Claims:We Claim:

1. An axle mounting bracket assembly (200) for a front fork suspension (100) comprising of:
• a bracket (15),
• an oil lock cap (20),
• a socket bolt (5),
• a washer (10),
• a suspension unit (50) with outer tube (54),
wherein,
- the bracket (15) has an upper cylindrical portion (15U) and a lower cylindrical portion (15L) with two exactly opposite flat surfaces (15OS1 and 15OS2) disrupting the curved surface of the lower cylindrical portion (15L); the flat surface (15OS1) has a horizontal bore (15HB) that passes all the way through the lower cylindrical portion (15L) of the bracket (15) and opens at the flat surface (15OS2); the lower cylindrical portion (15L) has a lower flat surface with a stepped vertical bore (15SVB) that intersects with the horizontal bore (15HB) and opens at the upper flat surface of the upper cylindrical portion (15U); the upper opening of the stepped vertical bore (15SVB) at the upper flat surface of the upper cylindrical portion (15U) has a stepped profile (15USP); the stepped vertical bore (15SVB) has another inverted stepped profile (15SP) located above the location of intersection of the horizontal bore (15HB) and the stepped vertical bore (15SVB) but below the upper opening of the stepped vertical bore (15SVB) at the upper flat surface of the upper cylindrical portion (15U);
- the socket bolt (5) passes through lower opening of a stepped vertical bore (15SVB) and is fitted and locked into position with a seat pipe (25);
- the oil lock cap (20) is positioned and locked in a stepped vertical bore (15SVB) at the upper flat surface of the upper cylindrical portion (15U) of the bracket (15) and said oil lock cap (20) is configured to position a lower end of the seat pipe (25) of the suspension unit (50) therein forming a hydraulic lock during bottoming out of the front fork of suspension unit (50);
- the washer (10) is positioned in the inverted stepped surface of the vertical bore (15SVB) of the bracket (15);
- said socket bolt (5) passing through lower opening of the stepped vertical bore (15SVB) of the bracket (15) fixes and locks into position the seat pipe (25), the oil lock cap (20), the bracket (15) and the washer (10) in that order with lower surface of the head of the socket bolt (5) resting against the washer (10); and
- said bracket (15) along with the seat pipe (25), the oil lock cap (20), the washer (10) and the socket bolt (5) is fitted and locked into position at a lower open end (54L) of an outer tube (54) of the suspension unit (50).

2. The axle mounting bracket assembly (200) as claimed in claim 1, wherein the upper cylindrical portion (15U) of the bracket (15) has outer diameter at least 1.2 times greater than the outer diameter than the lower cylindrical portion (15L) but not greater than 1.6 times.

3. The axle mounting bracket assembly (200) as claimed in claim 2, wherein the oil lock cap (20) has cylindrical inner curved surface and at least an inclined outer curved surface.

