Claims:We Claim:

1. A triple clamp assembly (100) for a front fork suspension (500) comprising:
• an upper piece (10),
• a lower piece (20), and
• a steering rod (600),
wherein,
- the upper piece (10) is configured to have a plurality of openings (10H1, 10H2, 10H3, 10HS1 and 10HS3) and a flat V-shaped profile with a wall (10W) proceeding downwards from the peripheral edges of the upper piece (10);
- the lower piece (20) is configured to have a plurality of matching openings (20H1, 20H2, 20H3, 20HS1 and 20HS3) and a flat V-shaped profile matching with the profile of the upper piece (10);
- the lower piece (20) is joined with the surface of the wall (10W) of the upper piece (10) in such way that it forms a hollow structure and the plurality of openings on the lower piece (20) and the upper piece (10) concentrically and exactly overlaps each of the respective openings; and
- the steering rod (600) is rigidly fitted into an opening (10H2) by a fastening means to form the triple clamp assembly (100).

2. The triple clamp assembly (100) as claimed in claim 1, wherein
- the openings (10H1, 10H2 and 10H3) on the upper piece (10) are positioned at the end of a first arm (10FA), at an edge (10JE) and at the end of a second arm (10SA), respectively;
- the openings (20H1, 20H2 and 20H3) on the lower piece (10) are positioned at the end of a first arm (20FA), at an edge (20JE) and at the end of a second arm (20SA), respectively; and
- the openings (10H1, 10H2 and 10H3) of the upper piece (10) concentrically and exactly overlap the openings (20H1, 20H2 and 20H3) of the lower piece (20) in the assembled condition of the upper piece (10) and the lower piece (20).

3. The triple clamp assembly (100) as claimed in claim 2, wherein
- each of the openings (10H1, 10H2 and 10H3) is provided with a cylindrical guide structure (10CGS1, 10CGS2 and 10CGS3) respectively projecting downwards from the upper piece (10);
- each of the openings (20H1, 20H2 and 20H3) is provided with a cylindrical guide structure (20CGS1, 20CGS2 and 20CGS3) respectively projecting upwards from the lower piece (20);
- said cylindrical guide structures (10CGS1, 10CGS2 and 10CGS3) on the upper piece (10) and the cylindrical guide structures (20CGS1, 20CGS2 and 20CGS3) on the lower piece (20) together are configured to receive and support a fork leg (510), steering rod (600) and a fork leg (520) respectively; and
- said guide structures (10CGS1, 10CGS2 and 10CGS3) on the upper piece (10) maintain a vertical clearance (C) with the corresponding guide structures (20CGS1, 20CGS2 and 20CGS3) on the lower piece (20) in assembled condition of the upper piece (10) and lower piece (20).

4. The triple clamp assembly (100) as claimed in claim 3, wherein
- the wall (10W) has clamping holes (10WH1 and 10WH2) located on the opposite faces on the first arm (10FA) and said clamping holes (10WH1 and 10WH2) are displaced vertically and horizontally from the plane containing the hole (10H1) and towards the plane containing the hole (10H2);
- the wall (10W) has clamping holes (10WH3 and 10WH4) located on the opposite faces on the second arm (10SA) and said clamping holes (10WH3 and 10WH4) are displaced vertically and horizontally from the plane containing the hole (10H3) and towards the plane containing the hole (10H2); and
- said clamping holes (10WH1 and 10WH2) on the first arm (10FA) and the clamping holes (10WH3 and 10WH4) on the second arm (10SA) are concentric and configured to receive the clamping bolt (30).

5. The triple clamp assembly (100) as claimed in claim 4, wherein
- the opening (10HS1) on the first arm (10FA) of the upper piece (10) originates along the edge of the opening (10H1) and the corresponding opening (20HS1) on the first arm (20FA) of the lower piece (20) originates along the edge of the opening (20H1); said openings (10HS1 and 20HS1) have two edges (E1 and E2) and each of the edges first progresses linearly towards the opening (10H2, 20H2) till they reach the vertical plane (VP) formed at the center of the openings (10WH1 and 10WH2) and thereafter each of the edges diverges outward by angle (a) from the central line on the openings (10HS1 and 20HS1); and then terminates before reaching the openings (10H2, 20H2) at a flat terminating edge surface (10FTE1 and 20FTE1 through the curved profiled surfaces (10CP1 and 20CP1); and
- the opening (10HS3) on the second arm (10SA) of the upper piece (10) originates along the edge of the opening (10H3) and the corresponding opening (20HS3) on the second arm (20SA) of the lower piece (20) originates along the edge of the opening (20H3); said openings (10HS3 and 20HS3) have two edges and each of the edges first progresses linearly towards the opening (10H2, 20H2) till they reach the vertical plane formed at the center of the openings (10WH3 and 10WH4) and thereafter each of the edges diverges outward by angle (a) from the central line on the openings (10HS3 and 20HS3); and then terminates before reaching the openings (10H2, 20H2) at a flat terminating edge surface (10FTE3, 20FTE3) through a curved profile (10CP3 and 20CP3).

