TWI898290B - Fork arch - Google Patents

Abstract

A fork arch is disclosed. The fork arch includes a torsional geometry portion to provide torsional stiffness. The fork arch also includes a transverse geometry portion to provide transverse shear stiffness, the transverse geometry portion intermingled with the torsional geometry portion to provide an optimized hybrid torsion and transverse shear stiffness for the fork arch.

Description

Fork arch

The embodiments of the present invention generally relate to the fields of vehicle frames, supporting components, etc.

Vehicle components, frames, members, suspension systems, and the like must resist forces that would tend to twist and/or bend these structures. Furthermore, it is desirable for such structures to remain in place relative to one another. This often requires appropriate reinforcement of the structures and/or the connections between them. Consequently, these structures are manufactured to meet a number of structural integrity requirements. These requirements may include the ability to support structural loads (e.g., weight, force, etc.) without fracturing or failing.

100, 100f, 100r: Fork arch

102: Front fork assembly

12: Pivot Point

15: Rear axle

202: Right leg

204: Right lower tube

208: Upper right tube

210: Crown

212: Steering tube

214: Upper left tube

218: Left lower tube

220:Left leg

224,226: Exit Department

24: Framework

26: Arm swing

28:Front wheel

30:Rear wheel

308: Negative spline

310A: Right fork arch shoulder

310B: Left fork arch shoulder

312: Second end

314: First end

32: Seat

33: Seatpost

36: Handlebars

38,48: Damper

405: Twisting Geometry

405a: First leg section

405b: Second leg section

406: Material Removal Area

407: Horizontal Geometry

407a: First leg section

407b: Second leg section

411,412: Width

431,450: Depth

433: Upper Depth

435: Lower Depth

441: Lower Width

442: Upper Width

50: Bicycle

69: Vertical direction (arrow)

85:Front axle

93: Horizontal direction

A-A: Vertical center plane

B-B, C-C: longitudinal center axis

T-T: plane

FIG1 is a perspective view of a bicycle having at least one fork arch according to an embodiment.

FIG2A is a perspective view of a front fork assembly having at least one fork arch coupled to the front portion of the fork according to one embodiment.

FIG2B is a perspective view of a front fork assembly having at least one fork arch coupled to the rear portion of the fork according to one embodiment.

FIG2C is a perspective view of a front fork assembly having at least one fork arch joined at the front of the fork and at least one fork arch joined at the rear of the fork according to one embodiment.

Figure 3 is an exploded view of the fork arch design, right lower tube, and left lower tube according to one embodiment.

FIG4A is an orthogonal perspective view of a fork arch according to one embodiment, illustrating various components incorporated into the fork arch.

FIG4B is a rear perspective view of a fork arch according to one embodiment, illustrating various components incorporated into the fork arch.

FIG4C is a side perspective view of a fork arch according to one embodiment, illustrating various components incorporated into the fork arch.

FIG4D is a front perspective view of a fork arch according to one embodiment, illustrating various components incorporated into the fork arch.

Figure 4E is a perspective top view of a fork arch according to one embodiment.

Unless otherwise specified, the drawings in this specification should be understood as not being drawn to scale.

The detailed description set forth below, in conjunction with the accompanying drawings, is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments in which the present invention may be practiced. Each embodiment described herein is provided merely as an example or illustration of the present invention and should not necessarily be construed as preferred or advantageous over other embodiments. In some instances, well-known methods, processes, objects, and circuits have not been described in detail to avoid unnecessarily obscuring aspects of the present invention.

In the following discussion, and for the sake of clarity, a bicycle is used as an example vehicle. However, in other embodiments, the vehicle may be any of a variety of vehicles, such as, but not limited to, a bicycle, a motorized bicycle, etc. Generally speaking, a motorized bicycle may include a bicycle with a combustion motor, an electric bicycle (e-bike), a hybrid electric and combustion bicycle, a hybrid motor and pedal-powered bicycle, etc.

