REAR STRUCTURE FOR A SADDLE TYPE VEHICLE

FIELD OF THE INVENTION

[0001] The present invention relates generally to a saddle type vehicle with swinging power unit, and more particularly, but not exclusively, to a rear structure for a saddle type vehicle with swinging power unit.

BACKGROUND OF THE INVENTION

[0002] A conventional saddle type vehicle with swinging power unit can be divided into a front portion and a rear portion. Both the portions are covered with several covers to hide the vehicle frame. Particularly, the rear portion is covered with a plurality of covers namely a left side cover, a right side cover and a rear cover at the juncture of the right side cover and the left side cover. The left and right side covers conceal the body frame below a seat from both sides namely, the left and right, the rear cover conceals the extreme rear end of the vehicle from rear and a tail lamp is attached to the rear end of the vehicle along with the rear indication lamps. Generally, the tail lamp along with the rear indication lamps forms a unitary tail lamp unit. Further, the left side cover, the right side cover, the rear cover and the tail lamp are separate members and are individually assembled on and secured to the vehicle thereby increasing the assembly time. The assembly is performed on a moving conveyor line with individual members mounted at different positions in the vehicle by different workmen. Hence, less time is available for a workman to complete the assembly on the conveyor line.

[0003] Individual assembly of members further creates an uneven gap between the individual members which gives an aesthetically poor look to the rear portion of the vehicle. In addition to this, over a period of time the gap further increase due to warpage. It is worth mentioning that the visual appearance of a vehicle can also be a significant factor in a customer's purchase decision, and a stimulating visual appearance positively influences the customer in his or her purchase decision.

SUMMARY OF THE INVENTION

[0004] One of the objects of the present invention is to provide a rear structure for a saddle type vehicle with a swinging power unit, which can be assembled as a whole off the conveyor line and is then directly mountable to the vehicle. Another object of the present invention is to provide a pre-assembled rear structure for the vehicle having a non unitary tail lamp unit which is easily mountable to a rear portion of the vehicle frame.

[0005] The present invention thereofore discloses a rear structure for a saddle type vehicle comprising a rear cover, a right side cover subassembly, a left side cover subassembly and mounted to the vehicle frame as a single individual unit. The load of the rear structure is borne by at least two frame mounting brackets. The rear structure is assembled to the vehicle with just six mounting and two locators and hence decreases the assembly time on the conveyor belt. The present invention also discloses a method of assembling the rear structure and mounting it to the saddle type vehicle.

[0006] The foregoing objectives and summary is provided to introduce a selection of concepts in a simplified form, and is not limiting. To fully appreciate these and other objects of the present subject matter as well as the subject matter itself, all of which will become apparent to those skilled in the art, the ensuing detailed description of the subject matter and the claims should be read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

[0007] The above and other features, aspects and advantages of the subject matter will be better understood with regard to the following description, appended claims and accompanying drawings where:

FIG. 1 shows a side elevation view of a saddle type vehicle exemplified in the form of a two wheeled scooter type motorcycle.

FIG. 2 shows a side view of the frame of the vehicle of FIG. 1.

FIG. 3 shows a rear view of said vehicle.

FIG. 4 shows an inner surface of a rear cover of the vehicle according to the present invention.

FIG. 5 shows a perspective view of the rear cover of the vehicle of FIG. 4.

FIG. 6 shows a section along the vehicle longitudinal axis showing an inner view of a left side cover subassembly according to the present invention.

FIG. 7 shows an exploded view of a rear structure of the vehicle according to the present invention.

FIG. 8 shows an assembled view of the rear structure of the vehicle of FIG. 7.

FIG. 9 shows a front view of the rear structure of the vehicle of FIG. 7.

FIG. 10 shows a perspective view of a frame mounting bracket.

FIG. 11 shows an exploded view of a right side cover subassembly according to the present invention.

FIG. 12 shows an exploded view of the mounting of rear structure on the vehicle frame.