4. An axle mounting bracket assembly (200A) for a front fork suspension (100) comprising of:
• a bracket (15A),
• a socket bolt (5),
• a washer (10),
• a suspension unit (50) with outer tube (54),
wherein,
- the bracket (15A) has an upper cylindrical portion (15AU) and a lower cylindrical portion (15AL) with two exactly opposite flat surfaces (15AOS1 and 15AOS2) disrupting the curved surface of the lower cylindrical portion (15AL); the flat surface (15AOS1) has a horizontal bore (15AHB) that passes all the way through the lower cylindrical portion (15AL) of the bracket (15A) and opens at the flat surface (15AOS2); the lower cylindrical portion (15AL) has a lower flat surface with a stepped vertical bore (15ASVB) that intersects with the horizontal bore (15AHB) and opens at the upper flat surface of the upper cylindrical portion (15AU); the upper flat surface of the upper cylindrical portion (15AU) has a projected cylindrical structure (16) forming an integral oil lock cap on the bracket (15A); the upper opening of the stepped vertical bore (15ASVB) at the upper flat surface of the upper cylindrical portion (15AU) is located within the integral oil lock cap structure (16); the stepped vertical bore (15ASVB) has another inverted stepped profile surface located above the location of intersection of the horizontal bore (15AHB) and the stepped vertical bore (15ASVB) but below the upper opening of the stepped vertical bore (15ASVB) on the upper flat surface of the upper cylindrical portion (15AU);
- the socket bolt (5) passes through lower opening of a stepped vertical bore (15ASVB) and is fitted and locked into position with a seat pipe (25);
- the integral oil lock cap (16) is configured to position a lower end of the seat pipe (25) of the suspension unit (50) therein forming a hydraulic lock during bottoming out of the front fork of suspension unit (50);
- the washer (10) is positioned in the inverted stepped surface of the vertical bore (15ASVB) of the bracket (15A);
- said socket bolt (5) passing through lower opening of the stepped vertical bore (15ASVB) of the bracket (15A) fixes and locks into position the seat pipe (25), the bracket (15A) and the washer (10) in that order with lower surface of the head of the socket bolt (5) resting against the washer (10); and
- said bracket (15A) along with the seat pipe (25), the washer (10) and the socket bolt (5) is fitted and locked into position at a lower open end (54L) of an outer tube (54) of the suspension unit (50).

5. The axle mounting bracket assembly (200A) as claimed in claim 4, wherein the upper cylindrical portion (15AU) of the bracket (15A) has a greater diameter than the lower cylindrical portion (15AL).

6. The axle mounting bracket assembly (200A) as claimed in claim 5, wherein the integral oil lock cap structure (16) has cylindrical inner curved surface and at least an inclined outer curved surface.

7. The axle mounting bracket assembly (200 or 200A) as claimed in claims 3 or 6 wherein the socket bolt (5) is fitted and locked into position with a seat pipe (25) through threaded joint wherein the lower end (25L) of the seat pipe (25) has threads on its inner surface matching with the threads on the stud (5S) of the socket bolt (5).

8. The axle mounting bracket assembly (200 or 200A) as claimed in claim 7, wherein
- the optimized range of threaded engagement of the stud (5S) of socket bolt (5) with the seat pipe (25) is 9 to 15 mm for better and effective alignment; and
- the optimized height of the oil lock cap (20 or 16) is in the range of 7 to 11 mm with 20 to 35% taper length of said height at its extreme end to suit the fork pipe spinning arrangement generating the required bottoming load for avoiding metal to metal contact.

9. The axle mounting bracket assembly (200 or 200A) as claimed in claim 8 wherein the bracket (15, 15A) is fitted into the lower open end (54L) of an outer tube (54) of the suspension unit (50) by the fastening means selected from press fitting / interference fitting and threaded joint followed by welding.

10. The axle mounting bracket assembly (200 or 200A) as claimed in claim 9, wherein said axle mounting bracket assembly (200 or 200A) and the suspension unit (50) jointly constitute the front fork suspension (100);
wherein
said suspension unit (50) comprises of an inner tube (52), the outer tube (54), a main spring (56), a rebound spring (58), a valve assembly (60), a seat pipe (25), a guiding and sealing assembly (68), a spacer tube (78), and a fork bolt (80),
wherein,
- the inner tube (52) is in telescopic association with the outer tube (54) and can hence slide freely within it;
- the bracket (15, 15A) is fitted at the lower open end of the outer tube (54);
- the seat pipe (25) fitted on the bracket (15, 15A) by means of the washer (10) and socket bolt (5) is located within the outer tube (54);
- the main spring (56) has its lower end resting upon the upper surface of a piston head of the seat pipe (25) and an upper surface on the spacer tube (78);
- the fork bolt (80) fitted at the upper open end of the inner tube (52) and supports and holds the spacer tube (78) in its position within the inner tube (52);
- the rebound spring (58) has an upper end resting upon the lower surface of the piston head of the seat pipe (25) and a lower end resting upon a valve assembly (60) fitted at the lower open end of the inner tube (52); and
- the guiding and sealing assembly (68) is located and fixed in a space given at the upper open end of the outer tube (54).