Typically, bicycle components are designed with a wide performance window to cover a wide range of consumers and riding styles. For example, a mountain bike sold in a store might have components designed to meet the needs of an intermediate rider weighing between, for example, 120 and 180 pounds. Therefore, a bicycle store would be able to use weight criteria to guide customers toward purchasing the right bike with the appropriate component performance level.

However, as riders become more skilled, the performance demands of one or more components of the bicycle may require upgrades. These upgrades may include various aspects such as a stronger structure, a lighter structure, and so on. Furthermore, depending on the type of bicycle and the type of terrain, features, jumps, bumps, performance expectations, etc., only one or a few components may need to be upgraded. In some extreme performance situations, it may be desirable to find even a very small weight and/or strength advantage that would allow a rider to be just a little faster, jump a little higher, gain just a little more top speed, and so on, than their competitors.

In one embodiment, the fork arch disclosed herein employs a first geometric characteristic that optimizes torsional stiffness. In one embodiment, the fork arch disclosed herein employs a second geometric characteristic that optimizes transverse shear stiffness. In one embodiment, the fork arch disclosed herein employs a combination of the first geometric characteristic that optimizes torsional stiffness and the second geometric characteristic that optimizes transverse shear stiffness.

In one embodiment, the fork arch disclosed herein utilizes one or more material removal zones to reduce the weight of the fork arch. In one embodiment, the material removal zones are off-plane. In one embodiment, the material removal zones are located in a low-stress region. In one embodiment, the material removal zones are both off-plane and located in a low-stress region.

In one embodiment, a material-removed region refers to an area where material has been partially removed from the fork arch, but some material remains (e.g., not a hole, window, etc.). In one embodiment, a material-removed region refers to an area where material has been completely removed from the fork arch (e.g., a hole, window, etc.). In one embodiment, a material-removed region is a combination of regions, some of which have had material partially removed, and some of which have had material completely removed.

For clarity, the discussion herein refers to "prong arches," which is a term of reference in the art. In one embodiment, the prong arches comprise some type of arch. However, in another embodiment, the prong arches will have another type of geometric shape, such as a triangle, rectangle, star, etc. In one embodiment, the prong arches are a hybrid type of geometry that combines many different geometric shapes, such as an arch, triangle, rectangle, star, square, etc.

Referring now to FIG. 1 , a schematic side view of a bicycle 50 having an optimized fork arch 100 incorporated therein is shown, according to an embodiment. In one embodiment, the bicycle 50 has a frame 24 with a suspension system including a swingarm 26 that is movable relative to the remainder of the frame 24 during use; this movement is permitted, among other things, by a damper 38. A front fork assembly 102 also provides suspension functionality via a damper 48 located in at least one of the fork legs; thus, the bicycle 50 is a full-suspension bicycle (such as an ATB or mountain bike).

However, the embodiments described herein are not limited to use on full-suspension bicycles. In particular, the term "suspension system" is intended to include vehicles having only a front suspension, only a rear suspension, only a seat suspension, a combination of two or more different types of suspension, etc.

In one embodiment, the swingarm 26 is pivotally attached to the frame 24 at the pivot point 12. While the pivot point 12 is shown at a particular location, it should be understood that the pivot point 12 can be found at different locations. In a hardtail bicycle embodiment, the pivot point 12 would not be present. In one embodiment of a hardtail bicycle, the frame 24 and swingarm 26 would form a fixed frame.

The bicycle 50 includes a front wheel 28 coupled to a front fork assembly 102 via a front axle 85. In one embodiment, a portion of the front fork assembly 102 (e.g., a steering tube) passes through the bicycle frame 24 and couples to the handlebars 36. In doing so, the front fork assembly and handlebars are rotationally coupled to the frame 24, thereby allowing the rider to steer the bicycle 50.