DETAILED DESCRIPTION OF THE INVENTION

[0008] The present invention discloses a rear structure for a saddle type vehicle with swinging power unit. The rear structure includes a left side cover, a right side cover, a rear cover, a tail lamp and plural rear indication lamps joined to form the rear structure of the vehicle. It is to be noted that in the ensuing description, the present invention is exemplified with a two wheeled scooter type motorcycle for better illustration. Further "front" and "rear", and "left" and "right" referred to in the ensuing description of the illustrated embodiment refer to front and rear, and left and right directions as seen in a state of being seated on a seat of the scooter type motorcycle. Furthermore, a longitudinal axis, except otherwise mentioned, refers to a front to rear axis relative to the said motorcycle, while a lateral axis, except otherwise mentioned, refers generally to a side to side, or left to right axis relative to the said motorcycle. Various other features and embodiments of the rear structure according to the present subject matter here will be discernible from the following further description thereof, set out hereunder.

The detailed explanation of the constitution of parts other than the subject matter which constitutes an essential part has been omitted at suitable places.

[0009] FIG. 1 shows a side elevation view of the saddle type vehicle embodied in the form of the scooter type motorcycle. The vehicle 1 includes a frame assembly made up of several tubes welded together which usually supports the body of the said vehicle. The vehicle 1 has a steerable front wheel 2 and a driven rear wheel 25 driven by driving force generated by a power unit 24. The front wheel 2 of the motorcycle 1 is axially supported at a lower end of a front fork 3, and the front fork 3 is pivoted in a steerable manner in a head pipe 31 (FIG. 2) of the vehicle frame. The vehicle 1 is covered by a plurality of vehicle body covers including a front panel 17, a leg shield 16, an under seat cover 21, a left side cover 50 and a right side cover 70. The side covers 50, 70 respectively are present on either side of the vehicle longitudinal plane. A lower member 18 of the front panel 17 functions as the front fender to cover the front wheel 2 whereas a rear fender 27 is provided to cover the rear wheel 25.

[00010] A handle bar 7 is attached to an upper end of the head pipe 31. A headlight unit 10 is arranged forwardly of the handle bar 7. A visor 9 is located upwardly of the headlight unit 10. The handlebar 7 and a seat 22 are supported at opposing ends of the frame assembly and a generally open area is defined there between known as floorboard 12 which functions as a step through space. The seat 22 for a driver and a pillion is placed forward to a fuel tank (not shown) and rearwardly of the floorboard 12. A side trim member 14 beneath an edge portion of the floorboard 12 is provided to cover a lower portion of the frame assembly from being visible. A side stand fixed to the left side of the body frame supports the vehicle such that vehicle inclines to the left side without falling.

[00011] In the vehicle, a rear suspension typically supports the power unit 24 configured to drive the rear wheel 25 of the vehicle. The power unit 24 is integrally formed with an engine and a transmission system, and the rear wheel 25 is connected to a drive shaft at the rear of the power unit 24. In an embodiment of the present invention, the engine is a four stroke single cylinder internal combustion engine.

[00012] FIG. 2 shows a side view of the frame assembly of said vehicle. The frame of the vehicle 1 is an elongated structure, which typically extends from a front end to a rear end of the vehicle. It is generally convex in shape, as viewed from a side elevational view. The frame assembly comprises of the head pipe 31, a downpipe 32 extending downwards from the head pipe 31, a lower pipe 33 supporting the low-slung floorboard 12 extending rearwards from a lower end of the downpipe 32, and a rear pipe 35 formed by curving a rear end section of the lower pipe 33 diagonally upwards. The rear pipe 35 is made of an inclined section 34 extending diagonally upwards from a rear end of the lower pipe 33, and a horizontal section 36 extending rearwards substantially horizontally from the inclined section 34 and is covered by the left side cover 50 and the right side cover 70. The rear pipe is made of at least two parallel tubes laterally spaced apart from each other, one on each side of the vehicle longitudinal axis.

