DESC: FIELD OF THE INVENTION

The present invention relates to a protective cover for suspension system of a saddle type vehicle or the like used for such vehicle. The invention is particularly applicable to the vehicles wherein the suspension elements are located within the mudguard or front fender.
BACKGROUND AND PRIOR ART

Automotive vehicles are provided with suspension system comprising suspension elements to absorb the road induced shocks and avoiding these shocks to be passed to the vehicle operator.
Generally, in a two wheeled or saddle type automotive vehicle, a front suspension system is provided between front wheel and steering mechanism like handle bar. The suspension system may comprise telescopic forks connected to the front wheel at lower end and to the steering mechanism, may be through a steering column at upper end.
The telescopic fork comprises a fixed part and moving part with a dampening arrangement. In one such arrangement, the hydraulic fluid is filled up between the fixed and moving part forming a hydraulic oil filled piston cylinder assembly. The arrangement helps to absorb the shock while riding the vehicle and provide necessary suspension for the vehicle.
While riding the vehicle, suspension system gets exposed to dirt, dust, debris, water, mud, etc. Exposure of the suspension system to external tough atmospheric and road conditions may cause damage to the suspension system. It is essential to protect the elements of suspension system (telescopic forks, piston and cylinder, etc.) from dirt, dust, debris, water, mud etc. to ensure their proper functioning and durability.
Previously, there have been attempts to provide protective covers for fork cases of the suspension system. However, these covers are easily removed and stolen. Further, they do not provide full, effective coverage of the fork case.
Use of a bellows to protect the inner tubes of fork in motorcycles is known. In case of a scooter however, the fork inner tubes are covered by a mud guard/fender. While the mudguard/ front fender prevents splashing of mud, dust, etc. on front part of the vehicle body, the entire dirt is thrown on its inner side where the fork inner tube lies. In spite of having a seal between the inner and the outer tubes of the fork, dirt gradually enters through the seal to contaminate the oil. No seal is airtight enough to prevent dirt from entering inside. Moreover, stones and gravel slinging onto the inner tube create dent marks and even may burst the fork tubes. Due to such vulnerabilities, it becomes essential to protect the fork inner tube in such a vehicle. If bellows usually made of rubber are used to cover the fork tubes, they might get torn. As bellow are mounted below the mudguard/ front fender, they are not visible from outside and their damage may go undetected. Thus, exposing the fork inner tubes to extreme atmospheric and road conditions for a long time and posing serious threat to its life. Moreover, conventionally used rubber bellows need more packaging space radially as well as along the length for its flexibility. With time, the bellows lose its flexibility and gets damaged.
Further, in motorcycles, the inner tube has enough ‘dead length’ which allows easier installation of the protective cover. In case of a scooter, to secure sufficient dead length for mounting of the protective cover, the fender or mud guard needs to be enlarged, which is difficult and need significant redesigning. Further, it also increases size and cost.
In view of above discussion, there exists a need for improved protective cover for suspension system to address issues and overcome the limitations stated above. Applicant has tried to mitigate these issues faced in the prior art.
OBJECTIVES OF THE INVENTION
Accordingly objective of the invention is to provide protective cover arrangement for suspension system which is very simple, cost effective and providing effective protection.
Yet another objective is to provide protective cover arrangement for suspension system which is easy to manufacture and can be easily assembled.
Yet another objective is to provide protective cover arrangement for suspension system which has less component count.
SUMMARY OF THE INVENTION
A protective cover arrangement for a suspension system comprising
the suspension system; said suspension system comprising at least one suspension element;
a protective cover having a hollow structure that at least partially accommodates the suspension element(s); and
a wheel fender covering a wheel attached to the suspension system;

wherein a substantial portion of the protective cover is positioned under the wheel fender.