Bicycle 50 includes a rear wheel 30 coupled to swing arm 26 at rear axle 15, and a rear damping assembly (e.g., damper 38) positioned between swing arm 26 and frame 24 to provide resistance to pivotal movement of swing arm 26 about pivot point 12. In one embodiment, seat 32 is coupled to frame 24 via seat post 33. In one embodiment, seat post 33 is a dropper post.

In one embodiment, one or more of the damper 48, damper 38, seatpost 33, handlebar 36, etc. include one or more active damping components. In one embodiment, one or more sensors and valve actuators (e.g., electric solenoid or linear motor type - note that rotary motors can also be used with rotary actuated valves), suspension components, suspension component controller(s) and/or data processing system(s), etc. can be coupled to and/or integrated with the vehicle structure, such as disclosed in U.S. Patents No. 7,484,603; No. 8,838,335; No. 8,955,653; No. 9,303,712; No. 10,036,443; No. 10,060,499; No. 10,443,671 and No. 10,737,546; the entire contents of each of which are incorporated herein by reference in their entirety. In addition, the sensors and valves or principles of the patents and other documents incorporated herein by reference may be incorporated into one or more embodiments herein, alone or in combination.

For purposes of the following discussion, the longitudinal direction 69 is the direction from the front end to the rear end of the bicycle 50.

Ground plane refers to the plane formed by the terrain on which the vehicle is traveling. Ground plane will include the line formed by arrow 69. In the upright position, bicycle 50 will be perpendicular (or approximately perpendicular) to the ground plane.

When bicycle 50 is in the upright position, vertical center plane A-A (as shown in at least FIG. 4B ) bisects the length of bicycle 50 (e.g., along the same line formed by arrow 69 from the front of bicycle 50 through the rear of bicycle 50) such that vertical center plane A-A is perpendicular to the ground plane.

The transverse direction 93 (as shown at least in FIG. 4B ) is perpendicular (or substantially perpendicular) to the vertical center plane A-A.

Plane T-T in FIG1 is parallel (or substantially parallel) to the ground plane and includes the rotational axes of the front wheel 28 and the rear wheel 30.

Referring now to FIG. 2A , a perspective view of the front fork assembly 102 (of FIG. 1 ) is shown, according to an embodiment, having at least one fork arch 100 coupled to the front portion of the front fork assembly 102. The front fork assembly 102 includes a right leg 202 and a left leg 220, respectively, as referenced by a person in a riding position on the bicycle 50. The right leg 202 includes a right upper tube 208 telescopically received within a right lower tube 204. Similarly, the left leg 220 includes a left upper tube 214 telescopically received within a left lower tube 218.

In one embodiment, the leg extension is reversed. That is, the right lower tube 204 of the right leg 202 is telescopically received within the right upper tube 208. Similarly, the left lower tube 218 of the left leg 220 is telescopically received within the left upper tube 214.

The crown 210 connects the right upper tube 208 to the left upper tube 214, thereby connecting the right leg 202 of the front fork assembly 102 to the left leg 220. Additionally, the crown 210 supports a steerer tube 212, which passes through and is rotatably supported by the frame 24 of the bicycle 50. The steerer tube 212 provides a means for connecting the handlebar 36 to the front fork assembly 102.

Each of the right and left lower tubes 204, 218 includes exit portions 224, 226, respectively, for connecting the front wheel 28 to the front fork assembly 102 via the front axle 85. In one embodiment, a fork arch 100 connects the right and left lower tubes 204, 218 to provide strength and minimize twisting of the right and left lower tubes 204, 218.

In one embodiment, the fork arch 100 faces forward, for example, toward the front wheel 28 of FIG. 1 .

Referring now to FIG. 2B , a perspective view of a front fork assembly 102 according to one embodiment is shown, having at least one fork arch 100 incorporated at a rear portion of the front fork assembly 102. In one embodiment, the components of FIG. 2A and FIG. 2B are similar, except that they are modified based on the opposite configuration of the fork arch 100. Therefore, for the sake of clarity, the discussion of similar components will not be repeated; instead, the discussion of FIG. 2A is incorporated herein by reference in its entirety.