Dated this 4th day of February 2022

Sahastrarashmi Pund
Head – IPR
Endurance Technologies Ltd.

To,
The Controller of Patents,
The Patent Office, at Mumbai. , Description:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

TITLE OF THE INVENTION
“AXLE MOUNTING BRACKET ASSEMBLY FOR A FRONT FORK SUSPENSION”

Endurance Technologies Limited
E-92, M.I.D.C. Industrial Area, Waluj,
Aurangabad – 431136, Maharashtra, India

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed.
Field of Invention

[001] The present invention is related to front suspension unit of motor vehicles. More particularly, it is related to the axle mounting bracket assembly employed for mounting the suspension unit on the axle of a wheel of a vehicle.

Background of the Invention

[002] In a conventional front fork suspension, the seat pipe must be held perfectly vertical to the base of the outer tube, firstly to ensure that the seat pipe does not end up scratching the inner tube when it reciprocates within the outer tube, and secondly to ensure that the main spring gets a perfectly flat base to rest on at the piston head of the seat pipe. While it is possible to cast an outer tube and then machine it to its final shape using conventional processes so as to ensure that seat pipe is attached on a flat base inside the outer tube, casting and then machining as way of manufacturing does not allow the domain experts / engineers the freedom to make different sections of the front fork out of materials more suited to the specific requirements of that section. In accordance with this line of thinking, manufacturing a tube and its axle mounting bracket separately and then assembling them together to form a finished outer tube for a front fork suspension is a known solution for creating structurally stronger and relatively light weight front fork suspensions.

[003] Manufacturing a suspension tube and a bracket separately and then assembling them to form an outer tube does create issues as far as ensuring perfect alignment of the seat pipe within the outer tube is concerned. This problem is faced while implementing the solutions similar to that which have been disclosed by the Indian patent application 202041013774. In the front fork suspension disclosed by this particular document, the bracket has a projected portion with threads on which the seat pipe having matching internal threads is mounted. Misalignment of parts during their assembly is a very common problem, and such misalignment here can create issues with regards to alignment of the seat pipe within the outer tube. This issue can end up causing reduction in life of the front fork.

[004] Additionally with regards to the solution disclosed in the Indian patent application 202041013774, there is no feature provided on the bracket to prevent metal to metal contact if and when the front fork is about to get fully compressed (i.e. in other words bottom out). Such metal to metal contact between the lower end of the inner tube and upper surface of the bracket normally happens when a particularly road surface irregularity is encountered while driving. As such metal to metal contact can badly damage a front fork suspension, it is necessary to provide at least some feature to deal with this problem. Thus, the available solution of mounting the suspension unit on the axle through a separate bracket does not teach about forming the hydraulic lock of the outer tube to take care of the undulating / rough road surfaces. Hence, in order to resolve all the issues as discussed above, a new axle mounting bracket for a front fork suspension of a vehicle is hereunder disclosed.

Objectives of the Present Invention

[005] The main object of the present invention is to provide an axle mounting bracket assembly for front suspension unit of a vehicle.
[006] Another objective of the present invention is to provide an axle mounting bracket assembly that facilitate creation of hydraulic lock, which thereby eliminates the chance of there being any metal to metal contact between the lower end of the inner tube and the inside upper surface of the bracket when the front fork suspension is just about to bottom out.

[007] Yet the another objective of the present invention to provide an axle mounting bracket assembly that eliminates the issues and concerns related to alignment of components and ensures that the seat pipe is held vertical to the base of the outer tube.

[008] Further, the objective of the present invention is to provide an axle mounting bracket assembly that ensures proper alignment of the seat pipe, reduce the friction force between the mating parts and eliminate/nullify fork pipe jamming concern of the suspension unit.

