ART OF THE INVENTION:
Many vehicles types like motorcycles, cycles, auto rickshaws, ATV's, snow mobiles and
many similar vehicles are provided with control levers (1) attached to the handlebar (3).
The control levers (1) perform various functions such as shifting gears and braking to
stop vehicle. These are mounted on handlebar (3) of vehicle so that a rider can
conveniently operate them with his both hands. In most cases the control lever (1) on left
side is referred to as clutch lever and is used to engage or disengage the clutch plates to
allow riders to shift gears whereas control lever (1) on right side is referred to as brake
lever and is used to stop the vehicle in case of emergency or to slow down the vehicle.
With reference to fig. 1, it can be seen that the control lever (1) of both types are pivotally
mounted to a lever holder (2), also sometimes described as mount, support or perch,
which is clamped firmly to the handlebar (3) of the vehicle, and is free to rotate about the
pivot axis PH between its free position and handlebar grip (4).
The control lever of both types is generally connected to their mechanism with the aid of
special cable called Bowden cable (12). Such type of control levers (1) has two portions
one that is used to hold it in the lever holder (2) referred to here as beam portion (13)
(shown in fig. 2) and another that is used to grip the control lever known as grip portion
(11) and also referred as elongated handle. The beam portion (13) of lever is held
between two flanges of the lever holder (21) which have circular holes to accommodate
the screw from one side and a nut to tighten on it from other side such that the control
lever is free to rotate between the flanges of lever holder (2) about pivot axis PH. In
normal mounting condition on vehicle, the control lever (1) abuts the lever holder (2) due
2
to pull action of Bowden cable (12) caused by spring tension in the mechanism connected
on the other side of wire. When the control lever (1) is pressed by the rider towards the
handlebar grip (4) by putting his fingers around the elongated handle (11), the control
lever rotates around pivot axis PH causing the Bowden cable (12) wire to be pulled
against spring force thus activating the desired mechanism. When the control lever (1) is
released, due to same tension in Bowden cable (12), control lever (1) rotates back and
abuts the lever holder (2) and the mechanism is disengaged.
Fig 2 shows prior art control lever (1) and illustrates its method of use and fitment of
Bowden cable (12). The Bowden cable (12) as illustrated has a cylindrical button (14)
referred to as Bowden cable button at the end and a Bowden cable (12) attached through
suitable means to the centre of the button. With reference to fig. 3, the lever has two slits
of sufficient width that allow Bowden cable (12) to pass through each of them, referred to
here as side slit (30) and middle slit (16). The side slit (30) is cut into lever symmetrically
with respect to hole (15) centre from side and has two vertical flanges (31) and (32).
Middle slit also referred to as cut portion (16) is cut symmetrically with respect to the
centre of lever and has two vertical flanges (17) and (18). Both slits end up to the blind
hole (15) of the control lever (1).
With reference to fig. 2, the Bowden cable button (14) is inserted into the control lever
(1) from side with the cable wire (12) is oriented vertically so that Bowden cable button
(14) is well received in the hole (15) and Bowden cable (12) is inserted between the
flanges (31) and (32) (shown in fig. 3) thereon rotating the Bowden cable (12) and then
passing it through cut portion (16) between flanges (17) and (18) (shown in fig. 3). The
cable wire is then passed through the similar slit in the lever holder (2) during assembly.
In the prior art or conventional control lever shown in fig. 2, the cut portion (16), hole
(15) and side slit (30) together divide the volume of control lever such that one side of
volume of control lever (1) is attached with rest of control lever (1) at a very weak cross
section. The stress concentration due to operation of control lever (1) is at this weak
portion. The control lever (1) is most vulnerable to crack or separate from rest of control
3
lever (1) at this weak portion which lies between hole (15) and beam portion (13) thus
causing the vehicle inoperable and annoyance to the rider.
As a result, there exists a need to develop control lever that has better strength, low cost
in terms of processing and is capable to bear sudden impact.