[00013] FIG. 3 shows a rear view of the said motorcycle. The left side cover 50 and right side cover 70 cover a rear portion of the vehicle frame along the vehicle front to rear axis and are joined with a rear cover 85. The rear cover covers the vehicle frame from the rearmost direction and joins the left side cover 50 and the right side cover 70. The rear cover 85 houses a tail lamp 99 arranged at a rear end of the seat 22. The tail lamp 99 also acts as brake lamp. Further, to convey the rider's intention to take a turn, at least two rear indication lamps 55, 75 are provided in the rear portion of the vehicle as described later.

[00014] A rear structure 100 which forms the subject matter of the present invention is an assembly of several individual components assembled together. It comprises of the left side cover 50, the right side cover 70, the tail lamp 99, a plurality of rear indication lamps namely a left rear indication lamp 55 and a right rear indication lamp 75; and the rear cover 85. The tail lamp and the rear indication lamps 55, 75 form a non-unitary tail light unit as the tail lamp 99 is housed in the rear cover and the rear indication lamps with respective side covers. Thus, the tail lamp and the rear indication lamps are not assembled together but separately of each other. Individual constituents of the rear structure are firstly described.

[00015] FIG. 4 shows an inner view of the rear cover 85 when seen from the vehicle front direction. The rear cover 85 includes an inner surface 86 facing the vehicle frame. The rear cover covers the rearmost portion of the vehicle in the longitudinal direction with the help of at least two arms, one arm 85a and one other arm 85b. Each arm extends from a planar upper portion of the rear cover 85 laterally and longitudinally towards the vehicle front direction. The inner surface 86 is provided with at least two symmetrical ribs 92, 92 extending downwardly
and inclinedly from the planar upper portion. The ribs provide structural strength and support to the arms of the rear cover 85. Each arm is provided with pip locator means on the inner surface 86 of the rear cover which helps in the assembly of the rear structure. In an embodiment, the one arm 85a comprises of a plurality of pip locator means 88 whereas the one other arm 85b comprises a plurality of identical pip locator means 89. In an embodiment, each pip locator means 88, 89 is a small through-hole for receiving and locating a protruding pip during rear structure assembly as described later.

[00016] The rear cover 85 also includes a tail lamp recess 87 at a central portion for housing the tail lamp 99 between the one arm 85a and the one other arm 85b. The tail lamp 99 is secured to the rear cover 85 through a plurality of bosses integrally formed with the inner surface 86 of the rear cover 85. At least two bosses 91a, 91b are provided on either side of the upper portion of the tail lamp recess 87 and two bosses 90a, 90b below the tail lamp recess 87. The said bosses in the vicinity of the tail lamp recess 87 aid in the attachment of the tail lamp 99 to the rear cover 85.

[00017] FIG. 5 shows a perspective view of the rear cover 85. The one arm 85a also includes a plurality of recesses proximately along the edge of the one arm 85a. Likewise, the one other arm 85b includes a plurality of recesses along the edge of the one other arm 85b. In an embodiment, at least three recesses 93a, 93b, 93c are provided on the one arm 85a and at least three recesses 95a, 95b, 95c on the one other arm 85b. The respective arm of the rear cover is fastened to the respective side cover through these recesses.

[00018] During the assembly of the rear structure 85, first one of the rear indication lamp 55 is connected to the left side cover 50 to form a left side cover subassembly. The connection is by fastening a plurality of lamp bosses 53a, 53b, 53c of the one rear indication lamp 55 to the left side cover 50. The location of lamp bosses depends on the structure and shape of the rear indication lamp 55. FIG. 6 shows a section along the vehicle longitudinal axis showing an inner view of the inner surface of the left side cover subassembly according to the present invention. Likewise, the right side cover 70 is secured with one other rear indication lamp 75 at the lamp bosses 73a, 73b, 73c to form a right side cover subassembly as shown in FIG. 11.