The protective cover preferably has hollow cylindrical structure that substantially conforms to shape of suspension element covered by it. The suspension element pass through the hollow structure of the protective cover. The protective cover is made up of a flexible plastic material, preferably polypropylene.
The protective cover is attached to the wheel fender through a fastening means. Preferably, the fastening means is in the form of a mounting provision provided on the protective cover that allows it’s mounting to the fender. The mounting provision is preferably integral part of the protective cover which can be fastened fixedly to the fender.

In one such embodiment, the protective cover preferably has a ledge at an upper end of the protective cover. The ledge is flexible and passes through a hole provided on the fender. The ledge abuts at the upper surrounding surface of the hole, thus forming a rigid joint/ connection. In such arrangement, fasteners are completely avoided as the ledge of the protective cover gets naturally clamped between fender and suspension under bracket.

Other option for joining the fender and protective cover can be a threading arrangement, nut and bolt arrangement, glue etc. or any known fastening arrangement or combination thereof.
As another embodiment of the invention, the fender and the protective cover can be formed integral with each other. Alternately, a separate mounting means may also be provided to the protective cover for attaching it to the fender for e.g. a separate mounting ring may be provided which helps to attach the protective cover with the fender.
In another embodiment the protective cover may be provided with plurality of slits on an edge having the ledge for facilitating the installation of the protective cover through the hole provided in the fender. Provision of the slits on the protective cover allows squizzing of the protective cover at the edge having the ledge so as to pass through the hole provided on the fender. This arrangement facilitates easy assembly and reduces assembly time and efforts.
In yet another embodiment, the protecting cover may be provided with plurality of ribs on the inside surface along the length of the protective cover. The provision of ribs enhances the strength and durability of the protective cover. Further, the ribs prevent direct surface contact between the protective cover and suspension element(s). Thus preventing generation of unwanted sound and friction between the protective cover and suspension element(s). This further enhances the durability of the protective cover.
The protective cover arrangement for a suspension system according to invention can be adopted for various types of saddle type vehicles. The arrangement is especially useful in a scooter type motorcycle.
The protective cover arrangement for a suspension system according to invention is cost effective and provides effective protection to suspension element(s) such as fork inner tubes from extreme atmospheric and road conditions. Further, the arrangement proposed by the invention is easy to manufacture, easy to assemble and durable.

BRIEF DESCRIPTION OF THE DRAWINGS
REFERENCE NUMBER TABLE
No. Feature
1 Vehicle
2 Front wheel
3 Telescopic fork/ Telescopic front fork assembly
4 Under bracket
5 Front fender
6 Suspension elements
6a Fork inner pipe
6b Fork outer pipe
7 Protective cover
8 Hole on the fender
9 Ledge
10 Outer surface of the hole
11 Handle bar
12 Steering column
13 Slits
14 Ribs