6. The triple clamp assembly (100) as claimed in claim 5, wherein the angle (a) ranges from 3 to 6 degree.

7. The triple clamp assembly (100) as claimed in claim 4, wherein
- the opening (10HS1) on the first arm (10FA) of the upper piece (10) originates along the edge of the opening (10H1) and the corresponding opening (20HS1) on the first arm (20FA) of the lower piece (20) originates along the edge of the opening (20H1); said openings (10HS1 and 20HS1) have two edges and each of the edges diverges outward at its starting point by angle (ß) from the central line on the openings (10HS1 and 20HS1); and then terminates before reaching the openings (10H2, 20H2) at a flat terminating edge surface (10FTE1, 20FTE1) through a curved profiled surface (10CP1 and 20CP1); and
- the opening (10HS3) on the second arm (10SA) of the upper piece (10) originates along the edge of the opening (10H3) and the corresponding opening (20HS3) on the second arm (20SA) of the lower piece (20) originates along the edge of the opening (20H3); said openings (10HS3 and 20HS3) have two edges and each of the edges diverges outward at its starting point by angle (ß) from the central line on the openings (10HS3 and 20HS3); and then terminates before reaching the openings (10H2, 20H2) at a flat terminating edge surface (10FTE3, 20FTE3) through a curved profile surface (10CP3 and 20CP3).

8. The triple clamp assembly (100) as claimed in claim 7, wherein the angle (ß) ranges from 3 to 6 degree.

9. The triple clamp assembly (100) as claimed in any of the claims 6 and 8, wherein the radius of curvature of the curved profiled surfaces (10CP1, 10CP3 and 20CP1, 20CP3) ranges from 2.0 to 4.0 mm.

10. The triple clamp assembly (100) as claimed in claim 9, wherein the width (W, W’) of the flat terminating surface (10FTE1, 10FTE3 and 20FTE1, 20FTE3) is 0.4 to 0.6 times the width (W1, W2) of the opening (10HS1, 10HS3 and 20HS1, 20HS3) at its originating point.

11. The triple clamp assembly (100) as claimed in claim 4, wherein
- the opening (10HS1) on the first arm (10FA) of the upper piece (10) originates along the edge of the opening (10H1) and the corresponding opening (20HS1) on the first arm (20FA) of the lower piece (20) originates along the edge of the opening (20H1); said openings (10HS1 and 20HS1) have two edges and each of the edges progresses linearly towards the openings (10H2, 20H2); and then terminates before reaching the openings (10H2, 20H2) by curving towards each other forming a curved terminating edge surface; and
- the opening (10HS3) on the second arm (10SA) of the upper piece (10) originates along the edge of the opening (10H3) and the corresponding opening (20HS3) on the second arm (20SA) of the lower piece (20) originates along the edge of the opening (20H3); said openings (10HS3 and 20HS3) have two edges and each of the edges progresses linearly towards the openings (10H2, 20H2); and then terminates before reaching the openings (10H2, 20H2) by curving towards each other forming a curved terminating edge surface.

12. The triple clamp assembly (100) as claimed in any of the claims 9 and 11, wherein
- the vertical clearance (C) between the guide structures (10CGS1, 10CGS2 and 10CGS3) on the upper piece (10) and the corresponding guide structures (20CGS1, 20CGS2 and 20CGS3) on the lower piece (20) in assembled condition of the upper piece (10) and lower piece (20) is in the range of 2.2 to 3.8 mm; and
- the length (L) of the openings (10HS1, 20HS1, 10HS3, 20HS3) is 0.2 to 0.4 times of the center distance between the openings (10H1, 20H1) and the openings (10H3, 20H3).