In one embodiment, the fork arch 100 faces rearward, for example, toward the rear wheel 30 of FIG. 1 .

Referring now to FIG. 2C , a perspective view of a front fork assembly 102 according to one embodiment is shown. The front fork assembly 102 has at least one fork arch 100 f coupled to the front portion of the front fork assembly 102 and at least one fork arch 100 r coupled to the rear portion of the front fork assembly 102. In one embodiment, the components of FIG. 2A and FIG. 2C are similar, except that these components are modified based on the front and rear positions of the fork arches. Therefore, for the sake of clarity, the discussion of similar components will not be repeated; instead, the discussion of FIG. 2A is incorporated herein by reference in its entirety.

In one embodiment, each of the fork arches 100r and 100f employs one or a combination of a first geometric characteristic that optimizes torsional stiffness and a second geometric characteristic that optimizes transverse shear stiffness, as described in further detail herein.

In one embodiment, fork arch 100r employs a first geometric characteristic that optimizes torsional stiffness, and fork arch 100f employs a second geometric characteristic that optimizes transverse shear stiffness, as described in further detail herein.

In one embodiment, fork arch 100r employs a second geometric characteristic that optimizes transverse shear stiffness, and fork arch 100f employs a first geometric characteristic that optimizes torsional stiffness, as described in further detail herein.

In one embodiment, one of the fork arch 100r and the fork arch 100f employs one or both of a first geometric characteristic that optimizes torsional stiffness and a second geometric characteristic that optimizes transverse shear stiffness, as described in further detail herein; while the other of the fork arch 100r and the fork arch 100f is a standard fork arch.

In one embodiment, one or both of the fork arch 100r and the fork arch 100f employ one or more material removal areas, as described in further detail herein.

Referring now to FIG. 3 , an exploded view of the fork arch 100, the right lower tube 204, and the left lower tube 218 is shown according to one embodiment.

In the following discussion of Figures 3-4E , for clarity, the fork arch 100 will be coupled to the front fork assembly 102 in a standard telescoping configuration in Figures 3-4E , although in one embodiment, the fork arch 100 can be coupled to the front fork assembly 102 in a reverse orientation.

Similarly, as discussed herein, for clarity, the fork arch 100 will be shown as being coupled to the front fork assembly 102 in FIGS. 3-4E , although in different embodiments the fork arch 100 can be coupled to the front fork assembly 102 forward of the steering axis (as shown in FIG. 2A ), rearward of the steering axis (as shown in FIG. 2B ), or both forward and rearward of the steering axis (as shown in FIG. 2C ).

In one embodiment, the fork arch 100 is coupled to the right lower tube 204 and the left lower tube 218. In an inverted fork embodiment, the fork arch 100 would be coupled to the right upper tube 208 and the left upper tube 214.

In one embodiment, the fork arch 100 is used to couple the fork legs together at a second location offset from the crown. In one embodiment, the fork arch 100 provides improved alignment of the left and right fork legs of a bicycle by allowing mid-assembly horizontal, vertical, and rotational adjustment of the fork legs via the fork arch 100.

In one embodiment, the fork arch 100, the right lower tube 204, and the left lower tube 218 are manufactured as a single piece. In one embodiment, the fork arch 100 is formed separately from the fork legs and/or the fork arch 100 and the fork legs are formed of different materials. In other words, the fork arch 100 is manufactured separately from the right lower tube 204 and the left lower tube 218. In one embodiment, the fork arch 100 is formed as a single piece with at least one of the down tubes. In one embodiment, the second down tube is subsequently attached, for example, during assembly.

In one embodiment, the fork arch 100 and/or the lower fork leg are made of a castable material such as magnesium, aluminum, or titanium. In one embodiment, the fork arch 100 and/or the lower fork leg are made of a fiber-reinforced polymer (e.g., carbon and/or glass-reinforced epoxy or PEEK or other polyaromatics) or any other suitable structural material that provides a suitably high level of strength, stiffness, and impact resistance, or any suitable combination of such materials.

