DESC: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
“Fork Assembly for Suspension System of Two and Three Wheeled Vehicles”

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 suspension systems of two and three wheeled motor vehicles. More particularly, the invention is related to front fork assembly with a seat pipe intelligently fitted with an axle mounting bracket of suspension system of two and three wheeled vehicle ensuring the orthogonal alignment of the seat pipe.

Background of the Invention

[002] Generally, in front fork leg assembly of the suspension system of two and three wheeled vehicles, an inner tube assembly is telescopically arranged inside the outer tube assembly. The outer tube assembly is formed by joining together two separate parts namely an outer tube and axel mounting bracket. The outer tube and axle mounting bracket are manufactured separately before being assembled to form the outer tube assembly for a front fork assembly, is a known solution for creating structurally stronger front fork leg for suspension systems of the vehicles. In leg assembly of a front fork, a seat pipe must be aligned orthogonally to inner top surface of the axle mounting bracket so that the seat pipe does not foul with the inner surface of the inner tube leading to scratches thereon.

[003] Conventionally, the outer tube and an axle mounting bracket manufactured separately and then assembling them to form an outer tube assembly does create the issues of mis-alignment of the seat pipe within the outer tube. In one of the conventional solution wherein the axle mounting bracket has a projected portion with threads on which the seat pipe having matching internal threads is mounted, the misalignment of parts during their assembly is a very common problem, and such misalignment here creates the issues with regards jam or sticky fork movement, rubbing noise, wear and tear of parts which consequently affect the damping performance of the suspension system and causes reduction in life of the front fork.

[004] Further in some of the conventional solutions, there is no feature provided on the axle mounting bracket to prevent metal to metal contact of inner tube and outer tube of the fork leg. When the front fork is about to get fully compressed (i.e. when it bottoms out), the metal to metal contact between the lower end of the inner tube and the inside surface of the outer tube normally happens when a large road surface irregularity is encountered while driving. In some cases, when the threaded joint between the seat pipe and axel mounting bracket is damaged due to mis-alignment, the whole outer tube assembly needs to be replaced with the new one, which is neither a desired solution nor an economical in terms of time and money. As such metal to metal contact can badly damage a front fork suspension, it is demanded to provide a solution that deals with such problem/s.

[005] Hence, in order to overcome the problems prevalent in the prior art and/or conventional solutions, there is prolonged unmet need to provide a solution which will not lead to misalignment of the components, totally eliminate the replacement of any of the components, eliminate the rework / rejection, makes the outer tube serviceable, imparts easiness in assembling the front fork assembly and that also by providing an economical solution. The present invention clearly addresses the drawbacks of the prior art and/or conventional solutions by providing a unique design of front fork assembly of a suspension system.
Objectives of the Present Invention

[006] The main objective of the present invention is to provide a front fork assembly for suspension system of two and three wheeled vehicles.

[007] Another objective of the present invention is to provide a front fork assembly for suspension system that ensures the perfect and orthogonal alignment of the seat pipe with its relevant components and eliminates the chance of any misalignment of any of the components of the front fork assembly.

[008] Yet, the objective of the present invention is to provide a front fork assembly for suspension system that eliminates the rework / rejection, makes the outer tube serviceable, and imparts easiness in assembling the front fork assembly and that also by providing an economical solution.

[009] Further, the objective of the present invention is to provide a front fork assembly for suspension system that does not deteriorate the manufacturing and assembly time; and enhances the life of the front fork suspension as the damage which can result from imperfect alignment of the seat pipe is eliminated.

[0010] Still the objective of the present invention is to provide a front fork assembly for suspension system that is simple in construction, easy to manufacture and facilitates the easy replacement of the insert in case of damage of threaded joints, instead of replacing the whole outer tube assembly.