Therefore the inventors of the present invention proposed to provide a polymer control
lever (1) which overcomes the drawbacks and problems associated with conventional
single piece levers both in metals and non-metals.
OBJECTIVE OF THE PRESENT INVENTION
The primary objective of the present invention is to provide a control lever which is more
robust and can withstand external forces applied in all practical loading conditions by
way of bridging gap at the opening of Bowden cable hole.
Another objective of the present invention is to provide a control lever that is made of
polymer, whereby the said polymer is molded with a metal plate as a reinforcing member
therein.
SUMMARY
Accordingly, the present invention relates to a control lever mounted on a handle bar for
operating a clutch or a brake system of a motor vehicle comprising an elongated handle
and a beam portion, whereby the said beam having an aperture at one end of the beam,
the said aperture allow the beam portion of the control lever to be pivotally fixed to a
lever holder, said lever holder is mounted on a handlebar of the motor vehicle; the said
control lever is characterized by an extended portion located at the intersection of the
elongated handle and the beam portion, wherein the extended portion comprising a
rectangular slot placed at front end of the extended portion, whereby the said front end
facing away from the rider; a circular slot provided at bottom surface of a top portion of
the elongated handle, said circular slot located tangentially to a bottom end of the
rectangular slot; and a cut portion (slit) extending from one side of the rectangular slot to
4
a proximal side of the beam portion, said rectangular slot and cut portion (slit) enables the
secure placement of a Bowden cable button and Bowden cable thereof; and the said
elongated handle is made of polymer, whereby the said polymer is molded with a metal
plate as a reinforcing member therein, the said reinforcing member is identical in shape to
the control lever.
According to another aspect of the present invention, the control lever is described,
wherein the extended portion is facing ground when control lever is mounted the lever
holder.
According to yet another aspect of the present invention, the control lever is described,
wherein the elongated handle, beam portion and extended portion is molded as a single
member.
According to still another aspect of the present invention, the control lever is described,
wherein the bottom surface of extended portion comprising a hole in line with the circular
slot made at the bottom of the elongated handle.
According to one more aspect of the present invention, the control lever is described,
wherein the polymer is selected from the group comprising of polypropylene (PP), high
density polyethylene (HDPE), nylon-6 and nylon-66.
According to another aspect of the present invention, the control lever is described,
wherein said polymer is reinforced with fibrous material.
According to yet another aspect of the present invention, the control lever is described,
wherein the fibrous material is selected from the group of glass fiber or carbon fiber or
both.
According to still another aspect of the present invention, the control lever is described,
wherein said fibers are short fibers or long fibers.
5
According to one more aspect of the present invention, the control lever is described,
wherein the metal plate comprises one or more notches and holes at various locations
across its length for better impregnation of polymer.
According to another aspect of the present invention, the control lever is described,
wherein the metal plate comprises a circular extension close to beam portion to increase
the strength of reinforcement of control lever.
According to yet another aspect of the present invention, the control lever is described,
wherein the control lever is optionally covered with a plastic strip to prevent dust.
According to one more aspect of the present invention, the control lever is described,
wherein the extended portion optionally comprising cushions.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects and advantages of the present invention will be readily understood from
the following detailed description with reference to the accompanying drawings.
Reference numerals have been used to refer to identical or functionally similar elements.
The figures together with a detailed description below, are incorporated in and form part
of the specification, and serve to further illustrate the embodiments and explain various
principles and advantages, in accordance with the present invention wherein:
Figure 1 illustrates typical handle bar assembly showing prior art lever and holder.
Figure 2 illustrates an isometric view of the control lever.
Figure 3 illustrates the top view of the control lever.
Figure 4 illustrates an isometric view of control lever according to present invention.
Figure 5 illustrates the top view of the control lever according to present invention.
Figure 6 illustrates isometric view of plug to close the front side area of the control lever.
Figure 7 illustrates metal member which is reinforced within a control lever.
Figure 8 illustrates the design of control lever incorporating the metal member.