Additional discussion of the operation and performance of the fork arch portion of the fork assembly can be found in U.S. Patent No. 9,975,595, the entire contents of which are incorporated herein by reference.

In one embodiment, during assembly, the individual pieces can be adjusted independently to achieve the desired alignment relative to one another. When properly aligned, the extension and contraction movement of the upper tube within the lower tube remains near or at a minimal friction level. Once the lower fork legs are positioned so that they are aligned in the same horizontal and vertical planes, this embodiment stabilizes these adjusted positions through attachment features (e.g., bolt holes, screw holes, glue cavities, etc.) present in both the fork arch 100 and the lower fork legs.

In one embodiment, if the components are manufactured as separate pieces, they can be fixedly coupled during assembly using a variety of methods, such as, but not limited to, coupling the fork arch 100 to the lower fork leg using horizontal and vertical attachment rods; coupling the fork arch 100 to the lower fork leg using matching positive and negative spline features; and then gluing, threading, bolting, or otherwise fixedly coupling the fork arch 100 to the lower fork leg.

In one embodiment, the right lower tube 204 has a first end 314, and the left lower tube 218 has a second end 312. In one embodiment, the first end 314 and the second end 312 include a set of negative splines 308. The set of negative splines 308 is a recessed portion formed in the first end 314 and the second end 312. In one embodiment, the fork arch 100 includes a right fork arch shoulder 310A and a left fork arch shoulder 310B. The inner surfaces (not shown) of the right fork arch shoulder 310A and the left fork arch shoulder 310B include a set of positive splines configured to fit within the set of negative splines 308. A set of positive splines is a raised vertically shaped block, formed so that the raised positive splines fit into the negative spline recesses.

In one embodiment, the raised positive splines are smaller in area than the negative spline recesses so that when the right and left fork arch shoulders 310A, 310B are placed on the first end 314 of the right and left lower tubes 204, 218, respectively, the right and left lower tubes 204, 218 can be rotated horizontally, vertically, and rotationally within the fixture before a more permanent attachment mechanism, such as, for example, adhesive, is applied.

Additional discussion of various methods and systems for coupling the fork arch 100 to the right and left lower tubes 204, 218 can be found in U.S. Patent 10,850,793, which is incorporated herein by reference in its entirety.

Referring now to FIG. 4A , an orthogonal perspective view of a fork arch 100 is shown illustrating various components incorporated into the fork arch 100, according to one embodiment.

In one embodiment, the fork arch 100 includes a first geometric feature, such as the torsional geometry 405, that optimizes torsional stiffness. Generally, torsional stiffness relates to torsional load. Essentially, if the front wheel 28 of the bicycle 50 is positioned in the bicycle frame (e.g., such that the front wheel cannot turn left or right) and a force is applied to attempt to turn the handlebars 36, a torsional load will be applied to the front fork assembly 102. Thus, in an operational example, when turning the bicycle (or otherwise leaning to one side), torsion occurs because the contact point of the front fork assembly 102 is not aligned with the axis of the front fork assembly 102. For example, using the tire envelope curvature, the torsional edge will follow the circumference of the tire.

In one embodiment, the twisted geometry 405 is an arch. In another embodiment, the twisted geometry 405 is another type of geometric shape, such as a triangle, rectangle, star, etc. In another embodiment, the twisted geometry 405 is a hybrid type of geometric shape that combines many different geometric shapes, such as an arch, triangle, rectangle, star, square, etc.

In one embodiment, the torsion geometry 405 extends upward (or is offset upward) from plane T-T, and at least a portion of the torsion geometry 405 extends in the lateral direction 93 of the bicycle 50. In one embodiment, a portion of the torsion geometry 405 also extends upward (or is offset upward) from plane T-T in the longitudinal direction 69 of the bicycle 50. In one embodiment, a majority of the torsion geometry 405 extends in the longitudinal direction 69 of the bicycle 50.