13. The triple clamp assembly (100) as claimed in claim 12, wherein
- the lower piece (20) and the upper piece (10) are made of sheet metal and the lower piece (20) is joined with the surface of the wall (10W) of the upper piece (10) by welded joint to form a hollow structure; and
- the steering rod (600) is rigidly fitted into an opening (10H2) of the said hollow structure by welding to form the triple clamp assembly (100).

14. The triple clamp assembly (100) as claimed in claim 15, wherein
- the cylindrical guide structures (10CGS1, 10CGS2 and 10CGS3) projecting downwards from the upper piece (10) has projection length (L’) in the range of 1.45 to 1.70 times the thickness (t) of the upper piece (10); and
- the cylindrical guide structures (20CGS1, 20CGS2 and 20CGS3) projecting upwards from the lower piece (20) has projection height (h’) in the range of 1.45 to 1.70 times the thickness (t’) of the lower piece (20).

15. The triple clamp assembly (100) as claimed in claim 16, wherein the fork legs (510 and 520) of the front fork suspension (500) having an inner tube (503, 513) and an outer tube (506, 516) telescopically slidable within one another, are capable of being received and supported on the triple clamp assembly (100) in the openings (10H1, 10H3, 20H1, 20H3) with cylindrical guiding structures given on both of the arms (10FA, 20FA and 10SA, 20SA).

Dated this 9th day of February 2022.

Sahastrarashmi Pund
Head – IPR
Endurance Technologies Ltd.

To,
The Controller of Patents,
The Patent Office, at Mumbai.
, Description: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
“TRIPLE CLAMP ASSEMBLY FOR A FRONT FORK SUSPENSION OF VEHICLE”

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 the invention and the manner in which it is to be performed.

Field of Invention

[001] The present invention is related to suspension system of a motor vehicle. More particularly, the invention is related to triple clamp assembly provided in front fork suspension unit of a vehicle for rigidly holding together the fork legs of a front fork suspension and joining it with the handle bar through steering rod.

Background of the Invention

[002] A conventional front fork suspension typically has two fork legs, which accommodate and hold the ends of a wheel axle at their respective bottom end. These fork legs are rigidly held together at a location above the wheel by a bracket assembly termed as the triple clamp assembly that is formed by a pair of brackets and a steering rod. Normally in such triple clamp assemblies the fork legs are located and fixed at two ends of the bracket while the steering rod is accommodated and fixed in the middle of the bracket. Such an assembly functions to contain the bending and flexing of the fork legs within acceptable limit. They also facilitate stable attachment of the front fork suspension with the vehicle chassis.

[003] Conventionally such bracket assemblies, made by forging and welding, are structurally strong enough to meet requirements for use in regular motor vehicles. Such bracket assemblies are however not light weight enough for use in a typical electric vehicle. Given the sensitivity with regards to weight in electric vehicles, every unit of weight reduced without affecting the strength of a component enables improvement in range and response of the vehicle. As such, for use in electric vehicles, there is need for the bracket assemblies that are light weight but equally strong enough capable of holding the fork legs without cracking under working loads. Such a bracket assembly must also avoid damaging the attachment surface of the fork legs when they are being assembled as it can end up reducing the life of the entire front fork assembly due to rusting and corrosion along the damaged attachment surface.

[004] The bracket assemblies conventionally available in the public domain do not take care of the desired functional and quality requirements as briefed above. Hence, there is a long pending unmet requirement of providing a uniquely profiled bracket assembly that takes care of all the functional and quality requirements and at the same time facilitate to guide the fork legs smoothly without imparting any damage to its surface. The present invention as described below provides such bracket assembly called as triple clamp assembly for employing in the front suspension unit of a vehicle.

Objectives of the Present Invention

[005] The main object of the present invention is to provide a tripe clamp assembly for front suspension system of a vehicle.

[006] Another objective of the present invention is to provide triple clamp assembly that is strong enough to resist cracking under working loads imposed during operation of a motor vehicle.

[007] Yet, another objective of the present invention is to provide a triple clamp assembly that stably holds the fork legs and the steering rod without imparting any damage to its outer surface.
[008] Yet, the objective of the present invention is to provide a triple clamp assembly that distributes the stresses effectively to ensure that the triple clamp assembly itself does not end up damaging the attachment surface with the fork legs.

[009] Still the objective of the present invention is to provide a triple clamp assembly that enhances the fork leg alignment and gripping due to the uniquely profiled cylindrical guide structures provided at its openings.

[0010] Further, the objective of the present invention is to provide a triple clamp assembly that is modular in nature and light in weight.

