DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
SWITCH INTEGRATED WITH HANDLEBAR GRIP

APPLICANT:
Varroc Engineering Limited
An Indian entity having address as:
L-4, MIDC Waluj, Aurangabad 431136, Maharashtra, India

The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
The present application claims priority from Indian provisional patent application no: 202121038656 filed on 26 August 2021.

TECHNICAL FIELD
Present disclosure generally relates to field of automobiles. Particularly, but not exclusively, the present disclosure relates to a switch integrated handlebar grip assembly for automobiles.

BACKGROUND
Presently, the handlebar of automobiles have control switches and the handlebar grips mounted separately on the handlebar pipe. Fig. 1 illustrates a conventional handlebar assembly 100 comprising a handlebar pipe 101, handlebar grip 102, an upper case of control switch 103, and a lower case of control switch 104. The handlebar grip 102, the upper case of control switch 103, and the lower case of control switch 104 are mounted on the handlebar pipe 101 to complete the handlebar and switch assembly.

Further, there is an increase in demand of new switches with increase in demand of additional functionality and features for ensuring driver’s safety and comfort while driving an automobile. The new switch may provide functionalities such as cruise-control, hazard module, user interface module.

However, due to the constraint of space on handlebar the switch case for fitment is becoming insufficient for ergonomic placement of any new switch. To make this additional space available for ergonomically sound placement of new switches utilizing some space available in handlebar grip for switch placement is the primary motive behind this technology. Also, the assembling of the handlebar grip, the upper case and the lower case of control switch on the handlebar pipe requires extra effort.

Therefore, there exists a need in the art to provide a switch integrated handlebar grip assembly which overcome the above-mentioned problems and to provide a plurality of switch options and ease of assembly.

SUMMARY
This summary is provided to introduce concept of switch integrated handlebar grip and the details of this concept are given further. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.

In an aspect, a switch integrated handlebar grip assembly is described. The switch integrated handlebar grip assembly comprises a switch casing having at least two hollow portions, a handlebar grip over molded on the switch casing, and a switch assembly snap locked inside a first hollow portion of the switch casing, The switch assembly comprises back cover plate, a PCB assembly comprising at least one tact switch, a spring lock plate attached to the membrane adapted to hold at least one spring corresponding to the at least one tact switch for performing a predefined function, a housing for encasing the switch assembly, and at least one knob mounted in the housing for operating the at least one switch. Thus, the switch integrated handlebar grip assembly provides ease of assembly and also allows implementation of plurality of control switches in a limited area.

In another aspect, a switch integrated handlebar grip assembly is described. The switch integrated handlebar grip assembly comprises a switch casing having at least two hollow portions, a throttle position sensor (TPS) unit comprising a throttle pipe, a handlebar grip over molded on the throttle pipe, and a switch assembly snap locked inside a first hollow portion of the switch casing. The switch assembly comprises back cover plate, a PCB assembly comprising at least one tact switch, a spring lock plate attached to the membrane adapted to hold at least one spring corresponding to the at least one tact switch for performing a predefined function, a housing for encasing the switch assembly, and at least one knob mounted in the housing for operating the at least one switch. Thus, the switch integrated handlebar grip assembly provides ease of assembly and also allows implementation of plurality of control switches in a limited area.

BRIEF DESCRIPTION OF THE DRAWINGS
The features, nature, and advantages of the present disclosure will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout. Some aspects of system and/or methods in accordance with aspects of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:
Fig. 1 illustrates a conventional handlebar assembly;
Fig. 2(a) illustrates an assembly view of a switch integrated handlebar grip assembly for automobiles, in accordance with an aspect of the present disclosure;
Fig. 2(b) illustrates components of a switch integrated handlebar grip assembly for automobiles, in accordance with an aspect of the present disclosure;
Fig. 3 illustrates an exploded view of a switch integrated handlebar grip assembly for automobiles, in accordance with an aspect of the present disclosure;
Fig. 4(a) illustrates an assembly view of a switch assembly, in accordance with the aspect of the present disclosure;
Fig. 4(b) illustrates a sectional view of the switch assembly, in accordance with the aspect of the present disclosure;
Fig. 5(a) illustrates an assembly view of a switch integrated handlebar grip assembly for automobiles, in accordance with the aspect of the present disclosure;
Fig. 5(b) illustrates an exploded view of a switch integrated handlebar grip assembly for automobiles, in accordance with the aspect of the present disclosure;
Fig. 6(a) illustrates an assembly view of a switch integrated handlebar grip assembly, in accordance with the aspect of the present disclosure; and
Fig. 6(b) illustrates a cross sectional view of a switch integrated handlebar grip assembly, in accordance with the aspect of the present disclosure.