[009] Still the further objective of the present invention is to provide an axle mounting bracket assembly that enhances the life of the front fork suspension as the damage which can result from imperfect alignment of the seat pipe is avoided.

[0010] Further objective of the present invention is to provide an axle mounting bracket assembly for front suspension unit that is simple in construction, light in weight and modular in nature and can be implemented without greatly affecting the manufacturing and assembly time.

Brief Description of Drawings

[0011] This invention is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein and advantages thereof will be better understood from the following description when read in conjunction with the following drawings, wherein

[0012] Figure 1a discloses the perspective view of the front suspension unit of a motor vehicle in accordance with the present invention.

[0013] Figure 1b presents the sectional view of the suspension unit shown in Fig. 1.

[0014] Figure 2 shows the exploded sectional view the axle mounting bracket assembly as per the present invention.

[0015] Figures 3a and 3b shows the assembly views of the axle mounting bracket assembly of the invention wherein Fig. 3a is a perspective assembly view and Fig. 3b is a sectional assembly view of the axle mounting bracket assembly.

[0016] Figure 4 shows the exploded sectional view of another embodiment of the axle mounting bracket assembly in accordance with the present invention.

[0017] Figures 5a and 5b shows the assembly views of another embodiment of the axle mounting bracket assembly of the invention wherein Fig. 5a is a perspective assembly view and Fig. 5b is a sectional assembly view of the axle mounting bracket assembly.
Detailed Description of the Present Invention

[0018] In accordance with the disclosed first embodiment of the invention, an axle mounting bracket assembly (200) for a front fork suspension (100) comprises of a bracket (15), an oil lock cap (20), a socket bolt (5), a washer (10) and a suspension unit (50) with outer tube (54) (refer Figs 2 & 3).

[0019] The bracket (15) has an upper cylindrical portion (15U) and a lower cylindrical portion (15L) with two exactly opposite flat surfaces (15OS1 and 15OS2) disrupting the curved surface of the lower cylindrical portion (15L). The flat surface (15OS1) has a horizontal bore (15HB) that passes all the way through the lower cylindrical portion (15L) of the bracket (15) and opens at the flat surface (15OS2). Providing the flat surfaces (15OS1 and 15OS2) and the horizontal bore (15HB) allows the axle of a wheel to be located and stably fixed on the bracket (15). The lower cylindrical portion (15L) has a lower flat surface with a stepped vertical bore (15SVB) that intersects with the horizontal bore (15HB) and opens at the upper flat surface of the upper cylindrical portion (15U). The upper opening of the stepped vertical bore (15SVB) at the upper flat surface of the upper cylindrical portion (15U) has a stepped profile (15USP). The stepped vertical bore (15SVB) has another inverted stepped profile (15SP) located above the location of intersection of the horizontal bore (15HB) and the stepped vertical bore (15SVB) but below the upper opening of the stepped vertical bore (15SVB) at the upper flat surface of the upper cylindrical portion (15U).

[0020] In the axle mounting bracket assembly (200), the upper cylindrical portion (15U) of the bracket (15) has a greater diameter than the lower cylindrical portion (15L). The outer diameter of the upper cylindrical portion (15U) of the bracket (15) has at least 1.2 times greater diameter than the outer diameter of lower cylindrical portion (15L) but not greater than 1.6 times. This feature ensures sufficient strength at the location where it is needed and reduces the weight of the bracket (15) in the region where it can be reduced, without compromising upon its strength.

[0021] The socket bolt (5) passes through lower opening of a stepped vertical bore (15SVB) and is fitted and locked into position with a seat pipe (25). The oil lock cap (20) is positioned and locked in a stepped vertical bore (15SVB) at the upper flat surface of the upper cylindrical portion (15U) of the bracket (15) and said oil lock cap (20) is configured to position a lower end of the seat pipe (25) of the suspension unit (50) therein facilitating formation of a hydraulic lock during bottoming out of the front fork of suspension unit (50). Additionally, the oil lock cap (20) also has cylindrical inner curved surface and at least an inclined outer curved surface. The front fork suspension (100) can be said to have bottomed out when an inner tube (52) has travelled into the outer tube (54) to such an extent that lower end of the inner tube (52) has just touched the inner upper surface of the bracket (15).