Brief Description of Drawings

[0011] This invention is illustrated in the accompanying drawings, throughout which like 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

[0012] Figure 1a discloses the perspective view of the triple clamp assembly from the top end in accordance with the present invention.

[0013] Figure 1b discloses the perspective view of the triple clamp assembly from the bottom end in accordance with the present invention.

[0014] Figure 2a and 2b discloses the perspective views of the upper piece (10) of a triple clamp assembly from the top and bottom end, respectively in accordance with the present invention.
[0015] Figure 3a and 3b discloses the perspective views of the lower piece (20) of a triple clamp assembly from the top and bottom end, respectively in accordance with the present invention.

[0016] Figure 4a and 4b discloses the perspective views of the upper piece (10) of a triple clamp assembly vertically cut at the opening (10H1).

[0017] Figure 5 shows the exploded view of the openings (10HS1, 10HS3, 20HS1, 20HS3) on the upper piece (10) and the lower piece (20) of a triple clamp assembly as per the first embodiment of the present invention.

[0018] Figure 6 shows the exploded view of the openings (10HS1, 10HS3, 20HS1, 20HS3) on the upper piece (10) and the lower piece (20) of a triple clamp assembly as per the second embodiment of the present invention.

[0019] Figure 7 shows the exploded view of the openings (10HS1, 10HS3, 20HS1, 20HS3) on the upper piece (10) and the lower piece (20) of a triple clamp assembly as per the third embodiment of the present invention.

[0020] Figure 8 shows the exploded view of the openings (10HS1, 10HS3, 20HS1, 20HS3) on the upper piece (10) and the lower piece (20) of a triple clamp assembly as per the fourth embodiment of the present invention.

[0021] Figure 9 shows the exploded view of the openings (10HS1, 10HS3, 20HS1, 20HS3) on the upper piece (10) and the lower piece (20) of a triple clamp assembly as per the fifth embodiment of the present invention.

[0022] Figure 10 shows the perspective view of the triple clamp assembly mounted with front fork suspension unit.
Detailed Description of the Present Invention

[0023] In accordance with the present the invention, referring to Figs. 1a and 1b, a triple clamp assembly (100) for a front fork suspension (500) comprises of an upper piece (10), a lower piece (20), and a steering rod (600). Referring to Figs 2a and 2b, the upper piece (10) of the triple clamp assembly is configured to have a plurality of openings (10H1, 10H2, 10H3, 10HS1 and 10HS3) and a flat V-shaped profile with a wall (10W). The wall (10W) proceeds downwards from the peripheral edges of the upper piece (10). The lower piece (20) of this embodiment is configured to have a plurality of matching openings (20H1, 20H2, 20H3, 20HS1 and 20HS3) and a flat V-shaped profile matching with the profile of the upper piece (10). The lower piece (20) is joined with the surface of the wall (10W) of the upper piece (10) in such way that it forms a hollow structure. The said joining of the lower piece and upper piece is done by the suitable joining means such as welding and like. The plurality of openings on the lower piece (20) and the upper piece (10) concentrically and exactly overlaps each of the respective openings. The steering rod (600) is rigidly fitted into an opening (10H2) by a fastening means to form the triple clamp assembly (100). The preferred fastening means to connect the steering rod (600) with the hollow structure in the opening (10H2) is welding. The upper piece (10) and the lower piece (20) together form a rigid structure capable of accepting and containing the effects of the working loads that may act through the fork legs and the vehicle chassis during vehicle operation.

[0024] Referring to Figs. 2a and 2b, the openings (10H1, 10H2 and 10H3) on the upper piece (10) are positioned at the end of a first arm (10FA), at an edge (10JE) and at the end of a second arm (10SA), respectively. Referring to Figs. 3a and 3b, the openings (20H1, 20H2 and 20H3) on the lower piece (10) are positioned at the end of a first arm (20FA), at an edge (20JE) and at the end of a second arm (20SA), respectively. The openings (10H1, 10H2 and 10H3) of the upper piece (10) concentrically and exactly overlap the openings (20H1, 20H2 and 20H3) of the lower piece (20) in the assembled condition of the upper piece (10) and the lower piece (20).