DETAILED DESCRIPTION
Reference throughout the specification to “various aspects,” “some aspects,” “one aspect,” or “an aspect” means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect. Thus, appearances of the phrases “in various aspects,” “in some aspects,” “in one aspect,” or “in an aspect” in places throughout the specification are not necessarily all referring to the same aspect. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more aspects.

In an aspect, a switch integrated handlebar grip assembly is described. The switch integrated handlebar grip assembly comprises a switch casing having at least two hollow portions, a handlebar grip over molded on the switch casing, and a switch assembly snap locked inside a first hollow portion of the switch casing, The switch assembly comprises back cover plate, a PCB assembly comprising at least one tact switch, a spring lock plate attached to the membrane adapted to hold at least one spring corresponding to the at least one tact switch for performing a predefined function, a housing for encasing the switch assembly, and at least one knob mounted in the housing for operating the at least one switch. Thus, the switch integrated handlebar grip assembly provides ease of assembly and also allows implementation of plurality of control switches in a limited area.

In another aspect, a switch integrated handlebar grip assembly is described. The switch integrated handlebar grip assembly comprises a switch casing having at least two hollow portions, a throttle position sensor (TPS) unit comprising a throttle pipe, a handlebar grip over molded on the throttle pipe, and a switch assembly snap locked inside a first hollow portion of the switch casing. The switch assembly comprises back cover plate, a PCB assembly comprising at least one tact switch, a spring lock plate attached to the membrane adapted to hold at least one spring corresponding to the at least one tact switch for performing a predefined function, a housing for encasing the switch assembly, and at least one knob mounted in the housing for operating the at least one switch. Thus, the switch integrated handlebar grip assembly provides ease of assembly and also allows implementation of plurality of control switches in a limited area.

Fig. 2(a) illustrates an assembly view of a switch integrated handlebar grip assembly 200a for automobiles, in accordance with an aspect of the present disclosure.

In an aspect of the present disclosure, the switch integrated handlebar grip assembly 200a may comprise a switch assembly 203 and a handlebar grip 201. The switch assembly 203 may comprise a plurality of switches associated with the respective functionalities. In one non-limiting aspect, the plurality of switches may be self-illuminated switches. The switches may be illuminated using any technique known to person skilled in the art.

Fig. 2(b) illustrates components of a switch integrated handlebar grip assembly for automobiles, in accordance with an aspect of the present disclosure.
In an aspect, the switch assembly 203 may comprise snap lock protrusion or screwing on at least two sides of the switch assembly 203 and the handlebar grip 201 may comprise a switch casing 205. The switch casing 205 may be hollow for accommodating the switch assembly 203. The handlebar grip 201 may be over molded on the switch casing 205.

The handlebar grip 201 may be over molded on the switch casing 205 using any technique known to person skilled in the art. The shape and size of the handlebar grip 201 and the switch assembly 203 may vary from one vehicle to another. In one non-limiting aspect of the present disclosure, the material used for over molding handlebar 201 may be PVC rubber whose shore A hardness-55. However, the material used for over molding is not limited to above example and any other material having similar properties is well within the scope of present disclosure.

The switch casing 205 may comprise snap lock grooves in the inner surface and the hollow switch case may be capable of accommodating the switch assembly 203 such that the snap lock protrusions fit into the respective groves of the hollow switch case, thereby forming an integrated assembly 200b. The switch assembly 203 is discussed in more detail in below aspects.

Fig. 3 illustrates an exploded view of a switch integrated handlebar grip assembly 300 for automobiles, in accordance with an aspect of the present disclosure.

In an aspect, the switch integrated handlebar grip assembly 300 may comprise a handlebar grip 316 over molded on a switch casing 205 having at least two hollow portion and the switch casing 205 may comprise a switch assembly snap locked inside the switch casing 205. In one non-limiting aspect, the switch assembly may also be fixed inside the switch casing 205 using a screw arrangement.

In an aspect, the switch assembly may be like switch assembly 203 as discussed in above aspects. The switch assembly 203 may comprise a back cover plate 315, a PCB assembly 313, a membrane 311, a spring lock plate 307, a housing 303, one or more springs 305, and one or more knobs 301.