Brief Description of Drawings

[0011] This invention is illustrated in the accompanying drawings, throughout which 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 with reference to the following drawings, wherein
Figure 1 discloses the perspective view of the front fork suspension system of two wheeled vehicles in accordance with the present invention.
Figure 2 shows the cut sectional view of the leg assembly of the front fork suspension system as per the present invention.
Figure 3 shows the magnified isometric view of the seat pipe in leg assembly of the front fork suspension system as per the present invention.
Figure 4 shows an exploded view of an outer tube assembly with a seat pipe and an embodiment of the axle mounting bracket according to the present invention.
Figure 5 shows an enlarged isometric cut view of an embodiment of the axle mounting bracket as disclosed in Fig. 4 as per the present invention.
Figure 6 provides an exploded view of an outer tube assembly with the seat pipe and another embodiment of the axle mounting bracket according to the present invention.
Figure 7 shows an enlarged isometric and cut view of another embodiment of the axle mounting bracket as disclosed in Fig. 6 as per the present invention.
Figure 8 presents an exploded view of an outer tube assembly with the seat pipe and third embodiment of the axle mounting bracket according to the present invention.
Figure 9 shows an enlarged cut sectional view of third embodiment of the axle mounting bracket as disclosed in Fig. 8 as per the present invention.
Figure 10(a) provides an exploded view of an outer tube assembly with the seat pipe and fourth embodiment of the axle mounting bracket according to the present invention.
Figure 10(b) shows an enlarged cut sectional view of fourth embodiment of the axle mounting bracket as disclosed in Fig. 10(a) as per the present invention.
Figure 11 discloses isometric view of the axle mounting bracket from the bottom as per the present invention.

Detailed Description of the Present Invention

[0012] Referring to the Fig. 1 and Fig. 2, the present invention discloses a front fork assembly (1000) for a suspension system of a two and three wheeled vehicles. The front fork assembly (1000) comprises of a pair of leg assemblies (100) and said leg assemblies are connected with each other with the help of a triple clamp assembly (15) to form the said front fork assembly (1000). The leg assembly (100) includes an inner tube assembly (10), an outer assembly (20) and a seal assembly (10S). The inner tube assembly (10) further comprises of a sleeve (10SL), an inner tube (12), a main spring (14), a rebound spring (16), and a fork bolt (10B). The outer tube assembly (20) includes an outer tube (22), an axle mounting bracket (40) and a seat pipe (30).

[0013] The inner tube assembly (10) is assembled in a way such that the fork bolt (10B) closes the inner tube (12) from the top end. The sleeve (10SL) is placed in the inner tube (12) such that that the one end of the sleeve (10SL) abuts against the lower face of the fork bolt (10B) and the other end of the said sleeve (10SL) arrest the top end of the main spring (14). The other end of the main spring (14) rests against the top surface of a piston (16P) of the seat pipe (30) of the outer tube assembly (20).

[0014] The outer tube assembly (20) is formed by assembling the outer tube (22) with the axle mounting bracket (40). The said axle mounting bracket (40) is press fitted and welded to the lower end of the outer tube (22). However, the axel mounting bracket (40) may be fitted to the bottom end of the outer tube (22) by any of fastening means selected from press fitting / interference fitting, threaded joints, and like followed by welding. The seat pipe (30) is fitted with the axle mounting bracket (40) with the help of threads provided on projecting portion (34) of the seat pipe (30). The annular space between the inner tube assembly (10) and the top end of the outer tube assembly (20) is closed by a seal assembly (10S) so as to eliminate the leakage of working fluid (oil) in the outer tube.

[0015] When the suspension unit is fitted on the vehicle, each of the fork leg assembly (100) is positioned on either sides of the front wheel. Each of the fork assemblies (100) is filled with fluid, preferably the oil, in order to achieve the damping performance and also for lubricating the various child parts of the assembly. It also helps in dissipating the heat energy generated as a result of damping of the shock loads and vibrations. The seal assembly (10S) includes a pair of dust seal and an oil seal is provided in the top portion of the outer tube to avoid entry of foreign particles into the leg assemblies (100) and leakage of hydraulic fluid therefrom.

[0016] Referring to Fig. 3, the seat pipe (30) is configured to have a cylindrical body (32) having a top end (32T) and bottom end (32B) and said cylindrical body (32) is having a plurality of orifices (32O) thereon forming the oil passage from inside of the seat pipe (30) to the outer tube (22). Further, the said seat pipe (30) has a projecting portion (34) projecting out from a bottom surface (32BS) of the cylindrical body (32) at its bottom end (32B). The seat pipe (30) has a piston (16P) integrated at its top end (32T). However, the said piston (16P) can be detachably attached to the seat pipe (30) at its top end (32T) by suitable fastening means. The diameter of the cylindrical body (32) of the seat pipe (30) is greater than the diameter of the projected portion (34) of the seat pipe (30). The projected portion (34) gets engaged inside the axel mounting bracket (40). The said projected portion (34) is profiled to have three portions viz. a plain portion (34P), a threaded portion (34T) and an entry portion (34E). The threaded portion (34T) is provided with a plurality of threads (34TT) on its outer surface. The threaded portion (34T) is formed between the plain portion (34P) and the entry portion (34E). The entry portion (34E) is formed by chamfering the extreme end of the projected portion (34).

