FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
COMPLETE SPECIFICATION (See section 10 and rule 13)
1. TITLE OF THE INVENTION:
"Composite Vehicular Handlebar"
2. APPLICANT:
a. NAME: MAHINDRA & MAHINDRA LIMITED
b. NATIONALITY: Indian Company registered under the provisions of
the Companies Act-1956.
c. ADDRESS: R&D Center, Automotive Sector, 89,
M.I.D.C., Satpur, NASHIK - 422 007 Maharashtra State, India
3. PREAMBLE TO THE DESCRIPTION:
COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.

Composite Vehicular Handlebar
Field of the invention
The present invention relates to a vehicular handlebar, and more particularly, to a composite vehicular handlebar having value added features.
Background of the invention
Handlebars for bicycle and motor cycle are presently made of a body of fabricated metal sheets and assembled on steering rod. The handle bar for three wheeler automotive bodies is more robust and manufactured by a metal casting process. The process involves extensive use of metal which increases the weight of the handle bar and hence of the vehicle. The overall weight of the vehicle should be reduced for meeting fuel economy standards and to compensate for the higher fuel prices.
Several attempts have been made to reduce the weight of the handle bar on the vehicle. Accordingly, US Patent No. 5557982, US Patent No. 5269196A, US Patent No.5503773 and PCT applicationWO2006/035921 Al disclose different types of handle bar made up of plastic materials. However, potential of using long glass fiber thermoplastic technology to satisfy the structural requirement of application as well as the possibility of integrating additional features like gear lever shifter support. mobile holder, mobile charger and cover with integrated speedometer into the handlebar has not been realized so far.
Accordingly, there is a need of a composite vehicular handle bar that enables reduction of overall weight of a vehicle while extending requisite structural requirement thereby overcoming drawbacks of the prior art.

Objects of the invention
An object of the present invention is to provide a lightweight, robust, rigid composite handlebar that enables overall weight reduction of a vehicle.
Another object of the present invention is to provide the composite vehicular handlebar that integrates additional features and improves the customer perceived quality.
Still another object of the present invention is to provide the composite vehicular handlebar that takes care of the load produced by rotational forces, torsion requirements and torque thereby increasing the fuel efficiency of the vehicle.
Yet another object of the present invention is to provide the composite vehicular handlebar that is adapted to be used with conventional hardware for controlling operation of gear lever and accelerator.
Further object of the present invention is to provide a cost effective method for manufacturing a composite vehicular handlebar with a feasible design and an improved form matching to the plastic surrounding dash board and capable of mass production.
Summary of the invention
Accordingly, the present invention provides a composite vehicular handlebar assembly. The composite vehicular handlebar assembly comprises a first member and a covering member that are manufactured using a long glass fiber filled thermoplastic/polypropylene material The first member includes a neck region, a first

insert, a plurality of reinforcement structures, a second insert, a plurality of third inserts, a wall, a fourth insert and at least two compartments.
The neck region includes at least two arms and a hub positioned therebetween. The arms extend from the neck region to mount the hub onto a steering rod of a vehicle. The first insert is molded at a bottom side of the neck region. The first insert extends upward from the neck region to form a central housing. The first insert includes a plurality of first set of holes and a gap. The plurality of first set of holes allows the arms to extend therethrough thereby mounting the hub onto the steering rod. The hub is locked into the gap of the first insert. The plurality of reinforcement structures is positioned on the neck region to support the hub on the steering rod.
The second insert is positioned centrally on the neck region. The second insert includes a plurality of second set of holes for locking a cable therein. The cable is connected to a hook of a gear shifter bar capable of undergoing a rotational movement The plurality of third inserts are positioned at edges of the neck region to allow the gear shifter bar to pass therebetween while undergoing rotational movement thereby locking the cable into the plurality of second set of holes of the second insert.
The wall restricts the rotational movement of the gear shifter bar. The fourth insert is positioned on the wall for mounting a clutch lever tube on the arms. The first insert, the second insert, the third inserts and the fourth insert are made up of a metal such as cast iron and steel. The at least two compartments are configured to the neck region for receiving a plurality of accessories for example, a mobile phone and a charger. The compartments include a storage bin and a USB port.
The covering member is detachably mounted over the central housing of the first member and includes an integral metering device. The metering device is a speedometer.