The PCB assembly 313 may be mounted on back cover plate 315 by means of screws 309. The PCB assembly may comprise one or more switches 314 and each switch 314 is mapped with a respective function. In an aspect, the function of the one or more switches 314 may be predefined and the predefined function may comprise a blinker/winker function, a horn function, a pass light function, mode selection function, engine/motor start/stop function, or a headlight function, SOS function, or music play/pause function. However, the predefined function is not limited to above example and any other control function that can be performed through a switch is well within the scope of present disclosure.

The switches 314 may be tact switches or self-illuminated switches having a respective LED. However, the type of switches mounted on the PCB assembly 313 is not limited to above example, any other switch that can be mounted on the PCB assembly 313 is well within the scope of present disclosure.

In one non-limiting aspect, the one or more switches 314 may be connected to a respective unit of the vehicle through a wiring harness 320 connected to the PCB assembly 313.Then the PCB assembly 313 may be is sealed with membrane 313 e.g., by matching projection in the rubber membrane with groove provided on backside of switch back cover plate 315 and by applying three bond sealants on inside faces of rubber membrane, and thus providing complete sealing against dust, water, moisture and other environmental conditions.

The spring lock-plate 307 may be mounted over the membrane 313 which is screwed with housing 303 using screws 309. The spring lock-plate 307 may be used for resting and guiding one or more springs 305. After spring fitment, the one or more knobs 301 may be fitted by inserting the knobs 301 inside housing 303 and guided by means of guideways provided in the housing 303. The knobs 301 may comprise an actuator in contact with at least one slot of the membrane, the actuator is adapted to turn ON/OFF the at least one tact switch.

Further a locating clamp is provided in handlebar grip 316 that may be mounted for obtaining exact fitment and orientation with respect to handlebar pipe inserted inside the handlebar grip 316, which may be fixed through a screw insert 317. The handlebar grip 316 may further have at least one hole in a front portion exactly matching with the outer diameter of the handlebar pipe for fitment on handlebar by means of application of PL-10 glue on inside diameter of handlebar grip 316. In one non-limiting aspect, for obtaining exact orientation of handlebar grip 316 with respect to handlebar pipe suitable fixture can be used.

The switch assembly 203 may then be located on handlebar grip by snap fitting with the insert molded grip by fitment of snaps provided on exterior side faces of housing 303 with window pockets provided in insert molded switch casing 205 present inside the handlebar grip 316.

In an aspect, the switch casing 205 comprising the two hollow portions may be made up of, but not limited to, plastic material. A first hollow portion may accommodate the switch assembly 203 and a second hollow portion may accommodate at least a portion of the handlebar pipe to complete the switch integrated handlebar assembly. In one non-limiting aspect, the switch integrated handlebar grip assembly 300 may be mounted and assembled on the left-hand (LH) side of the handlebar pipe.

Thus, the switch integrated handlebar grip assembly 300 facilitates ease of assembly, low-cost solution for implementing plurality of switches to meet the demand of the increasing functionalities of vehicles, incorporation of low current switches having higher operating life, thereby providing a reliable switching solution.

Fig. 4(a) illustrates an assembly view 400a of a switch assembly 203, in accordance with the aspect of the present disclosure. As shown in Fig. 4(a), the switch assembly 203 may comprise a plurality of knobs 301 corresponding to respective switch mounted on the PCB assembly as discussed in above aspect.

Fig. 4(b) illustrates a sectional view 400b across sectional line BB of the switch assembly 203. The sectional view 400b shows the arrangement of the back cover plate 315, the PCB assembly 313 comprising the tact switches 314, the membrane 311, the spring lock plate 307, the housing 303, the one or more springs 305, and the one or more knobs 301. The switch assembly 203 may be snap fitted inside a hollow portion of the switch casing 205 as discussed in above aspect.

Fig. 5(a) illustrates an assembly view 500a of a switch integrated handlebar grip assembly for automobiles, in accordance with the aspect of the present disclosure.

In an aspect of the present disclosure, the switch integrated handlebar grip assembly may comprise a switch casing 501, a switch assembly 510, and a handlebar grip assembly 520. A portion of the handlebar grip assembly 520 may be inserted inside the switch casing 501 and fixed using a cover plate. The switch casing 501 may be capable of accommodating the switch assembly 510 inside using the snap lock arrangement as discussed in above aspects. Further, the switch assembly 510 may have a structure and arrangement similar to that that of switch assembly 203 as discussed in detail above in explanation of fig. 3, 4a, and 4b and same is not mentioned again for the sake of brevity. However, the number of switches present on the switch assembly 510 may vary based on the number of functionalities to be controlled through the switch assembly 510.

Fig. 5(b) illustrates an exploded view 500b of a switch integrated handlebar grip assembly for automobiles, in accordance with the aspect of the present disclosure.