In one embodiment, the fork arch 100 includes a second geometric feature, such as the lateral geometry 407, that optimizes lateral shear stiffness. Lateral shear stiffness refers to the stiffness of the fork arch 100 relative to the differential upward and/or downward motion of the two fork legs. For example, lateral shear occurs when the right lower tube 204 experiences a given upward force while the down tube 218 does not experience the same upward force. For example, again using the tire envelope curvature, lateral shear will be directed radially outward from the tire envelope.

In one embodiment, the transverse geometric portion 407 is an arch. In another embodiment, the transverse geometric portion 407 is another type of geometric shape, such as a triangle, rectangle, star, etc. In another embodiment, the transverse geometric portion 407 is a hybrid type of geometric shape that combines many different geometric shapes, such as an arch, triangle, rectangle, star, square, etc.

In one embodiment, the transverse geometric portion 407 extends upward (or is offset upward) from the plane T-T. In one embodiment, at least a portion of the transverse geometric portion 407 extends along the longitudinal direction 69.

In one embodiment, a majority of the transverse geometric portion 407 extends upward (or is offset upward) from the plane T-T along the transverse direction 93.

In one embodiment, the fork arch 100 utilizes a combination (or hybrid, etc.) of the torsional geometry 405 and the transverse geometry 407 to provide a blended optimization of both torsional stiffness and transverse shear stiffness. For example, the fork arch 100 provides optimized blended torsional and transverse shear stiffness. In one embodiment, the torsional geometry 405 and the transverse geometry 407 utilize different geometric shapes. In another embodiment, the torsional geometry 405 and the transverse geometry 407 utilize similar geometric shapes.

In one embodiment, the transverse geometry 407 is positioned at an angle relative to the torsion geometry 405. In one embodiment, the torsion geometry 405 is formed integrally with the transverse geometry 407 during manufacturing. In one embodiment, the torsion geometry 405 is formed separately and coupled to the transverse geometry 407 during manufacturing.

In one embodiment, the fork arch 100 utilizes one or more material removal areas 406 to reduce the weight of the fork arch 100. In one embodiment, the one or more material removal areas 406 are thinning portions (e.g., recesses, protrusions, grooves, etc.), openings, or a combination thereof. In one embodiment, the material removal areas 406 are located in low-stress regions.

In one embodiment, the material removal areas 406 are areas where material has been partially removed from the fork arch 100, but some material remains (e.g., not holes, windows, etc.). In one embodiment, the material removal areas 406 are areas where material has been completely removed from the fork arch (e.g., holes, windows, etc.). In one embodiment, the material removal areas 406 are a combination of areas, some of which have had material partially removed, and some of which have had material completely removed.

In one embodiment, the transverse geometry 407 and/or the torsional geometry 405 includes at least one material removal region 406. In one embodiment, the transverse geometry 407 includes at least eight material removal regions 406. In some embodiments, the transverse geometry 407 includes fewer than or more than eight material removal regions 406. In one embodiment, the torsional geometry 405 includes at least two material removal regions 406. In some embodiments, the torsional geometry 405 includes at least six material removal regions 406. In some embodiments, the torsional geometry 405 includes fewer than or more than six material removal regions 406.

In one embodiment, the prong arch 100 is metal. In another embodiment, the prong arch 100 is a composite material. The composite material may be carbon fiber, carbon fiber short strands, graphene helices, etc. In one embodiment, the composite material may be in the form of a woven fabric or a pad, and may be preferentially oriented using a unidirectional reinforcement manufacturing method to anticipate greater stress in a given orientation, for example.

Examples of different metals may include, but are not limited to, aluminum, steel, titanium, magnesium, and the like.