[0025] Referring to Figs. 4a and 4b, each of the openings (10H1, 10H2 and 10H3) is provided with a cylindrical guide structure (10CGS1, 10CGS2 and 10CGS3) respectively projecting downwards from the upper piece (10). Each of the openings (20H1, 20H2 and 20H3) is provided with a cylindrical guide structure (20CGS1, 20CGS2 and 20CGS3) respectively projecting upwards from the lower piece (20). The cylindrical guide structures (10CGS1, 10CGS2 and 10CGS3) on the upper piece (10) and the cylindrical guide structures (20CGS1, 20CGS2 and 20CGS3) on the lower piece (20) together are configured to receive and support a fork leg (510), steering rod (600) and a fork leg (520) respectively. The guide structures (10CGS1, 10CGS2 and 10CGS3) on the upper piece (10) maintain a specific vertical clearance (C) with the corresponding guide structures (20CGS1, 20CGS2 and 20CGS3) on the lower piece (20) in assembled condition of the upper piece (10) and lower piece (20). The preferred range of the said vertical clearance (C) is from 2.2 to 3.8 mm. These cylindrical guiding structures provide a large contact surface area along which the loads/stresses can be distributed. This reduces the pressure on the attachment surface of the fork legs and the steering rod located within them. This helps in preventing any damage to these surfaces during assembling of the fork legs in the triple clamp assembly and also during operation of the motor vehicle. The vertical clearance (C) between the guiding structures on the upper piece and the lower piece as provided, is significant from the view point of balancing both weight and strength requirement of the triple clamp assembly (100).

[0026] The wall (10W) has clamping holes (10WH1 and 10WH2) located on the opposite faces on the first arm (10FA) and said clamping holes (10WH1 and 10WH2) are displaced vertically and horizontally from the plane containing the opening (10H1) and towards the plane containing the opening (10H2). The wall (10W) has clamping holes (10WH3 and 10WH4) located on the opposite faces on the second arm (10SA) and said clamping holes (10WH3 and 10WH4) are displaced vertically and horizontally from the plane containing the opening (10H3) and towards the plane containing the opening (10H2). The clamping holes (10WH1 and 10WH2) on the first arm (10FA) and the clamping holes (10WH3 and 10WH4) on the second arm (10SA) are concentric and configured to receive the clamping bolt (30). These clamping holes allow fastening means viz. the clamping bolts and like to be inserted and fastened through them. Providing these clamping holes thereby allows for safe assembly and disassembly of fork legs from the triple clamp assembly (100) and also provide the desired clamping grip to the fork legs (510, 520).

[0027] Referring to Fig. 5, the triple clamp assembly (100) for front fork suspension (500) has an opening (10HS1) on the first arm (10FA) of the upper piece (10) that originates along the edge of the opening (10H1) and the corresponding opening (20HS1) on the first arm (20FA) of the lower piece (20) and originates along the edge of the opening (20H1). Said openings (10HS1 and 20HS1) have two edges (E1 and E2) and each of the edges first progresses linearly towards the opening (10H2, 20H2) till they reach the vertical plane (VP) formed at the center of the openings (10WH1 and 10WH2) and thereafter each of the edges (E1 and E2) diverges outward by angle (a) from the central line on the openings (10HS1 and 20HS1); and then terminates before reaching the openings (10H2, 20H2) at a flat terminating edge surface (10FTE1, 20FTE1) through a curved profile surfaces (10CP1 and 20CP1). The width (W) of the flat terminating surface (10FTE1, 20FTE1) is 0.4 to 0.6 times the width (W1) of the opening (10HS1) at its originating point. The flat surface profile (10FTE1, 20FTE1) of the terminating ends reduces the stress concentration and facilitate effective clamping to the fork legs. The radius of curvature of the curved profile surfaces (10CP1 and 20CP1) ranges from 2.0 to 4.0 mm. The angle (a) made by the diverged edges of the openings (10HS1, 20HS1) with the central line of the said opening ranges from 3 to 6 degree.