6
Skilled artisans will appreciate that elements in the drawings are illustrated for simplicity
and have not necessarily been drawn to scale. For example, the dimensions of some of
the elements in the drawings may be exaggerated relative to other elements to help to
improve understanding of embodiments of the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
Referring now to the drawings, there is shown an illustrative embodiment of the
invention control lever. It should be understood that the invention is susceptible to
various modifications and alternative forms; specific embodiment thereof has been shown
by way of example in the drawings and will be described in detail below. It will be
appreciated as the description proceeds that the invention may be used varyingly in
different circumstances.
Before describing in detail embodiments it may be observed that the novelty and
inventive step that are in accordance with the present invention reside in the construction
of the control lever, accordingly, the drawings are showing only those specific details that
are pertinent to understanding the embodiments of the present invention so as not to
obscure the disclosure with details that will be readily apparent to those of ordinary skill
in the art having benefit of the description herein.
The terms "comprises", "comprising", or any other variations thereof, are intended to
cover a non-exclusive inclusion, such that a setup, device that comprises a list of
components does not include only those components but may include other components
not expressly listed or inherent to such setup or device. In other words, one or more
elements in a system or apparatus proceeded by "comprises... a" does not, without more
constraints, preclude the existence of other elements or additional elements in the system
or apparatus. The following paragraphs explain various aspect of the present invention
with reference to figures.
Accordingly, the present invention relates to a control lever (1) which is more robust and
can withstand external forces applied in all practical loading conditions by way of
bridging gap at the opening of Bowden cable hole (12) present in the prior art.
7
The control lever (1) of present embodiment can also be pivotally mounted in same way
as prior art control lever (1) is mounted to a lever holder (2). For simplicity of explaining
the invention the control lever (1) is divided into two portions elongated handle (11) and
a beam portion (13), whereby the said beam (13) has an aperture (19) at one end of the
beam, the said aperture (19) allows the beam portion (13) of the control lever (1) to be
pivotally fixed to a lever holder (2), said lever holder (2) is mounted on a handlebar of the
motor vehicle. Thus, the control lever (2) is free to rotate about the pivot axis PH .
The actuation of mechanism and operation of present embodiment is also similar to as
described in the prior art. The assembly of Bowden cable (12) in the control lever (1) is
much simpler in case of present invention than the prior art as described further.
With reference to fig. 4, the control lever (1) of present embodiment has material added
on one side at the mount portion around opening of hole (15). This extended portion (20)
faces the ground in the mounting condition on a vehicle so that it is not visible to the
rider. The extended portion (20) is above surface (21) by an amount dependable on the
strength requirement of the control lever (1) and the width of the Bowden cable button
(14). The control lever (1) has a rectangular slot (22) cut on the top side of lever which
must be sufficient to accommodate the Bowden cable button (14) with sufficient
clearance on all sides. This control lever (1) has one cut portion (slit) (16) with sufficient
width cut symmetrical with respect to the centre of lever and ends up at the rectangular
slot (22) so that Bowden cable (12) can be passed through vertical flanges (17) and (18)
(shown in fig. 5) formed by this cut portion (16). The rectangular slot (22) matches
tangentially with a circular slot or blind hole (15) so that the Bowden cable button (14)
slides through rectangular slot (22) and is securely placed in circular slot or blind hole (2)
of the control lever. With the slight action of side force on Bowden cable (12), the
Bowden cable button (14) is pushed inside the circular slot or blind hole (15) towards
surface (33) (shown in fig. 5) so that the Bowden cable (12) reaches the center of lever
before cut portion (slit) (16) and after slight rotation easily can pass through the space
between flanges (38) and (39) (shown in fig. 5). The depth of bottom surface (33) (shown
8
in fig. 5) of the blind hole must be sufficient to accommodate opposite face of Bowden
cable button (14) and do not allow it to come out easily during operation.
In the present embodiment, the side slit (30) as shown in fig. 2 of prior art has been
removed and the volume is filled with material. In present embodiment, the weak portion
as described in prior art is now fully supported.