In one embodiment, the fork arch 100 is formed additively, subtractively, or both. Additive refers to a process that adds (or augments) material to create a part. Examples of additive processes include 3D printing, casting, molding, extrusion, lamination, casting, and the like.

Subtractive machining refers to the process of removing material from an existing block of material to create a part. An example of a subtractive process is a milling machine that removes material from a block of material to create a part.

Referring now to FIG. 4B , a rear perspective view of a fork arch 100 is shown, illustrating various components incorporated with the fork arch 100, according to one embodiment. In one embodiment, the components of FIG. 4B are similar to those illustrated and described in FIG. 4A . Therefore, for the sake of clarity, the discussion of similar components will not be repeated; instead, the discussion of FIG. 4A is incorporated herein by reference in its entirety.

In one embodiment, one or more material removal areas 406 are geometric shapes such as triangles, rectangles, stars, etc. In one embodiment, one or more material removal areas 406 are mixed-type geometric shapes that combine multiple different geometric shapes.

In one embodiment, one or more material removal areas 406 have different geometric shapes. In one embodiment, one or more material removal areas 406 have similar geometric shapes.

In one embodiment, some of the one or more material removal areas 406 are open across the fork arch 100 (such as shown, for example, at the portion of the fork arch 100 closest to the right lower tube 204 and the left lower tube 218), while other of the one or more material removal areas 406 include only partially removed material (such as shown, for example, in the transverse geometry 407).

However, it should be understood that other embodiments may have more, fewer, or different material removal zones 406. Furthermore, in one embodiment, one or more material removal zones 406 may not include openings. In one embodiment, all of the one or more material removal zones 406 may include openings. In one embodiment, the one or more material removal zones 406 that have openings and those that do not may differ from those shown in the embodiment configuration.

For clarity and as an embodiment, the location, number, shape, and use of one or more material removal areas 406 with and without openings are provided herein.

Still referring to FIG. 4B , a vertical center plane A-A is shown. In one embodiment, the vertical center plane A-A generally bisects the length of the bicycle 50 from the front of the bicycle 50 to the rear of the bicycle 50. In one embodiment, the fork arch 100 is shown in FIG. 4B in a direction transverse to the vertical center plane A-A (e.g., such as the width of the bicycle 50).

In one embodiment, the longitudinal center axis C-C of the right lower tube 204 and the longitudinal center axis B-B of the left lower tube 218 are shown.

In one embodiment, the transverse geometry 407 includes a first leg portion 407a and a second leg portion 407b. In one embodiment, the first leg portion 407a is symmetrical with respect to the second leg portion 407b. In one embodiment, the first leg portion 407a is asymmetrical with respect to the second leg portion 407b.

In one embodiment, transverse geometry 407 has a width 411 at its central region and a width 412 proximate right lower tube 204 and left lower tube 218. In one embodiment, width 411 is less than width 412. In another embodiment, width 411 is equal to width 412. In another embodiment, width 411 is greater than width 412.

In one embodiment, the width of the first leg portion 407a is variable along the length of the transverse geometric portion 407. In one embodiment, the width of the second leg portion 407b is variable along the length of the transverse geometric portion 407.

In one embodiment, different widths, shapes of the lateral geometry 407 and one or more material removal areas 406 are different for different use cases, as discussed in further detail herein.

Referring now to FIG. 4C , a side perspective view of a fork arch 100 is shown, illustrating various components incorporated into the fork arch 100, according to one embodiment. In one embodiment, the components of FIG. 4C are similar to those illustrated and described in FIG. 4A and FIG. 4B . Therefore, for the sake of clarity, the discussion of similar components will not be repeated; instead, the discussion of FIG. 4A and FIG. 4B is incorporated herein by reference in its entirety.

In one embodiment, the transverse geometric portion 407 has a depth 431. In one embodiment, the depth 431 is variable along the length of the transverse geometric portion 407.