[00019] The left side cover subassembly and the right side cover subassembly are assembled off the conveyor line. They are then brought together and the rear cover 85 is secured to this assembly. The left side cover subassembly is connected to the one other arm 85b of the rear cover 85 through the protruding pips 57 which locate themselves into the pip locator means 89. The left side cover subassembly is further secured to the one other arm 85b atleast at three mounting points. To accomplish that, the left side cover 50 includes a plurality of cover mounting bosses 51a, 51b, and 51c. Fasteners pass through the recesses 95a, 95b, 95c on one other arm 85b and secure the one other arm 85b to the cover mounting bosses 51a, 51b, and 51c of the left side cover subassembly. Likewise, the right side cover subassembly is supported and located into the one arm 85a of the rear cover 85 through the protruding pips 77 (FIG. 11) which locate themselves into the pip locator means 88. The right side cover sub-assembly is further secured to the one other arm 85a atleast at three mounting points. To accomplish that, the right side cover includes a plurality of cover mounting bosses 71a, 71b, and 71c as shown in FIG. 7. Fasteners pass through the recesses 93a, 93b, 93c on one arm 85a and secure it to the cover mounting bosses 71a, 71b, and 71c of the right side cover subassembly. Thereafter, the tail lamp 99 is received in the tail lamp recess 87 from the inner surface 86 of the rear cover 85 and is secured to the rear cover 85 through the two bosses 90a, 90b below the tail lamp recess 87.

[00020] The thusformed rear structure is then supported on the rear portion of the vehicle frame through at least two frame mounting brackets 60, 80 as shown in FIG. 7. Specifically, the rear structure is supported on the horizontal section 36 of the rear pipe 35. It is to be noted that the vehicle has two identical and parallel running rear pipes but only one is shown in the drawings. A detailed structure of the frame mounting bracket 60 is shown in FIG. 10. The other frame mounting bracket 80 is symmetrical to the frame mounting bracket 60. The frame mounting bracket 60 for the left side cover subassembly has a first member 60a and a second member 60c opposite to the first member 60a. A lateral third member 60b protruding from the middle portion of the frame mounting bracket 60 is also provided. All the three members have through holes for fasteners to pass through. According to an embodiment, the frame mounting bracket 60 is a metal plate having an L-shaped cross section and the first member 60a is perpendicular to the second member 60c to enable attachment to the tail lamp 99. The first member 60a of the frame mounting bracket 60 is placed over the tail lamp edge and is secured to the boss 91b in such a manner that the tail lamp 99 is between the first member 60a and the boss 91b.

[00021] Further, as shown in FIG. 7, the left side cover 50 also includes at least two laterally protruding portions 54, 56 which protrude toward the vehicle longitudinal axis. The first protruding portion 54 is longer whereas the second protruding portion 56 is nearer to the tail lamp and is shorter than the first protruding portion 54. The first protruding portion 54 comprises a recess 54a. As shown in FIG. 12, the lateral third member 60b of the frame mounting bracket 60 is secured to the second protruding portion 56. Thereafter, the first protruding portion 54 fastened to the horizontal section 36 of the rear pipe 35 through the second member 60c of the frame mounting bracket 60. In a symmetrical manner (FIG. 11), the right side cover 70 has a longer first protruding portion 74 with a recess 74a and a second shorter protruding portion 76. The right side cover subassembly is supported on horizontal section 36 of the parallel rear pipe 35 through a second member 80c of the frame mounting bracket 80. The first member 80a of same bracket secures the tail lamp to the boss 91a of the rear cover 85. The third member 80b secures the second protruding portion 76. In this way, the rear structure of the vehicle is supported on the rear pipe 35 through the frame mounting brackets 60, 80.

[00022] From the foregoing description, it will be appreciated that the present invention offers many advantages including those described above. Because the rear structure is a complete assembly in itself, the entire rear structure is mounted or dismounted to the vehicle in one go as a single individual unit without worrying about the wiring harness as the wiring harness is located in the side covers itself and not on the frame. It reduces the assembly time on the conveyor belt. Further, the rear structure is not having any gap between its constituents increasing the visual appeal of the vehicle which leads to higher merchantability and reduced warpage. It is also cheaper to produce and leads to better fit and finish of the vehicle.