[0022] In the axle bracket mounting assembly (200), the washer (10) is positioned in the inverted stepped surface of the vertical bore (15SVB) of the bracket (15). The socket bolt (5) passing through lower opening of the stepped vertical bore (15SVB) of the bracket (15) fixes and locks into position the seat pipe (25), the oil lock cap (20), the bracket (15) and the washer (10) in that order with lower surface of the head of the socket bolt (5) resting against the washer (10). The bracket (15) along with the seat pipe (25), the oil lock cap (20), the washer (10) and the socket bolt (5) is fitted and locked into position at a lower open end (54L) of an outer tube (54) of the suspension unit (50).

[0023] The washer (10) deforms when the socket bolt (5) is torqued during assembling of the front fork suspension (100). This causes the material from the washer (10) to flow and close any and all free/open spaces within the stepped vertical bore (15SVB) that exist between the socket bolt (5) an the bracket (15). This thereby reduces the probability of leakage of damping fluid filled inside the front fork suspension (100) through the stepped vertical bore (15SVB), during motor vehicle usage. As the upper opening of the stepped vertical bore (15SVB) at the upper flat surface of the upper cylindrical portion (15U) has a stepped profile (15USP), the oil lock cap (20) and hence the seat pipe (25) are therefore stably held in perfect alignment in the outer tube (54).

[0024] The oil lock cap (20) having its unique profile, the lower end of the inner tube (52) and the outer tube (54), in the condition approaching the bottoming out of the front fork suspension (100), together end up trapping some amount of damping fluid in a confined space. The condition approaching the bottoming out of the front fork suspension (100) is a condition in which the inner tube (52) has travelled further enough into the outer tube (54) while reciprocating such that the lower end of the inner tube (52) is close to hitting the inner upper surface of the bracket (15). This creates a hydraulic lock because liquids are not very highly compressible. This stops the inner tube (52) before it hits the bracket (15). The oil lock cap (20) allows the damping fluid filled in the front fork suspension (100) to slowly seep past its outer inclined outer curved surface and back between the inner tube (52) and the outer tube (54), when the inner tube (52) under the action of the stored energy in the compressed main spring (56) starts moving up and out of the outer tube (54).

[0025] In accordance with another embodiment of the invention, the axle mounting bracket assembly (200A) for a front fork suspension (100) comprises of a bracket (15A), a socket bolt (5), a washer (10) and a suspension unit (50) with outer tube (54) (refer Figs. 4 & 5).

[0026] The bracket (15A) has an upper cylindrical portion (15AU) and a lower cylindrical portion (15AL) with two exactly opposite flat surfaces (15AOS1 and 15AOS2) disrupting the curved surface of the lower cylindrical portion (15AL). The flat surface (15AOS1) has a horizontal bore (15AHB) that passes all the way through the lower cylindrical portion (15AL) of the bracket (15A) and opens at the flat surface (15AOS2). Providing the flat surfaces (15AOS1 and 15AOS2) and the horizontal bore (15AHB) allows the axle of a wheel to be located and stably fixed on the bracket (15). The lower cylindrical portion (15AL) has a lower flat surface with a stepped vertical bore (15ASVB) that intersects with the horizontal bore (15AHB) and opens at the upper flat surface of the upper cylindrical portion (15AU).

[0027] The upper flat surface of the upper cylindrical portion (15AU) has a projected cylindrical structure (16) forming an integral oil lock cap on the bracket (15A). The upper opening of the stepped vertical bore (15ASVB) at the upper flat surface of the upper cylindrical portion (15AU) is located within the integral oil lock cap structure (16). The stepped vertical bore (15ASVB) has another inverted stepped profile surface located above the location of intersection of the horizontal bore (15AHB) and the stepped vertical bore (15ASVB) but below the upper opening of the stepped vertical bore (15ASVB) on the upper flat surface of the upper cylindrical portion (15AU). The socket bolt (5) passes through lower opening of a stepped vertical bore (15ASVB) and is fitted and locked into position with a seat pipe (25).