Figure 1 shows a side view of a vehicle front half comprising a protective cover arrangement according to one of the embodiments of the invention.
Figure 2 shows an isometric view of a telescopic front fork assembly mounted with a protective cover arrangement as shown in figure 1 along with handlebar.
Figure 3 shows an isometric view depicting the protective cover arrangement located within a mudguard and suspension elements passing through it.
Figure 4A and 4B shows details of connection between the protective cover and the mudguard according to one of the embodiments of the invention.
Figure 5 shows details of mounting arrangement of the protective cover over a fork inner pipe and a fork outer pipe and mudguard according to one of the embodiments of the invention.
Figure 6A, 6B and 6C shows the details of the protective cover according to one of the embodiments of the invention.
DETAILED DESCRIPTION
Following description and drawings are in reference to one of the embodiment of the invention where the protective cover arrangement is adopted for saddle type vehicle having a suspension system with two suspension elements. However, it is evident that such arrangement can be conveniently adopted in vehicles having a suspension system with one suspension element as well
Referring to figure 1, 2 and 3, the vehicle (1) comprising front wheel (2) is connected with the frame through a telescopic front fork assembly (3). The telescopic front fork assembly (3) comprises a suspension system including plurality of suspension elements. Typically in saddle type vehicle, suspension system include two suspension elements (6). Each suspension element (6) comprises a fork inner pipe (6a) slidably fitted inside a fork outer pipe (6b). The suspension system connected with a steering column (12) through an under bracket (4). The suspension system is partially or fully covered by a front fender (5) mounted between the fork inner pipe (6a) and the under bracket (4). The suspension system is connected to handle bar (11) of the vehicle through steering columns (12).
During the vehicle travel when the vehicle encounters any undulations or bumps on the road, force is exerted on the front wheel of the vehicle. This force is in turn transferred to the suspension system. Due to the force transmitted from the front wheel to the suspension system, the fork inner pipe (6a) slides inside the fork outer pipe (6b) and thus absorbing the shock. The arrangement helps to protect the driver from the shocks generated during vehicle ride.
Operation of the suspension system largely depends on smooth movement of the fork inner pipe (6a) inside the fork outer pipe (6b). When dirt, dust, etc. enters inside clearance between the fork inner pipe (6a) and the fork outer pipe (6b), smooth operation of the suspension system gets hindered. Further, it also leads to accelerated wear and tear and may cause part failure.
In case of scooter type vehicle described above where the suspension system is installed partially or fully under the front fender, the suspension system is exposed to dirt, dust, debris, water, mud etc. constantly. It is necessary to protect the fork inner pipe (6a) and the fork outer pipe (6b) from these extreme road conditions to ensure smooth operation of the suspension system and avoid potential failure. In order to protect the fork inner pipe (6a) and the fork outer pipe (6b) from dirt, dust, debris, water, mud etc., arrangement of a protective cover (7) is proposed.
The protective cover (7) is cylindrical in shape and hollow from inside. The shape of the protective cover corresponds to the outer structure/contour of the fork inner pipe (6a) and the fork outer pipe (6b) of the suspension element (6). A substantial portion of the protective cover (7) is positioned under the wheel fender (5). The protective cover (7) may be accommodated partially or fully inside the front fender (5). As shown in figure 4A, 4B and 4C, protective cover (7) fits over the suspension elements (6) and covers point at which the fork inner pipe (6a) and the fork outer pipe (6b) meet. Length of the protective cover (7) is such that during maximum extension or contraction of the suspension system, point at which the fork inner pipe (6a) and the fork outer pipe (6b) meet remains covered by the protective cover (7) from all side and along the entire length.
The protective cover (7) is made of flexible plastic material which is stiff and reliable. Preferred material for manufacturing the protective cover (7) includes propylene copolymer such as Polypropylene.
Referring to figure 4A, 4B and 4C, in one of the embodiments, the protective cover (7) is provided with a ledge (9) at one of its end (as shown in figure 4B). The ledge (9) facilitates fitting of the protective cover (7) in hole (8) provided in the fender (5). As the protective cover (7) is flexible, the end with the ledge of the protective cover is squizzed and passed through the hole provided in the fender. Once the ledge portion (9) passes through the hole (8), the ledge abuts against the outer surface (10) of the hole, thus securing its connection with the fender (5) rigidly. The ledge (9) helps to mount the protective cover on the fender and keep the protective cover in a fixed position. The protective cover (7) is closely controlled between hole (8) provided in fender (5) and fork inner pipe (6a) such that it conveniently gets co-centrically aligned with telescopic fork thus avoiding damage due to friction or noise due to rubbing and also provides very good sealing at hole (8) provided in the fender (5). Further, the ledge (9) is used for fitting of the protective cover (7) in the hole (8) provided in the fender (5), need for fasteners is completely avoided as the ledge (9) of the protective cover (7) gets naturally clamped between the fender (5) and suspension under bracket.