[0028] The opening (10HS3) on the second arm (10SA) of the upper piece (10) originates along the edge of the opening (10H3) and the corresponding opening (20HS3) on the second arm (20SA) of the lower piece (20) originates along the edge of the opening (20H3); said openings (10HS3 and 20HS3) have two edges (E1 and E2) and each of the edges first progresses linearly towards the opening (10H2, 20H2) till they reach the vertical plane formed at the center of the openings (10WH3 and 10WH4) and thereafter each of the edges diverges outward by angle (a) from the central line on the openings (10HS3 and 20HS3); and then terminates before reaching the openings (10H2, 20H2) at a flat terminating edge surface (10FTE3, 20FTE3) through a curved profile (10CP3 and 20CP3). The width (W) of the flat terminating surface (10FTE3, 20FTE3) is 0.4 to 0.6 times the width (W1) of the opening (10HS3) at its originating point. The radius of curvature of the curved profile surfaces (10CP3 and 20CP3) ranges from 2.0 to 4.0 mm. The angle (a) made by the diverged edges of the openings (10HS3 and 20HS3) with the central line of the said opening ranges from 3 to 6 degree. Providing the openings (10HS1, 10HS3 and 20HS1, 20HS3) on the upper piece (10) and the lower piece (20) with the profile as described above, prevents deflection and cracking of the triple clamp assembly (100) under force applied by the fastening means i.e. the clamping bolt (30), fastened though the clamping holes (10WH1 and 10WH2) on the first arm (10FA) and the clamping holes (10WH3 and 10WH4) on the second arm (10SA).

[0029] Referring to Fig. 6, in another embodiment of the opening (10HS1) on the first arm (10FA) of the upper piece (10) originates along the edge of the opening (10H1) and the corresponding opening (20HS1) on the first arm (20FA) of the lower piece (20) originates along the edge of the opening (20H1). The openings (10HS1 and 20HS1) have two edges and each of the edges first progresses linearly towards the opening (10H2, 20H2) till they reach the vertical plane formed at the center of the openings (10WH1 and 10WH2) and thereafter each of the edges diverges outward by angle (a) from the central line on the openings (10HS1 and 20HS1), and then terminates before reaching the openings (10H2, 20H2) at a curved terminating surface (10CTS1, 20CTS1). The radius of curvature of the said curved terminating surface (10CTS1 and 20CTS1) ranges from 2.5 to 4.5 mm. The angle (a) in this variant ranges from 3 to 6 degree.

[0030] The opening (10HS3) on the second arm (10SA) of the upper piece (10) originates along the edge of the opening (10H3) and the corresponding opening (20HS3) on the second arm (20SA) of the lower piece (20) originates along the edge of the opening (20H3). The openings (10HS3 and 20HS3) have two edges and each of the edges first progresses linearly towards the opening (10H2, 20H2) till they reach the vertical plane formed at the center of the openings (10WH3 and 10WH4) and thereafter each of the edges diverges outward by angle (a) from the central line on the openings (10HS3 and 20HS3) and then terminates before reaching the openings (10H2, 20H2) at a curved terminating surface (10CTS3, 20CTS3). The radius of curvature of the said curved terminating surface (10CTS3, 20CTS3) ranges from 2.5 to 4.5 mm and the angle (a) in this variant ranges from 3 to 6 degree. Providing the opening (10HS3 and 20HS3) with the profile as described above, prevents deflection and cracking of the triple clamp assembly (100) under load applied by the fastening means i.e. the clamping bolt (30), fastened though the clamping holes (10WH1 and 10WH2) on the first arm (10FA) and the clamping holes (10WH3 and 10WH4) on the second arm (10SA).

[0031] Referring to Fig. 7 in a third embodiment of the opening (10HS1) on the first arm (10FA) of the upper piece (10), it originates along the edge of the opening (10H1) and the corresponding opening (20HS1) on the first arm (20FA) of the lower piece (20) originates along the edge of the opening (20H1). The openings (10HS1 and 20HS1) have two edges (E3 and E4) and each of the edges diverges outward at its starting point by angle (ß) from the central line on the openings (10HS1 and 20HS1) and then terminates before reaching the openings (10H2, 20H2) at a flat terminating edge surface (10FTE1, 20FTE1) through a curved profiled surfaces (10CP1 and 20CP1). The width (W’) of the flat terminating surface (10FTE1, 20FTE1) is 0.4 to 0.6 times the width (W2) of the opening (10HS1) at its originating point. The radius of curvature of the curved profile surfaces (10CP1 and 20CP1) ranges from 2.0 to 4.0 mm. The angle (ß) made by the diverged edges (E3 and E4) of the openings (10HS1 and 20HS1) with the central line of the said opening ranges from 3 to 6 degree.