[0028] The integral oil lock cap (16) is configured to position a lower end of the seat pipe (25) of the suspension unit (50) therein facilitating formation of a hydraulic lock during bottoming out of the front fork of suspension unit (50). Additionally, the integral oil lock cap structure (16) has cylindrical inner curved surface and at least an inclined outer curved surface. The front fork suspension (100) can be said to have bottomed out when an inner tube (52) has travelled into the outer tube (54) to such an extent that lower end of the inner tube (52) has just touched the inner upper surface of the bracket (15).

[0029] In the axle bracket mounting assembly (200A), the washer (10) is positioned in the inverted stepped surface of the vertical bore (15ASVB) of the bracket (15A). The socket bolt (5) passing through lower opening of the stepped vertical bore (15ASVB) of the bracket (15A) fixes and locks into position the seat pipe (25), the bracket (15A) and the washer (10) in that order with lower surface of the head of the socket bolt (5) resting against the washer (10). The bracket (15A) along with the seat pipe (25), the washer (10) and the socket bolt (5) is fitted and locked into position at a lower open end (54L) of an outer tube (54) of the suspension unit (50).

[0030] The washer (10) deforms when the socket bolt (5) is torqued during assembling of the front fork suspension (100). This causes the material from the washer (10) to flow and close any and all free/open spaces within the stepped vertical bore (15ASVB) that exist between the socket bolt (5) an the bracket (15A). This thereby reduces the probability of leakage of damping fluid filled inside the front fork suspension (100) through the stepped vertical bore (15ASVB), during motor vehicle usage. The projected cylindrical structure (16) forming an integral oil lock cap on the bracket (15A) provides a stable partially confined space where the lower end (25L) of the seat pipe (25) can be located and stably held. As the integral oil lock cap (16) (also identifiable as the projected cylindrical structure) forming integral oil lock cap on the bracket (15A) cannot be accidentally/unintentionally displaced from its postion on the bracket (15A) during assembly of the front fork suspension (100), the seat pipe (25) is therefore held within confines of a stable structure and in perfect alignment in the outer tube (54).

[0031] The integral oil lock cap (16) having its unique profile, the lower end of the inner tube (52) and the outer tube (54), in the condition approaching the bottoming out of the front fork suspension (100), together end up trapping some amount of damping fluid in a confined space. The condition approaching the bottoming out of the front fork suspension (100) is a condition in which the inner tube (52) has travelled further enough into the outer tube (54) while reciprocating such that the lower end of the inner tube (52) is close to hitting the inner upper surface of the bracket (15A). This creates a hydraulic lock because liquids are not very highly compressible. This stops the inner tube (52) before it hits the bracket (15A). The oil lock cap (20) allows the damping fluid filled in the front fork suspension (100) to slowly seep past its outer inclined outer curved surface and back between the inner tube (52) and the outer tube (54), when the inner tube (52) under the action of the stored energy in the compressed main spring (56) starts moving up and out of the outer tube (54).

[0032] The axle mounting bracket (200A), the upper cylindrical portion (15AU) of the bracket (15A) has a greater diameter than the lower cylindrical portion (15AL). This feature ensures sufficient strength at the location where it is needed and reduces the weight of the bracket (15) in the region where it can be reduced, without compromising upon its strength.