Brief description of the drawings
The objectives and advantages of the present invention will become apparent from the following description read in accordance with the accompanying drawings wherein.
Figure 1 shows a front perspective view of a composite handle bar assembly, in accordance with the present invention;
Figure 2 a perspective bottom view of figure 1 showing a cut section of a first member of the composite handle bar assembly;
Figure 3 shows a bottom view of figure 2;
Figure 4 shows a perspective view of a reinforcement structure along a section A-A of figure 1 passing through a hub and a locking metal pin member axis;
Figure 5 shows a perspective view of the reinforcement structure along a section B-B of figure 2 passing through a gear shifter bar and a locking insert: and
Figure 6 shows types of inserts used in the integrated structural unit of figure 2.
Detailed description of the invention
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with the prior art techniques and approaches are overcome by the present invention as described below in the preferred embodiment.
The present invention provides a composite vehicular handlebar with value added features. The composite vehicular handlebar is manufactured using a long fiber

injection molded composite material that reduces the weight of the handlebar and thus of the vehicle resulting in an increased fuel efficiency of the vehicle.
This present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.
Referring now to figure 1, a composite vehicular handlebar assembly (100) (herein after "the assembly (100)"), in accordance with the present invention is shown. The assembly (100) is mountable on a steering rod (not shown) of the vehicle. The assembly (100) is used for three wheeler automotive bodies. However, it is, understood that the assembly (100) can be used for any type of vehicle in other alternative embodiments of the composite handlebar assembly. In an embodiment, the assembly (100) is manufactured by an injection molding process using a long glass fiber filled with a composite material such as polypropylene or a thermoplastic that is suitable for high volume production. The assembly (100) includes a first member (80) and a covering member (90).
Referring now to figures 2 to 6, there is shown the first member (80). The first member (80) is alternatively referred as a single integrated structural unit. The first member (80) is a light weight hybrid structural molded part mounted on the steering rod of the vehicle. The first member (80) includes a neck region (70), a first insert (50A), a second insert (50B). a plurality of reinforcement structures (60), at least two compartments (40), and a wall (30).
The neck region (70) includes at least two arms (not numbered) extending therefrom and a hub (not numbered) positioned between the arms. The neck region (70) is molded with the first insert (50A) at a bottom side to form the hub that is mounted on

the steering rod. The arms extend from the neck region (70) to the steering rod through the first insert (50A) for mounting the hub (70) onto the steering rod.
The first insert (50A) is alternatively referred to as casted metal hub insert. The first insert (50A) includes a plurality of first set of holes (not shown) and a gap (not numbered). The arms extend from the neck region (70) through the first set of holes of first insert (50A) for mounting the hub onto the steering rod. The hub is locked onto the steering rod by a pin (51) that gets inserted into the first set of holes of the first insert (50A). The pin (51) is tightened/press fitted using a nut (52). The nut (52) is inserted into the gap on the first insert (50A) and tightened thereon to reduce the gap thereon as shown in figure 4. However, it is. understood that any suitable means known in the art can be used for locking and press fitting the hub against the steering rod. Such a robust joining with more strength and locking feature helps for better rotating effect of a gear shifter bar (53).
The load generated when the arms of the neck region (70) extends to the steering rod is equally distributed from the arms to the steering rod with the help of the plurality of reinforcement structures (60). The reinforcement structures (60) are rib shaped structures (as shown in figures 2-4) that are provided at various positions on the neck region (70) for supporting the neck region (70) onto the steering rod. In an embodiment, the first member (80) includes five reinforcement structures (60A, 60B. 60C, 60D, 60E). The reinforcement structure (60A) is positioned on a top side of the neck region (70) for completely supporting the neck region (70) on the steering rod. The reinforcement structures (60B, 60C. 60D) are positioned on the bottom side of the hub of the neck region (70) for proper mounting onto the steering rod and for providing required stiffness to the neck region (70). The reinforcement structure (60E) supports and improves the torsion of the steering rod that is caused during an operation of the assembly (100).

The second, third, and the fourth inserts (50B, 50C. 50D) are used for providing robustness to the first member (80) useful for load bearing. The second insert (SOB) is t positioned centrally on the neck region (70) and includes a plurality of second set of holes (not numbered) for locking a cable (54) therein. The cable (54) is connected to a hook (55) of the gear shifter bar (53) (as shown in figure 5). The gear shifter bar (53) is capable of undergoing a rotational movement by a suitable mechanism required therefor.
When undergoing the rotational movement, the gear shifter bar (53) passes between the plurality of third inserts (50C) positioned at edges of the neck region (70) thereby locking the cable (54) into the plurality of second set of holes of the second insert (50B). In an embodiment, there are three numbers of the third insert (50C) that are of cylindrical shape. The rotational movement of the gear shifter bar (53) is restricted by the wall (30). The wall (30) is alternatively referred to as an accelerator restriction arrangement. The fourth insert (50D) is positioned on the wall (30) for mounting a clutch lever tube (not shown) on the arms of the neck region (70). In an embodiment, the inserts (50A, 50B. 50C, 50D) are made up of a metal selected from cast iron and mild steel. The first insert (50A) is made from cast iron and the inserts (50B, 50C and 50D) are made from mild steel.
Further, the first member (80) includes at least two compartments (40) as an integral part. The compartments (40) are configured to the neck region (70) for receiving a plurality of accessories (not shown). In an embodiment, the compartments (40) are additional/value added features such as a storage bin (40A) and a USB (universal serial bus) (40B) that is integrated in a switch pad (not numbered) of the assembly (100). The storage bin (40A) is adapted to receive a mobile phone and the USB port (40B) is adapted to receive a mobile charger.