Since the rectangular slot (22) from which the Bowden cable (12) enters, faces away
from the rider in mounting condition. The wind blowing enters into rectangular slot (22)
during ride unless it is provided with shield. Also, dust, water and debris may enter
through rectangular slot (22) and cut portion (slit) (16) in the control lever (1) which may
increase the friction between the control lever (1) and Bowden cable (12) over a period of
time. To overcome this problem it is further proposed that a plastic strip (24) as shown in
fig. 6 of the same size and shape of the openings in lever of present embodiment can be
press fitted, glued or snap fitted over the lever after assembly of Bowden cable (12) thus
stopping the entry of foreign material into the functioning area.
Furthermore, in order to reduce friction between Bowden cable button (14) and control
lever (1), small bushings may be incorporated in hole (15) of lever.
In addition to above, in order to make the control lever more robust, polymer is used,
whereby the said polymer is molded with a metal plate (23) as a reinforcing member
therein, the said reinforcing member is identical in shape to the control lever (1). The
metal plate (23) is enclosed within the control lever (1) so that it is not exposed to the
atmosphere outside.
The polymer used for manufacturing control lever (1) is selected from the group
comprising of polypropylene (PP), high density polyethylene (HDPE), nylon-6 and
nylon-66. The polymer is further reinforced with fibrous material whereby the fibrous
material is selected from the group of glass fiber or carbon fiber or both. Also, the said
9
fibers may be short fibers or long fibers. Short fibers have their length between 1mm to
3mm and long fibers have their length between 4mm to 10mm.
The metal plate (23) that is inserted within the control lever (1) is similar in shape to that
of control lever (1). Further, the metal plate (23) has a first circular hole (231) at a
location similar to that present on beam portion (13) of the control lever (1). A second
circular hole (232) is present at a location similar to circular slot or blind hole (33)
provided at bottom surface of a top portion of the elongated handle (11). The portion
where this second circular hole (232) is present on the metal plate (23) is at a surface
which is at a different level to that of rest of the metal plate (23). This is done so as to
easily incorporate the metal plate (23) inside the control lever (1). Further, to the circular
holes the metal plate (23) comprises of one or more notches and holes at various
locations across its length for better impregnation with the polymer. A first of these
notches (233) is present close to the beam portion. Here the metal is cut and is turned
around, thus creating a type of embossment or a circular extension (233). It was seen
during experiments that the control lever is most vulnerable at this point. However,
cutting the metal plate and turning it around the area of the cut showed that the area is
strengthened and thus it no more remains a weak point. In addition, there are bigger
notches (234) for better impregnation of the metal plate with the polymer. A few small
circular notches (235) can also be present at various locations along the length of the
metal plate. Two 'V cuts (236) are present near the end of the length of the metal plate
(23).
EXPERIMENTAL RESULTS
The inventors of the present invention conducted various mechanical testing for the
present control lever. More particularly, the testing method includes the static strength
test in various positions of control lever as indicated by CMP-SST-2-1, CMP-SST-2-2,
and CMP-SST-2-3 and impact dento test.
It is assumed that if the control lever indicates less than 5 mm deflection, while applying
force in the range of 15 to 20 kgf, the control lever is acceptable. However, if the control
10
lever indicate more that 5mm deflection, it is not acceptable for lever application. The
reference for
Example 1 (CMP-SST-2-1)
It is indicated that a curve has been drawn between deflection (y axis) and load, for the
control lever made of metal (Al) and the present control lever made of nylon 6 30% GF
(without insert or reinforcing member). The values are indicated in table . The load
direction on the control lever is indicated (i.e. from side)
It can be inferred from the deflection curve that up to 20 kgf force, the displacement in
the control lever is comparable to aluminum lever and the displacement is less than 5mm.
Further, the residual displacement in plastic control lever is equal to lever made of
aluminum.
Load (Kgf)
5
10
15
20
25
30
35
40
Al
0.88
1.48
1.95
2.39
2.83
3.28
3.73
4.11
Nylon 6 30%GF (1.2E)
(Present Invention)
1.51
2.64
3.63
4.43
5.23
6.07
6.90
7.77
Example 2 (CMP-SST-2-2)
The graph indicate that control lever of the present invention (plastic lever) can sustain
maximum force up to 25 Kgf up 80 mm deflection, whereas aluminum control lever can
sustain up to 27 Kgf up to 50 mm deflection.