[0033] In both the embodiments of the axle mounting bracket assembly (200 and 200A), the socket bolt (5) is fitted and locked into position with a seat pipe (25) through threaded joint wherein the lower end (25L) of the seat pipe (25) has threads on its inner surface matching with the threads on the stud (5S) of the socket bolt (5). The optimized range of threaded engagement of the stud (5S) of the socket bolt (5) with the seat pipe (25) is in the range of 9 to 15 mm for better and effective alignment. Lower the engagement within the range, better is the alignment of seat pipe (25). The proper alignment of mating part (particularly stud of the socket bolt) of the bracket assembly with the seat pipe (25) reduces the friction force after the assembly and also avoids or nullify fork pipe jamming concern after the fork assembly. The optimized height of the oil lock cap (20 or 16) is in the range of 7 to 11 mm with taper length of 20 to 35% of said height at the extreme end to suit the fork pipe spinning arrangement generating the required bottoming load for avoiding metal to metal contact.

[0034] The bracket (15, 15A) is fitted into the lower open end (54L) of an outer tube (54) of the suspension unit (50) by the suitable fastening means viz. press fitting / interference fitting, threaded joints, and like followed by welding. These features help in maintaining perfect alignment of the seat pipe (25) with respect to the outer tube (54) during and after completion of assembly of the front fork suspension (100).

[0035] The axle mounting bracket assembly (200 or 200A) and the suspension unit (50) jointly constitute the front fork suspension (100). The front fork suspension (100) so formed is typically filled with a damping fluid (e.g. oil). The suspension unit (50) itself is comprised of an inner tube (52), the outer tube (54), a main spring (56), a rebound spring (58), a valve assembly (60), a seat pipe (25), a guiding and sealing assembly (68), a spacer tube (78), and a fork bolt (80).

[0036] The inner tube (52) is in telescopic association with the outer tube (54) and can hence slide freely within it. The bracket (15, 15A) is fitted at the lower open end (54L) of the outer tube (54). The seat pipe (25) fitted on the bracket (15, 15A) by means of the washer (10) and socket bolt (5) is located within the outer tube (54). The main spring (56) has its lower end resting upon the upper surface of a piston head of the seat pipe (25) and an upper surface on the spacer tube (78). The fork bolt (80) fitted at the upper open end of the inner tube (52) and supports and holds the spacer tube (78) in its position within the inner tube (52). The rebound spring (58) has an upper end resting upon the lower surface of the piston head of the seat pipe (25) and a lower end resting upon a valve assembly (60) fitted at the lower open end of the inner tube (52). The guiding and sealing assembly (68) is located and fixed in a space given at the upper open end of the outer tube (54).

[0037] As such this description aims to establish that the axle mounting bracket (200, 200A) can be provided in any typical suspension unit (50) having at least features such as the main spring (56) for absorbing energy when vehicle travels over a road surface irregularity, and the seat pipe (25) and the valve assembly (60) for dissipating this energy absorbed by the main spring (56). The guiding and sealing assembly (68) provided in suspension unit (50) is formed by typical set of sub-components capable of guiding the movement of inner tube (52) within the outer tube (54) and also sealing and protecting the components accommodated inside them from external dust and foreign elements.

[0038] The axle mounting bracket for a front fork suspension in accordance with embodiments of the disclosed embodiments provides the following advantages:
- Its features facilitate creation of hydraulic lock, which thereby eliminates the chance of there being any metal to metal contact between the lower end of the inner tube and the inside upper surface of the bracket when the front fork suspension is just about to bottom out .
- It ensures that the seat pipe is held vertical to the base of the outer tube.
- It enhances the life of the front fork suspension as the damage which can result from imperfect alignment of the seat pipe is avoided.
- It provides a simple solution that can be implemented without greatly affecting the manufacturing and assembly time.

[0039] The disclosed invention hence overcomes the limitation of the known solutions. It provides an axle mounting bracket that is easy to provide within all front fork suspensions where outer tube and axle mounting bracket are manufactured separately and then joined together. Altering the components forming the suspension unit (50) does not directly affect the performance of the axle mounting bracket in accordance with the disclosed invention. Such alterations must therefore not be considered to be taking any assembly out of the scope of claims of this invention.

[0040] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.