The first member (80) forms a central housing (not numbered) when the first insert (50A) extends upward from the centre area of the first member (80). The housing of the first member (70) is mounted with the covering member (90). The covering member (90) includes an integral meter unit/ metering device (not shown). In an embodiment, the metering device is a speedometer. The covering member (90) is mounted onto the housing of the first member (80) by means of screws. However, it is, understood that any suitable means known in the art can be used for fitting the covering member (90). The covering member (90) is detachable to allow easy servicing of the metering device.
Advantages of the present invention
• The assembly (100) is rigid, weighing at least 330 gm thereby reducing the overall weight of the vehicle.
• The assembly (100) is economical in cost and results in increased fuel efficiency.
• The assembly (100) takes care of more robust requirement of the clutch lever tube and the gear shifter bar (53) as compared to regular handlebar of bicycles and motorcycles.
• The assembly (100) offers additional features such as mobile holder and mobile charger as an integrated part hence no separate part or arrangement is required,
• The assembly (100) is manufactured with varying material texture and color as per requirement.
• The assembly (100) provides robust method for joining handlebar to steering rod with casted metal inserts and for locking of the hub and the shaft for more strength and better rotating effect.

• The assembly (100) uses a detachable cover allowing easy servicing of the meter unit.
• The assembly (100) includes steel metal inserts to addresses the issue of stress concentration, failures and functional requirement during operating condition in high load concentration areas.
• The assembly (100) provides increased glass percentage and specially structured rib arrangement at neck region (70) that results in even force distribution against load on handlebar.
• The assembly (100) shows no appearance of any metal sheet member on upper surface.
• The assembly (100) integrates many parts into a single structural unit.
• The assembly (100) offers a stylish form of foot step with improved look.
• The method for manufacturing the assembly (100) with the long fiber technology is suitable for high volume production.
• The neck portion of the assembly (100) is reinforced with rib structures (60)
to take care of the torsion requirement at two extended arm and to provide ' support for mounting the gear lever tube and the clutch lever tube.
• The assembly (100) includes two metal reinforcements one at the hub to
protect and connect the steering joint to the neck region, another one at the
gear lever wire rope insertion area to avoid the material rubbing and crushing
due to cable movement.
The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment. Detailed descriptions of , the preferred embodiment are provided herein; however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details

disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure, or matter. The embodiments of the invention as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the spirit and scope of the invention.

We Claim:
1. A composite vehicular handlebar assembly comprising: a first member having
• a neck region mountable onto a steering rod of a
vehicle, the neck region having
at least two arms extending therefrom, and
a hub positioned between the arms, t a first insert molded at a bottom side of the neck region, the first insert extending upward forming a central housing, the first insert having,
a plurality of first set of holes allowing the arms to extend therethrough thereby mounting the hub onto the steering rod, and
a gap locking the hub therein,
• a plurality of reinforcement structures positioned on the neck region for supporting the hub on the steering rod,
• a second insert positioned centrally on the neck region, the second insert having a plurality of second set of holes locking a cable therein, the cable connected to a hook of a gear shifter bar,
• a plurality of third inserts positioned at edges of the neck region allowing a rotational movement of the gear shifter bar therebetween to cause the locking of the cable into the plurality of second set of holes of the second insert,
• a wall restricting the rotational movement of the gear shifter bar,
• a fourth insert positioned on the wall for mounting a clutch lever tube on the arms, and
• at least two compartments configured to the neck region to receive a plurality of accessories; and

a covering member detachably mounted over the central housing of the first member, the covering member having a metering device integrated therewith.
2. The composite vehicular handlebar assembly of claim 1, wherein the first member and the covering member are manufactured using a long glass fiber filled thermoplastic/polypropylene material.
3. The composite vehicular handlebar assembly of claim 1. wherein the first insert, the second insert, the third inserts and the fourth insert are made up of a metal selected from cast iron and mild steel.
4. The composite vehicular handlebar assembly of claim 1, wherein the compartments includes a storage bin and a USB port.
5. The composite vehicular handlebar assembly of claim 1, wherein the plurality of accessories includes a mobile phone and a charger.
6. The composite vehicular handlebar assembly of claim 1, wherein the metering device is a speedometer.