In an aspect, the switch integrated handlebar grip assembly may comprise a switch casing 501, a switch assembly 510, and a handlebar grip assembly 520. The switch casing 501 may have at least two hollow portions out of which first hollow portion accommodates the switch assembly 510 and the second hollow portion accommodates the handlebar grip assembly 520 from one end and handlebar pipe from another end. In one non-limiting aspect of the present disclosure, the switch integrated handlebar grip assembly may be implemented/installed on right-hand (RH) side of the handlebar pipe.

The handlebar grip assembly 520 may be a throttle position sensor (TPS) unit comprising a throttle pipe 505 which is over molded with the handlebar grip. The material used for over molding the handlebar grip is similar to the one discussed in above aspect and not mentioned again for the sake of brevity. Further, the over molding may be done though any process known to person skilled in the art.

The TPS unit 520 may further comprise a magnet 507 assembled on at least one portion of the throttle pipe 505 on at least one end. In one non-limiting aspect, the magnet 507 may be covered with a potting material. The TPS unit 520 may also comprise torsion spring 503 assembled at least one end of the throttle pipe. The switch casing may comprise a connection pin present inside the switch casing 501 for connecting to one end of the torsion spring 503 of the TPS unit and adapted to hold one end of the torsion spring when the throttle pipe 505 is rotated in clockwise or anticlockwise direction. In an aspect, connection pin is an integrated part of switch casing 501.

The TPS unit 520 may further comprise a TPS PCB assembly 515 comprising a hall sensor circuit. The hall sensor circuit may be operated in conjunction with the magnet 507 to control an acceleration of the automobile. The TPS PCB assembly 515 may be inserted into at least one hollow slot of the switch casing 501 and covered with potting material. The arrangement of the TPS PCB assembly 515 inside the switch casing 501 and the magnet 507 assembled on the throttle pipe 505 is such that the throttle pipe 505 may change the magnetism detected by the hall sensor circuit when the throttle pipe 505 is rotated in clockwise and anti-clockwise direction.

In an aspect, the switch casing 501 may comprise the second hollow portion having a diameter greater than a diameter of the throttle pipe 505 and handlebar pipe. The throttle pipe is inserted into the switch casing from a first end of the second hollow portion and a cover plate 509 fixed after inserting the TPS unit 520 inside the switch casing 501. The cover plate 509 may be adapted to restrict an axial movement of the throttle pipe assembled inside the switch casing 501. The cover plate may also facilitate protection of TPS unit 520 against the dust, water, moisture and other environmental conditions.

In one non-limiting aspect, the switch casing 501 may also comprise at least one clamp 511 attached to a second end of the second hollow portion. The at least one clamp 511 is adapted to guide at least a portion of handlebar pipe inside the switch casing 501 and the throttle pipe 505.

Thus, the switch integrated handlebar grip assembly facilitates ease of assembly, low-cost solution for implementing plurality of switches to meet the demand of the increasing functionalities of vehicles, incorporation of low current switches having higher operating life, thereby providing a reliable switching solution.

Fig. 6(a) illustrates an assembly view 600a of a switch integrated handlebar grip assembly, in accordance with the aspect of the present disclosure. As shown in Fig. 6(a), the switch assembly 510 and TPS unit 520 may be integrated inside a switch case 501.

Fig. 6(b) illustrates a sectional view 600b across sectional line AA of the switch integrated handlebar grip assembly. The sectional view 600b shows the arrangement of the switch assembly 510 and TPS unit 520 inside the switch case 501. The magnet 507 assembled on the throttle pipe 505 such that magnet 507 is arranged in line with the TPS PCB assembly 515 comprising the hall sensor circuit. A rotation of throttle pipe 505 in clockwise or anticlockwise direction may vary the magnetism detected by the hall sensor circuit, which in turn control the acceleration of the vehicle.

Further in accordance with the exemplary aspect of the present disclosure the switch used have low current, low profile type tactile switch working on operating current as low as 5mA. As the low current switches are used there is less chance of occurrence of spark between the contact points, less heat generation. These advantages may result in higher operating life & more reliable switching solution. Integration of this switches with handlebar grip may provide additional advantage of ease of assembly, ergonomically sound switch placement & cost effectiveness.