[00023] The present subject matter is thus described. The description is not intended to be exhaustive nor is it intended to limit the invention to the precise form disclosed. It will be apparent to those skilled in the art that the disclosed embodiments may be modified in light of the above description. The embodiments described are chosen to provide an illustration of principles of the invention and its practical application to enable thereby one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Therefore the forgoing description is to be considered exemplary, rather than limiting, and the true scope of the invention is that described in the appended claims.

We claim:

1. A rear structure (100) for a saddle type vehicle with a swinging power unit comprising: a rear cover (85) housing a tail lamp (99) and having a one arm (85a) and a one other arm (85b),
a right side cover subassembly (45) connected to the one arm (85a) of the rear cover, a left side cover subassembly (46) connected to the one other arm (85b) of the rear cover, wherein the rear structure (100) is located on a rear portion of the vehicle frame as a single individual unit and mounted through at least two frame mounting brackets (60,80).

The rear structure as claimed in claim 1, wherein the right side cover subassembly (45) comprises of a right side cover (70) and a right rear indication lamp (75) connected to and housed in the right side cover (70).

The rear structure as claimed in claim 1, wherein the left side cover subassembly (46) comprises of a left side cover (50) and a left rear indication lamp (55) connected to and housed in the left side cover (50).

The rear structure as claimed in claim 2 or claim 3, wherein the tail lamp (99), the left rear indication lamp (55) and the right rear indication lamp (75) jointly form a non-unitary tail lamp unit.

The rear structure as claimed in claim 2 or claim 3, wherein the left side cover (50) comprises a plurality of cover mounting bosses (51a, 51b, 51c) and protruding pips (57), the right side cover (70) being symmetrical to the left side cover (50).

The rear structure as claimed in claim 1, wherein each frame mounting bracket (60,80) further comprises of a first member (60a, 80a) securing the tail lamp (99) to a boss (91b, 91a) of the rear cover (85) and a second member (60c, 80c) securing a laterally first protruding portion (54, 74) of the side cover to the vehicle frame.

A method of assembling a rear structure (100) of a saddle type vehicle with a swinging power unit comprising:a left side cover (50),
a right side cover (70) symmetrical to the left side cover (50), a tail lamp (99) and at least two rear indication lamps namely a right rear indication lamp (75) and a left rear indication lamp (55), a rear cover (85) with a one arm (85a) and a one other arm (85b), wherein,the tail lamp (99), the left rear indication lamp (55) and the right rear indication lamp (75) form a non-unitary tail light unit, the left side cover (50) comprises a plurality of cover mounting bosses (51a, 51b, 51c) and protruding pips (57), the method further comprising:
securing the left rear indication lamp (55) to the left side cover (50) to form a left side cover subassembly (46), securing the right rear indication lamp (75) to the right side cover (70) to form a right side cover subassembly (45);
locating the left side cover sub-assembly (46) into the one arm (85a) of the rear cover through the protruding pips (57) and securing it to the one arm through atleast at three cover mounting bosses (51a, 51b, 51c); locating the right side cover sub-assembly (45) into the one other arm (85b) of the rear cover through the protruding pips (77) and securing it to the one other arm through atleast at three cover mounting bosses (71a, 71b, 71c); securing the tail lamp (99) to an inner surface (86) of the rear cover (85), and supporting thus formed rear structure on a rear portion of the vehicle frame through at least two frame mounting brackets (60, 80); and wherein further each frame mounting bracket jointly connects the respective side cover and the tail lamp to at least one tube in the rear portion of the vehicle frame.

The rear structure as claimed in claim 1 or claim 7, wherein each frame mounting bracket (60, 80) is made of a metal plate and has an L-shaped cross section.

The rear structure as claimed in claim 1 or claim 7, wherein the rear cover (85) further comprises of at least one rib (92) extending downwardly and inclinedly from an upper portion of the one arm (85a) and the one other arm (85b).

The rear structure as claimed in claim 1 or claim 7, wherein an edge portion of each arm (85a, 85b) of the rear cover comprises of a plurality of pip locators (88, 89).