[0017] Referring to Figs. 4 and 5, the axel mounting bracket (40) according to the present invention is configured to have a cylindrical upper portion (42) at its top end, a stem portion (44), an axle eye portion (40B) and a metal insert (45). The cylindrical upper portion (42) is having a flat top surface (42TS). The cylindrical upper portion (42) has an opening (42H) at its top surface (42TS) that opens into a slot (44S) made inside the stem portion (44) of the axle mounting bracket (40). The opening (42H) has a stepped profile (42HS) on its inner surface. The stepped profile (42HS) houses a washer (70) inside it and also facilitate to reduce the chances of misalignment of the seat pipe (30) from its required position while assembling it with the axle mounting bracket (40). The top surface (70TS) of the washer (70) is in contact with the bottom surface (32BS) of the cylindrical body (32) of the seat pipe.
[0018] During assembly of the seat pipe (30) with the axle mounting bracket (40), the entry portion (34E) of the projected end (34) at the bottom end of the seat pipe (30) facilitates the easy entry of the projected portion (34) of the seat pipe (30) inside the stepped profiled opening (42HS) of the axle mounting bracket (40) and also facilitate the easy and orthogonal alignment of the seat pipe (30) when it is fixed inside the axel mounting bracket (40) of the outer tube assembly (20). The seat pipe (30) is fitted inside the bracket (40) by means of the washer (70) and threaded engagement. The projected portion (34) receives the washer (70) that rests over outer surface of its plain portion (34P). The washer (70) works as a seat for cylindrical portion (32) of the seat pipe (30) and helps to prevent the leakage of oil.

[0019] Referring to Fig. 5, the stem portion (44) of the axle mounting bracket (40) is configured to have a slot (44S) and an axel eye portion (40B) is configured to have an opening for accommodating the axle of the vehicle. The slot (44S) is having a predefined depth up to its backside surface (44SBS). The said slot (44S) is made using any known metal removing process, preferably the milling. The backside surface (44SBS) is having a hole (44SBH) that opens in the slot (44S). The said hole (44SBH) is provided for removing the metal insert (45) fitted in the slot (44S) of the stem portion (44). The inside top surface (44ST) of the said slot (44S) is configured to have a circular relieve opening (44SR) that receives the entry portion (34E) of the seat pipe (30).

[0020] The axel mounting bracket (40) is adapted to have an insert (45) that gets fitted inside the slot (44S) by means of press fitting. The slot (44S) is having a quadrilateral cross section preferably a rectangular or a square shaped cross section. The metallic insert (45) has a thorough opening (45H) and said opening (45H) is profiled to have threads on its inner surface. The opening (42H) of the cylindrical upper portion (42), the opening (45H) of the insert (45) and the relieve opening (44SR) are concentric in assembled condition of the axle mounting bracket (40) with the outer tube (22). The opening (45H) of the insert (45) and the relieve opening (44SR) are having the same diameter. The said threaded portion (34T) of the seat pipe (30) passes through the opening (42H) of the cylindrical upper portion (42) and gets meshed inside the threaded opening (45H) of the insert (45). For removing or replacing the insert (45) in case of thread damage the insert (45) needs to be hit using a pin through the hole (44SBH).

[0021] Referring to Fig. 6, another embodiment of the axle mounting bracket (340) has a stem portion (344) and said stem portion (344) is configured to have a thorough opening (344S). The top surface of the cylindrical portion (342) has an opening (342H) and said opening (342H) is configured to have a stepped profile (342HS) communicating with the relieve opening (344SR) that receives the entry portion (34E) of the seat pipe (30). The axel mounting bracket (340) is adapted to have a cylindrical insert (345) that gets fitted inside the thorough opening (344S) by means of press fitting. The cylindrical insert (345) is having a threaded opening (345H) which is perpendicularly drilled to its cylindrical axis. The opening (342H) of the cylindrical portion (342), the opening (345H) of the cylindrical insert (345) and the relieve opening (344SR) are concentric in its assembled condition. The opening (345H) of the cylindrical insert (345) and the relieve opening (344SR) are having the same inner diameter. The threaded portion (34E) of the projecting end (34) of the seat pipe (30) passes through the opening (342H) of the cylindrical upper portion (342) and gets meshed with the threads provided on the inner surface of the opening (345H) of the cylindrical insert (345). For removing or replacing the insert (345) in case of thread damage, the insert (345) needs to be hit using a pin from any side of the said insert (345).