ADVANTAGES OF THE PRESENT DISCLOSURE
Exemplary aspects discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include those provided by the following features:
In an aspect, the present disclosure ease of assembly buy reducing the number of parts required for assembly.
In an aspect, the present disclosure provides a low-cost solution for implementing plurality of switches to meet the demand of the increasing functionalities of vehicles.
In an aspect, the present disclosure facilitates incorporation of low current switches having higher operating life.
In an aspect, the present disclosure provides a compact and a reliable switching solution.
It also helps to provide compact or optimistic handlebar assembly solution by integration switch casing with handlebar grip which may results to achieve variety of switch functions
,CLAIMS:We Claim:

1. A switch integrated handlebar grip assembly for automobiles, comprising:
a switch casing having at least two hollow portions;
a handlebar grip over molded on the switch casing; and
a switch assembly snap locked inside a first hollow portion of the switch casing, wherein the switch assembly comprises:
a back cover plate;
a PCB assembly mounted on the back cover plate, wherein the PCB assembly comprises at least one tact switch operable to perform a predefined function;
a membrane comprising at least one slot for accommodating at least one tact switch, wherein the PCB assembly is sealed with the rubber membrane;
a spring lock plate attached to the membrane adapted to hold at least one spring corresponding to the at least one tact switch;
a housing for encasing the switch assembly, wherein the housing comprises at one guideway corresponding to at least one tact switch; and
at least one knob corresponding to the at least one switch, wherein the at least one knob is mounted on the housing.

2. The switch integrated handlebar grip assembly as claimed in claim 1, wherein the at least knob comprises an actuator in contact with at least one slot of the membrane, and wherein the actuator is adapted to turn ON/OFF the at least one tact switch.

3. The switch integrated handlebar grip assembly as claimed in claim 1, wherein a second hollow portion corresponds to a size of a handlebar pipe is adapted to accommodate at least a portion of the handlebar pipe.

4. The switch integrated handlebar grip assembly as claimed in claim 1, wherein the predefined function comprises a blinker/winker function, a horn function, a pass light function, mode selection function, engine/motor start/stop function, or a headlight function, SOS function, or music play/pause function.

5. A switch integrated handlebar grip assembly for automobiles, comprising:
a switch casing having at least two hollow portions;
a throttle position sensor (TPS) unit comprising a throttle pipe;
a handlebar grip over molded on the throttle pipe; and
a switch assembly snap locked inside a first hollow portion of the switch casing, wherein the switch assembly comprises:
a back cover plate;
a first PCB assembly mounted on the back cover plate, wherein the first PCB assembly comprises at least one tact switch operable to perform a predefined function;
a membrane comprising at least one slot for accommodating at least one tact switch, wherein the first PCB assembly is sealed with the rubber membrane;
a spring lock plate attached to the membrane adapted to hold at least one spring corresponding to the at least one tact switch;
a housing for encasing the switch assembly, wherein the housing comprises at one guideway corresponding to at least one tact switch; and
at least one knob corresponding to the at least one switch, wherein the at least one knob is mounted on the housing.

6. The switch integrated handlebar grip assembly as claimed in claim 5, wherein the at least knob comprises an actuator in contact with at least one slot of the membrane, and wherein the actuator is adapted to turn ON/OFF the at least one tact switch.

7. The switch integrated handlebar grip assembly as claimed in claim 5, wherein the TPS unit comprises:
a magnet assembled on at least one portion of at least one end of the throttle pipe;
a torsion spring connected to the at least one end of the throttle pipe; and
a second PCB assembly comprising a hall sensor circuit, wherein the hall sensor circuit is adapted to control acceleration of the automobile.

8. The switch integrated handlebar grip assembly as claimed in claim 7, wherein the switch casing comprises:
a second hollow portion having a diameter greater than a diameter of the throttle pipe, wherein the throttle pipe is inserted into the switch casing from a first end of the second hollow portion;
a connection pin present inside the switch casing connected to the torsion spring of the TPS unit and adapted to hold one end of the torsion spring when the throttle pipe is rotated in clockwise or anticlockwise direction; and
a cover plate adapted to restrict an axial movement of the throttle pipe assembled inside the switch casing.

9. The switch integrated handlebar grip assembly as claimed in claim 8, wherein the switch casing comprises:
at least one clamp attached to a second end of the second hollow portion, wherein the at least one clamp is adapted to guide at least a portion of handlebar inside the switch casing and the throttle pipe.

10. The switch integrated handlebar grip assembly as claimed in claim 5, wherein the predefined function comprises a blinker/winker function, a horn function, a pass light function, mode selection function, engine/motor start/stop function, or a headlight function, SOS function, or music play/pause function.

Dated this 26th Day of August 2021

Priyank Gupta
Agent for the Applicant
IN/PA-1454