Load (Kgf)
5
26
Al
0.32
0.84
Nylon 6 30%GF (1.2E)
(Present Invention)
0.21
0.96
Example 3 (CMP-SST-2-3)
11
In this test the load is applied on the control lever from the rear side and found that results
are almost comparable to aluminum lever.
Deflection (mm)
2
4
6
8
10
12
14
16
18
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
84
88
92
Nylon6 30%GF(1.2E)
(Present Invention)
0.78
1.77
2.91
4.21
5.35
6.58
7.81
8.82
9.86
10.93
12.93
14.70
16.28
17.73
19.03
20.17
20.97
21.89
22.62
23.34
23.93
24.10
24.26
24.27
24.38
23.59
23.96
23.30
Al
4.82
7.13
9.24
11.04
12.76
13.88
15.36
16.81
18.21
20.78
23.05
25.15
27.00
28.03
25.36
19.16
16.88
15.85
15.89
15.25
14.71
14.27
13.35
12.30
10.39
Example 4 (IMPACT TESTING)
In this test a steel ball of weight of 20 kg is dropped from the various height (1 meter,
and 2 meter) on the control lever and found that the plastic lever with or without insert
are capable to sustain.
12
Material
Nylon 6 30% GF
(Present
Invention)
Al
Reinforcement
Type
13 (1.2E)
Impact Test
No. of Samples
Tested
6
2
Tested OK
6
1
Dento Test
Samples
Tested
2
1
Tested
OK
2*
1
TABLE A
In addition to this, the inventors of the present invention carried the same test with plastic
lever with insert of various thicknesses such as 1.1, 1.2 1.5 and 1.6 mm and the inventors
found that displacement level is decreased, from the cases whereby the control lever is
made of only polymer. A person skilled in the art can vary the thickness of the insert i.e.
reinforcing member and achieve desired displacement.
LAf
S. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
5 TESTING OF PLASTIC LEVER CONCEP1
HI
5
10
15
20
25
30
35
40
45
50
55
60
65
70
80
90
Standar
d
*
**
Aluminium
0.91
1.64
2.19
2.69
3.18
3.72
4.24
4.78
5.48
6.21
7.18
8.31
9.70
11.44
Present Invention
Nylon 6 (30% GF)
Without Insert
1.71
2.82
3.85
4.83
5.80
6.84
782
8.55
952
10.51
11.63
13.43
14.78
16.19
20.13
Present Invention
Nylon 6 (30% GF)
With Insert-13
T= 1.6 mm
1.45
2.39
3.15
3.90
4.63
5.41
6.21
6.98
7.81
8.65
9.62
10.61
11.54
12.71
Commercial Available
Material 1 Nyion 6
(30% GF) Without
Insert
1.40
2.48
3.45
4.36
5.35
6.23
7.14
8.03
8.89
9.76
10.65
11.82
13.04
14.28
^ - 1 (trial 3)
Commercial Available
Material 1 Nylon 6
(30% GF) With Insert
-13 T = 1.6 mm
1.26
2.11
2.81
3.55
4.28
4.95
5.71
6.56
7.31
8.11
8.98
9.86
11.02
11.99
Commercial Available
Material 2 Nylon 6
(60% GF) Without
Insert
1.26
1.96
2.59
3.12
3.59
4.16
4.57
4.99
5.45
5.93
6.38
6.86
7.33
7.84
8.54
Commercial Available
Material 2 Nylon 6
(60% GF) With Insert
-13T = 1.6mm
0.85
1.44
1.93
2.38
2.81
3.22
3.61
4.00
4.39
4.78
5.16
5.67
6.09
6.45
7.33
* As per HMSI lever spec 53172-GHA-6000, standard for max. deflection at 20Kgf as per performance test 2-1 is 5mm.