[0022] Referring to Figs. 8 and 9, in another embodiment of the axle mounting bracket (340), said axle mounting bracket has a stem portion (344) and stem portion (344) is configured to have a thorough opening (344S). The top surface of the cylindrical portion (342) has an opening (342H) and said opening (342H) is configured to have a stepped profile (342HS) communicating with the relieve opening (344SR) that receives the entry portion (34E) of the seat pipe (30). The axel mounting bracket (340) is adapted to have a cylindrical insert (445) having a collar (445C) at its one end and said insert (445) gets fitted inside the opening (344S) by means of press fitting. The said collar (445C) rests on the outer surface of the stem (344) completely covering the opening (344S) from its one side when the insert (445) is press fitted inside the opening (344S). The collar (445C) restricts the axial movement of the insert (445) when press fitted inside the opening (344S). The cylindrical insert (445) is provided with a threaded thorough opening (445H) perpendicular to its cylindrical axis. The opening (342H) of the cylindrical upper portion (342), the opening (445H) of the cylindrical insert (445) and the relieve opening (344SR) are concentric and the opening (445H) of the cylindrical insert (445) and the relieve opening (344SR) are having the same inner diameter. The threaded portion (34T) of the seat pipe (30) passes through the opening (342H) of the cylindrical upper portion (342) and gets meshed with the threads provided on the inner surface of the opening (445H) of the cylindrical insert (445). For removing or replacing the insert (445) from the opening (344S) in case of thread damage, the insert (445) needs to be hit using a pin from its non-collar end.

[0023] Referring to Figs. 10(a) and 10(b), the axel mounting bracket (340) is adapted to have a cylindrical insert (545) made of two parts and each of the parts is having a circular collar (545C1, 545C2) at its outer end (545E1, 545E2). Both the parts of the insert (545) are fitted inside the opening (344S) by means of press fitting in such way that the respective collar rests on the outer surface of the stem portion (344) of the axle mounting bracket (340). Thus, the cylindrical insert (545) is formed when two separately formed machined parts namely a left insert (545L) and a right insert (545R) gets press fitted together. The left insert (545L) is press fitted inside the opening (344S) through its left opening and the right insert (545R) is press fitted inside the opening (344S) through its right opening. The said left insert (545L) and the right insert (545R) are having threaded semi-cylindrical regions (545LT, 545RT) respectively. The said threaded semi-cylindrical regions (545LT, 545RT) are formed by machining and threading the two insert (545L, 545R) together as a single part metal insert (545). The said left and the right inserts (545L, 545R) when press fitted together the said semicircular region (545LT, 545RT) forms a uniform threaded opening (545H) which is perpendicular to their cylindrical insert axes. The opening (342H) of the cylindrical upper portion (342), the threaded opening (545H) formed in the cylindrical insert (545) and the relieve opening (344SR) are concentric and having same diameter. The said threaded opening (545H) receives the threaded portion (34T) of the seat pipe (30) there inside through the opening (342H) of the cylindrical upper portion (342) of the axle mounting bracket (340).

[0024] Referring to Fig. 11, the axle eye portion of the axle mounting bracket (340) is configured to have a flat profiled surface (340F) at its outer bottom surface. The flattening is done by machining or it can be done by forging followed by machining while manufacturing the axle mounting bracket (340). This flat profiled surface (340F) of the axle mounting bracket facilitates the easiness in fitting the said bracket with the outer tube. Further, this flat surface leads to require less efforts and less time while fitting the axle mounting bracket with the outer tube leading the reduction in cycle time of assembling the outer tube assembly.

[0025] The front fork assembly of the present invention in accordance with the embodiments as discussed above provides the following technical advantages that contributes to the technical advancement of the front fork assembly of the suspension system of two wheeled and three wheeled vehicles.
- It facilities easy replacement of the insert in case of thread damage instead of replacing the whole outer tube assembly.
- It ensures the desired alignment of the seat pipe in orthogonal direction w.r.t. the top cylindrical surface of the axle mounting bracket.
- It enhances the life of the front fork suspension as the damage which can result from misalignment of the seat pipe is completely eliminated.
- It provides a simple solution that can be implemented without affecting the manufacturing and assembly time.