It may be noted that, the protective cover (7) may be connected to respective holes (8) through threading arrangement or by using fastening means such as nut/bolt arrangement, glue etc. or using any other suitable fastening arrangement or combination thereof. As another aspect of the invention, the fender (5) and the protective cover (7) can be formed integral with each other. Alternately, a separate mounting means may also be provided to the protective cover (7) for attaching it to the fender (5).
In another aspect of the invention, as shown in figure 6A, 6B and 6C, the protective cover (7) may be provided with plurality of slits (13) on the end with the ledge (9) of the protective cover. Provision of slits (13) facilitates squizzing and insertion of the protective cover (7) inside the hole (8). This reduces assembly time, efforts and eliminates the possibility of breakage of the protective cover (7) while attaching it with the fender (5)
The protective cover (7) may also be provided with plurality of ribs (14) on the inside surface along the length of the protective cover (as shown in figure 6C). The provision of ribs enhances the strength and durability of the protective cover (7). Further, the ribs prevent direct surface contact between the protective cover (7) and suspension elements (6). Thus preventing generation of unwanted sound and friction between the protective cover (7) and suspension elements (6). This further enhances the durability of the protective cover.
The protective cover arrangement for a suspension system according to invention is cost effective, easy to manufacture, easy to assemble, durable and provides effective protection to suspension element(s) such as fork inner tubes from extreme atmospheric and road conditions. The protective cover arrangement for a suspension system according to invention can be adopted for various types of saddle type vehicles. The arrangement is especially useful in a scooter type motorcycle. Further, arrangement can be easily adopted for the suspension system with one or more suspension elements.
It is understood that variations and modifications to the preferred embodiment will be apparent to those skilled in the art without departing the scope and the spirit of the present invention. The applicant also relies on the provisional specification and drawings annexed to the provisional specification in support of this specification.
,CLAIMS:1. A protective cover arrangement for a suspension system comprising the suspension system; said suspension system comprising at least one suspension element (6);
a protective cover (7) having a hollow structure that at least partially
accommodates the suspension element(s) (6); and a wheel fender (5)
covering
a wheel (2) attached to the suspension system;
wherein a substantial portion of the protective cover (7) is positioned under
the wheel fender (5).
2. The protective cover arrangement according to claim 1, wherein the protective cover (7) has a hollow cylindrical shape that substantially conforms to the shape of the suspension element (6) and at least partially covers the suspension element (6).
3. The protective cover arrangement according to claim 1, wherein the protective cover (7) is attached to the wheel fender (5) through a fastening means
4. The protective cover arrangement according to claim 3, wherein the fastening means is a ledge (9) provided at a one end of the protective cover (7) for ensuring rigid joint between the protective cover (7) and the wheel fender (5).
5. The protective cover arrangement according to claim 3, wherein the protective cover (7) is provided with a plurality of slits (13) at an end which is connected to the wheel fender (5) for facilitating insertion of the protective cover inside a hole (8) provided in the wheel fender (5).
6. The protective cover arrangement according to claim 3, wherein the fastening means may be a threading arrangement or a nut and bolt arrangement or a glue or combination thereof.
7. The protective cover arrangement according to claim 1, wherein the protective cover (7) is integral part of the wheel fender (5).
8. The protective cover arrangement according to claim 1, wherein the protective cover (7) may be provided with at least one rib (14) on an inner surface of the protective cover (7).
9. The protective cover arrangement according to claim 1 where the suspension element(s) (6) include a fork inner tube (6a) slidably fitted inside a fork outer tube (6b) wherein a length of the protective cover (7) is such that during maximum extension or contraction of the suspension system, a point at which the fork inner pipe (6a) and the fork outer pipe (6b) meet remains covered by the protective cover (7) from all sides.
10. The protective cover arrangement according any of the preceding claims, wherein the protective cover (7) is made of a flexible plastic material, preferably polypropylene.
11. A method of assembling the protective cover (7) according to claim 4 with the wheel fender (5), the method comprises squizzing the end of the protective cover (7) on which the ledge (9) is provided, inserting the squizzed end inside a hole (8) provided on the wheel fender, and releasing the squizzed end so that the ledge (9) abuts at the surface (10) of the hole and form a rigid joint.
12. The saddle ride type vehicle comprising the protective cover arrangement according to claim 1.