** As per HMSI lever spec 5317Z-GHA-6000 performance test 2-1, lever should not break at load less than 60 Kgf
The results are indicated in table A, wherein the control lever made of aluminum is
compare with control lever of present invention (without and with insert) made of nylon-
6 30GF and commercial available material 1, 2 and 3 (without and with insert). It is
further in the purview of the person skilled in the art to vary the fiber proportion in the
polymer as per requirement and application.
While the particular preferred embodiments of the present invention have been shown
and described, it will be obvious to those skilled in the art that changes and modifications
13
may be made without departing from the teachings of the invention. It is therefore
contemplated that the present invention covers any and all modifications, variations or
equivalents that fall within the scope of the basic underlying principles disclosed above
and claimed therein.
ADVANTAGES OF PRESENT INVENTION
1. The control lever of the present invention is sturdy and therefore susceptible to
rough use.
2. The control lever of the present invention is light in weight.
3. The control lever of the present invention is easy to manufacture.
4. The control lever of the present invention is economical.
5. The control lever of the present invention fulfills accomplishes many tests thereby
being advantageous over its counterparts.

WE CLAIM
1) A control lever (1) mounted on a handlebar (3) for operating a clutch or a brake
system of a motor vehicle comprising:
a. an elongated handle (11) and a beam portion (13), whereby the said beam
having an aperture (19) at one end of the beam portion (13), the said aperture
(19) allow the beam portion (13) of the control lever (1) to be pivotally fixed
to a lever holder (2), said lever holder (2) is mounted on the handlebar (3) of
the motor vehicle; the said control lever (1) is characterized by:
b. an extended portion (20) located at the intersection of the elongated handle
(1) and the beam portion (2), wherein the extended portion (20) comprising:
i. a rectangular slot (22) placed at front end of the extended portion
(20), whereby the said front end facing away from the rider;
ii. a circular slot (15) provided at bottom surface of a top portion of the
elongated handle (11), said circular slot (15) located tangentially to a
bottom end of the rectangular slot (22); and
iii. a cut portion (slit) (16) extending from one side of the rectangular slot
(22) to a proximal side of the beam portion (13), said rectangular slot
(22) and cut portion (slit) (16) enables the secure placement of a
Bowden cable button (14) and Bowden cable (12) thereof; and
c. the said control lever (1) is made of polymer, whereby the said polymer is
molded with a metal plate (23) as a reinforcing member therein, the said
reinforcing member is identical in shape to the control lever (1).
2) The control lever (1) as claimed in claim 1, wherein the extended portion (20) is
facing ground when control lever (1) is mounted the lever holder (2).
3) The control lever (1) as claimed in claim 1, wherein the elongated handle (11), beam
portion (13) and extended portion (20) is molded as a single member.
4) The control lever (1) as claimed in claim 1, wherein the bottom surface of extended
portion (20) comprising a hole in line with the circular slot (15) made at the bottom
of the elongated handle (11).
15
5) The control lever (1) as claimed in claim 1, wherein the polymer is selected from the
group comprising of polypropylene (PP), high density polyethylene (HDPE), nylon-6
and nylon-66.
6) The control lever (1) as claimed in claim 5, wherein said polymer is reinforced with
fibrous material.
7) The control lever (1) as claimed in claim 6, wherein the fibrous material is selected
from the group of glass fiber or carbon fiber or both.
8) The control lever (1) as claimed in claim 7, wherein said fibers are short fibers or
long fibers.
9) The control lever (1) as claimed in claim 1, wherein the metal plate (23) comprises
one or more notches and holes at various locations across its length for better
impregnation of polymer.
10) The control lever (1) as claimed in claim 1, wherein the metal plate comprises a
circular extension (233) close to beam portion to increase the strength of
reinforcement of control lever.
11) The control lever (1) as claimed in claim 1, wherein the control lever is optionally
covered with a plastic strip to prevent dust (24).
12) The control lever as claimed in claim 1, wherein the extended portion optionally
comprising cushions.