[0026] The disclosed invention thus overcomes the limitation of the known solutions of the front fork assembly. 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 to form outer tube assembly. Altering the components forming the suspension unit does not directly affect the performance of the front fork assembly in accordance with the disclosed invention. Such alterations must therefore not be considered to be out of the scope of the present invention.

[0027] The foregoing description of the specific embodiment of the invention will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. 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.
,CLAIMS:We Claim

1. A fork leg assembly (100) for suspension system (1000) of two and three wheeled vehicles comprising of:
- an inner tube assembly (10) comprising of an inner tube (12), a main spring (14), a sleeve (10SL), a rebound spring (16) and fork bolt (10B);
- a sealing assembly (10S); and
- an outer tube assembly (20) comprising of an outer tube (22), an axle mounting bracket (40, 340) and a seat pipe (30); wherein
- the seat pipe (30) is configured to have a cylindrical body (32) having a top end (32T), a bottom end (32B) and a projecting portion (34) integrated and projecting out from a bottom surface (32BS) of the cylindrical body (32) at its bottom end (32B); and said cylindrical body is configured to have a plurality of orifices (32O) thereon forming the oil passage from inside of the seat pipe (30) to the outer tube (22);
- the said projecting portion (34) is configured to have a plain portion (34P), a threaded portion (34T) and an entry portion (34E); wherein said threaded portion (34T) is formed between the plain portion (34P) and the entry portion (34E) and said entry portion (34E) is formed by chamfering the extreme end of the projected portion (34);
- the axle mounting bracket (40, 340) is configured to have an opening (42H, 342H) on the top surface of the cylindrical portion (42, 342) to receive the projecting portion (34) of the seat pipe (30); and said opening (42H, 342H) is configured to have a stepped profile (42HS, 342HS); and
- said axle mounting bracket (40, 340) is fitted to the bottom end of the outer tube (22) by the fastening means selected from press fitting, interference fitting, threaded joint followed by welding;
- said inner tube assembly (10) is telescopically assembled inside the outer tube assembly (20) in such way that the annular space between the inner tube assembly (10) and the top end of the outer tube assembly (20) is closed by the sealing assembly (10S).

2. The fork leg assembly (100) for suspension system (1000) of two and three wheeled vehicles as claimed in claim 1, wherein the axle mounting bracket (40) is configured to have a cylindrical upper portion (42), a stem portion (44), an axle eye portion (40B) and a metal insert (45); wherein
- the stem portion (44) has a slot (44S) with a predefined depth up to its backside surface (44SBS) and said backside surface (44SBS) has a hole (44SBH) opening into the slot (44S);
- the inside top surface (44ST) of the said slot (44S) is configured to have a circular relieve opening (44SR) opening into the stepped profiled opening (42HS);
- the metal insert (45) is configured to have a thorough opening (45H) and said opening (45H) is profiled to have threads on the inner surface of the opening; and
- said metal insert (45) is press fitted in the slot (44S) of the axle mounting bracket (40) such that the threaded portion (34T) of the seat pipe (30) is threadedly fixed within the threaded opening (45H) of the metal insert (45).

3. The fork leg assembly (100) for suspension system (1000) as claimed in claim 2, wherein
- the opening (42H) of the axle mounting bracket (40) has a stepped profile (42HS) on its inner surface and said stepped profile (42HS) houses a washer (70) inside it to ensure orthogonal alignment of the seat pipe (30); and
- said stepped profiled opening (42H), relieve opening (44SR) and the thorough opening (45H) of the metal insert (45) are concentric in assembled condition.

4. The fork leg assembly (100) for suspension system (1000) as claimed in claim 3, wherein
- the seat pipe (30) has a piston (16P) detachably attached to the top end (32T) of the said seat pipe (30); and
- the metal insert (45) is configured to have quadrilateral profiled cross section selected from rectangular and square profile.