[0032] The opening (10HS3) on the second arm (10SA) of the upper piece (10) originates along the edge of the opening (10H3) and the corresponding opening (20HS3) on the second arm (20SA) of the lower piece (20) originates along the edge of the opening (20H3). The openings (10HS3 and 20HS3) have two edges and each of the edges diverges outward at its starting point by angle (ß) from the central line on the openings (10HS3 and 20HS3) and then terminates before reaching the openings (10H2, 20H2) at a flat terminating edge surface (10FTE3, 20FTE3) through a curved profile (10CP3 and 20CP3). The flat surface profile (10FTE3, 20FTE3) of the terminating ends reduces the stress concentration and facilitate effective clamping to the fork legs. The radius of curvature of the curved profile surfaces (10CP3 and 20CP3) ranges from 2.0 to 4.0 mm. The angle (ß) made by the diverged edges of the openings (10HS3 and 20HS3) with the central line of the said opening ranges from 3 to 6 degree. Providing the openings (10HS1, 10HS3 and 20HS1, 20HS3) with the profile as described above, prevents deflection and cracking of the triple clamp assembly (100) under force applied by the fastening means i.e. the clamping bolt (30), fastened though the clamping holes (10WH1 and 10WH2) on the first arm (10FA) and the clamping holes (10WH3 and 10WH4) on the second arm (10SA).

[0033] In the triple clamp assembly (100) for front fork suspension (500), in accordance with the first and third variant, the radius of curvature of the curved profiles (10CP1 and 20CP1, and 10CP3 and 20CP3) ranges from 2.0 to 4.0 mm. The length (L) of the openings (10HS1, 20HS1, 10HS3, 20HS3) is 0.2 to 0.4 times of the center distance between the openings (10H1, 20H1) and the openings (10H3, 20H3).

[0034] Referring to Fig. 8 in fourth embodiment of the opening (10HS1) on the first arm (10FA) of the upper piece (10), it originates along the edge of the opening (10H1) and the corresponding opening (20HS1) on the first arm (20FA) of the lower piece (20) originates along the edge of the opening (20H1). The openings (10HS1 and 20HS1) have two edges and each of the edges diverges outward at its starting point by angle (ß) from the central line on the openings (10HS1 and 20HS1); and then terminates before reaching the openings (10H2, 20H2) at a curved terminating surface (10CTS1, 20CTS1). The radius of curvature of the said curved terminating surface (10CTS1 and 20CTS1) ranges from 2.5 to 4.5 mm. The angle (ß) ranges from 3 to 6 degree.

[0035] The opening (10HS3) on the second arm (10SA) of the upper piece (10) originates along the edge of the opening (10H3) and the corresponding opening (20HS3) on the second arm (20SA) of the lower piece (20) originates along the edge of the opening (20H3). The openings (10HS3 and 20HS3) have two edges and each of the edges diverges outward at its starting point by angle (ß) from the central line on the openings (10HS3 and 20HS3); and then terminates before reaching the openings (10H2, 20H2) at a curved terminating surface (10CTS3, 20CTS3). The radius of curvature of the said curved terminating surface (10CTS3 and 20CTS3) ranges from 2.5 to 4.5 mm. The angle (ß) ranges from 3 to 6 degree. Providing the openings (10HS1, 20HS1 and 10HS3, 20HS3) with the profile as described above, prevents deflection and cracking of the triple clamp assembly (100) under the force applied by the fastening means i.e. the clamping bolt (30), fastened though the clamping holes (10WH1 and 10WH2) on the first arm (10FA) and the clamping holes (10WH3 and 10WH4) on the second arm (10SA).

[0036] In accordance with the second and fourth disclosed variants of the triple clamp assembly (100) for front fork suspension (500), the radius of curvature of the curved terminating surface (10CTS1 and 20CTS1, and 10CTS3 and 20CTS3) ranges from 2.5 to 4.5 mm.

[0037] Referring to Fig. 9, the fifth embodiment of the opening (10HS1) on the first arm (10FA) of the upper piece (10), it originates along the edge of the opening (10H1) and the corresponding opening (20HS1) on the first arm (20FA) of the lower piece (20) originates along the edge of the opening (20H1). The openings (10HS1 and 20HS1) have two edges and each of the edges progresses linearly towards the openings (10H2, 20H2); and then terminates before reaching the openings (10H2, 20H2) by curving towards each other forming a curved terminating edge surface.

[0038] The opening (10HS3) on the second arm (10SA) of the upper piece (10) originates along the edge of the opening (10H3) and the corresponding opening (20HS3) on the second arm (20SA) of the lower piece (20) originates along the edge of the opening (20H3); said openings (10HS3 and 20HS3) have two edges and each of the edges progresses linearly towards the openings (10H2, 20H2); and then terminates before reaching the openings (10H2, 20H2) by curving towards each other forming a curved terminating edge surface. Provision of these openings with the profile as described above, prevents cracking of the triple clamp assembly (100) under load applied by the fastening means i.e. the clamping bolt (30), fastened though the clamping holes (10WH1 and 10WH2) on the first arm (10FA) and the clamping holes (10WH3 and 10WH4) on the second arm (10SA). Therefore, this feature allows for safe assembly and disassembly of fork legs from the triple clamp assembly (100).