5. The fork leg assembly (100) for suspension system (1000) as claimed in claim 1, wherein
- the axle mounting bracket (340) has a stem portion (344) and said stem portion (344) is configured to have a thorough opening (344S);
- the top surface of the cylindrical portion (342) of the axle mounting bracket (340) has an opening (342H) and said opening (342H) is configured to have a stepped profile (342HS) communicating with the relieve opening (344SR) that receives the entry portion (34E) of the seat pipe (30); and
- the axel mounting bracket (340) is adapted to have a cylindrical insert (345) fitted inside the thorough opening (344S) by means of press fitting.

6. The fork leg assembly (100) for suspension system (1000) as claimed in claim 5, wherein
- the cylindrical insert (345) has a threaded opening (345H) perpendicularly drilled to its cylindrical axis;
- the opening (342H) of the cylindrical portion (342) of axle mounting bracket (340), the opening (345H) of the cylindrical insert (345) and the relieve opening (344SR) are concentric in its assembled condition; and
- the opening (345H) of the cylindrical insert (345) and the relieve opening (344SR) are configured to have the same inner diameter.

7. The fork leg assembly (100) for suspension system (1000) as claimed in claim 6, wherein the threaded portion (34E) of the projecting end (34) of the seat pipe (30) passes through the opening (342H) of the cylindrical upper portion (342) and gets meshed with the threads provided on the inner surface of the opening (345H) of the cylindrical insert (345) to get fitted with the axle mounting bracket (340).

8. The fork leg assembly (100) for suspension system (1000) as claimed in claim 1, wherein
- the axle mounting bracket has a stem portion (344) and said stem portion (344) is configured to have a thorough opening (344S);
- the top surface of the cylindrical portion (342) of the axle mounting bracket (340) has an opening (342H) and said opening (342H) is configured to have a stepped profile (342HS) communicating with the relieve opening (344SR) that receives the entry portion (34E) of the seat pipe (30);
- the axel mounting bracket (340) is adapted to have a cylindrical insert (445) having a collar (445C) at its one end and said insert (445) is fitted inside the opening (344S) by means of press fitting; and
- said collar (445C) of the insert (445) rests on the outer surface of the stem (344) completely covering the opening (344S) from its one side when the insert (445) is press fitted inside the opening (344S) and said collar (445C) restricts the axial movement of the insert (445) when press fitted inside the opening (344S).

9. The fork leg assembly (100) for suspension system (1000) as claimed in claim 8, wherein
- the cylindrical insert (445) is provided with a threaded thorough opening (445H) perpendicular to its cylindrical axis in such way that the opening (342H) of the cylindrical upper portion (342), the opening (445H) of the cylindrical insert (445) and the relieve opening (344SR) are concentric;
- the opening (445H) of the cylindrical insert (445) and the relieve opening (344SR) are configured to have the same inner diameter; and
- the threaded portion (34T) of the seat pipe (30) passes through the opening (342H) of the cylindrical upper portion (342) and gets meshed with the threads provided on the inner surface of the opening (445H) of the cylindrical insert (445) to get the seat pipe (30) fitted with the axle mounting bracket (340).

10. The fork leg assembly (100) for suspension system (1000) as claimed in claim 1, wherein
- the axel mounting bracket (340) is adapted to have a cylindrical insert (545) made of two parts (545L and 545R) and each of the parts is having a circular collar (545C1, 545C2) at its outer end (545E1, 545E2);
- said parts of the insert (545) are fitted inside the opening (344S) by means of press fitting in such way that the respective collar rests on the outer surface of the stem portion (344) of the axle mounting bracket (340);
- the left insert (545L) and the right insert (545R) are configured to have threaded semi-cylindrical regions (545LT, 545RT), respectively and said threaded semi-cylindrical regions (545LT, 545RT) are formed by machining and threading the two insert (545L, 545R) together as a single part metal insert (545); and
- the opening (342H) of the cylindrical upper portion (342), the threaded opening (545H) formed in the cylindrical insert (545) and the relieve opening (344SR) are concentric and configured to have the same diameter.

11. The fork leg assembly (100) for suspension system (1000) as claimed in any of the claims 2, 7, 9 and 10, wherein
- the axle mounting bracket (40, 340) is configured to have an axle eye portion (40B) to accommodate the axle of the vehicle; and
- the bottom surface of said axle mounting bracket (40, 340) is configured to have a flat profiled face (340F) obtained by forging followed by machining.

Dated this 10th day of Aug. 2023

Sahastrarashmi Pund
Head – IPR
Endurance Technologies Ltd.

To,
The Controller of Patents,
The Patent Office, at Mumbai