[0039] In all the variants of the triple clamp assembly (100) for front fork suspension (500), the vertical clearance (C) between the guide structures (10CGS1, 10CGS2 and 10CGS3) on the upper piece (10) and the corresponding guide structures (20CGS1, 20CGS2 and 20CGS3) on the lower piece (20) in assembled condition of the upper piece (10) and lower piece (20) is in the range of 2.2 to 3.8 mm. The clearance (C) as provided, is significant for balancing two parameters viz. weight and strength of the triple clamp assembly (100).

[0040] In all of the variants of the triple clamp assembly (100) for front fork suspension (500), the lower piece (20) and the upper piece (10) are made of sheet metal and the lower piece (20) is joined with the surface of the wall (10W) of the upper piece (10) by welded joint to form a hollow structure. The cylindrical guide structures (10CGS1, 10CGS2 and 10CGS3) projecting downwards from the upper piece (10) has projection length (L’) in the range of 1.45 to 1.70 times thickness (t) of the upper piece (10); and the cylindrical guide structures (20CGS1, 20CGS2 and 20CGS3) projecting upwards from the lower piece (20) has projection height (h’) in the range of 1.45 to 1.70 times thickness (t’) of the lower piece (20). The thickness (t) of the upper piece (10) and the thickness (t’) of the lower piece (20) can be same or it may vary depending on the functional requirement. The steering rod (600) is rigidly fitted into an opening (10H2) of the said hollow structure by welding to form the triple clamp assembly (100). These features of the triple clamp assembly (100) allow it to be strong and also very light in weight. Maintaining the projection length (L’) of the cylindrical guide structures (10CGS1, 10CGS2 and 10CGS3) and the projection height (h’) of the cylindrical guide structures (20CGS1, 20CGS2 and 20CGS3) in the given range and ensuring the vertical clearance (C) during the assembled condition of the upper and lower pieces (10 and 20) enables the provision for sufficient surface area for load/stress distribution while also maintaining their strength.

[0041] Again, in all of the variants of the triple clamp assembly (100) for front fork suspension (500), the fork legs (510 and 520) of the front fork suspension (500) have at least an inner tube (503, 513) and outer tube (506, 516) capable of telescopically sliding within one another, and also capable of being received and supported on the triple clamp in the openings respectively given on both of the arms (identified as the first arm and the second arm) having cylindrical guiding structures. As such, the triple clamp assembly (100) has a very wide utility, and can be used with fork legs having various internal features for absorbing (e.g. a spring) and dissipating energy (e.g. a damping mechanism) from shocks experienced on the vehicle when it travels over a road surface irregularity.

[0042] The triple clamp assembly for a front fork suspension in accordance with embodiments of the disclosed invention provides the following technical advantages:
- It is strong enough to resist deflection and cracking under working loads imposed during operation of a motor vehicle.
- It provides a triple clamp assembly that firmly holds the fork legs and the steering rod.
- It is capable of distributing the stresses effectively so as to ensure that the triple clamp assembly itself does not end up damaging surface along which the fork legs are fixed within it, both during assembly and operation of the motor vehicle.
- It is both light weight and equally strong enough capable of resisting bending and flexing while enabling improvement in range and response of the vehicle.
- It enhances the fork leg alignment and gripping due to the uniquely profiled cylindrical guide structures provided at its openings.
- It is modular in nature and very easy to manufacture.

[0043] The disclosed invention hence overcomes the limitation of the known solutions. It provides a triple clamp assembly that can be utilized in motor vehicles where keeping the weight low is an extremely important objective. The disclosed invention also provides a structurally strong assembly that is sufficiently capable of preventing damage due to loads that may act upon it during its assembly with the fork legs and also during operation of the motor vehicle by a user. While care has been taken to comprehensively describe all the favorable aspects of the invention, it must be noted that changing orientation of the fork legs from a conventional to an upside down orientation does not affect the overall working of the disclosed triple clamp assembly and hence this change must not be viewed as taking any such an assembly out of the scope of claims of this invention.

[0044] 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.