In one embodiment, the depth of the twist geometry varies along the length of the twist geometry 405. In one embodiment, the twist geometry 405 has an upper depth 433 and a lower depth 435. In one embodiment, the upper depth 433 is greater than the lower depth 435. In one embodiment, the upper depth 433 is equal to the lower depth 435. In one embodiment, the upper depth 433 is less than the lower depth 435. In one embodiment, the upper depth 433 is variable along the length of the twist geometry 405. In one embodiment, the lower depth 435 is variable along the length of the twist geometry 405.

In one embodiment, both the transverse geometry 407 and the torsional geometry 405 extend in the transverse direction 93, but in one embodiment, the depth of 405 extends further in the longitudinal direction 69 than the depth of the transverse geometry 407.

Referring now to FIG. 4D , a front perspective view of a fork arch 100 is shown, illustrating various components incorporated into the fork arch 100, according to one embodiment. In one embodiment, the components of FIG. 4D are similar to those illustrated and described in FIG. 4A and FIG. 4B . Therefore, for the sake of clarity, the discussion of similar components will not be repeated; instead, the discussion of FIG. 4A and FIG. 4B is incorporated herein by reference in its entirety.

As discussed in FIG4B , the vertical center plane A-A, the longitudinal center axis C-C of the right lower tube 204, and the longitudinal center axis B-B of the left lower tube 218 are shown.

In one embodiment, the transverse geometry 407 includes a first leg portion 407a and a second leg portion 407b.

In one embodiment, the twisting geometry 405 includes a first leg portion 405a and a second leg portion 405b. In one embodiment, the width of the first leg portion 405a is variable along the length of the twisting geometry 405. In one embodiment, the width of the second leg portion 405b is variable along the length of the twisting geometry 405.

In one embodiment, the first leg portion 405a is symmetrical with respect to the second leg portion 405b. In one embodiment, the first leg portion 405a is asymmetrical with respect to the second leg portion 405b.

In one embodiment, the twisted geometry 405 has an upper width 442 and a lower width 441. In one embodiment, the upper width 442 is greater than the lower width 441. In one embodiment, the upper width 442 is equal to the lower width 441. In one embodiment, the upper width 442 is less than the lower width 441.

In one embodiment, the first leg portion 407a is connected to the upper portion of the first down tube 204, and the second leg portion 407b is connected to the upper portion of the second down tube 218.

In one embodiment, the first leg portion 407a includes at least one portion connected to the upper portion of the first lower tube 204 and extending distally relative to the vertical center plane A-A. In one embodiment, the first leg portion 407a includes at least one portion connected to the upper portion of the first lower tube 204 and extending proximally toward the vertical center plane A-A.

In one embodiment, the second leg portion 407b includes at least one portion connected to the upper portion of the second lower tube 218 and extending distally relative to the vertical center plane A-A. In one embodiment, the second leg portion 407b includes at least one portion connected to the upper portion of the second lower tube 218 and extending proximally toward the vertical center plane A-A.

In one embodiment, the first leg portion 407a and the third leg portion 405a include at least one common portion that extends proximally toward the vertical center plane A-A and connects to the upper portion of the first lower tube 204.

In one embodiment, the second leg portion 407b and the fourth leg portion 405b include at least one common portion that extends proximally toward the vertical center plane A-A and connects to the upper portion of the second lower tube 218.

Referring now to FIG. 4E , a top perspective view of fork arch 100 is shown, according to one embodiment. In one embodiment, the components of FIG. 4E are similar to those shown and described in FIG. 4A and FIG. 4B . Therefore, for the sake of clarity, the discussion of similar components will not be repeated; instead, the discussion of FIG. 4A and FIG. 4B is incorporated herein by reference in its entirety.

In one embodiment, the torsional geometry 405 has a depth 450. In one embodiment, the transverse geometry 407 has a depth 450. In one embodiment, one or more material removal areas 406 are shown in the torsional geometry 405.

In one embodiment, the depths of the torsional geometry 405 and the transverse geometry 407 are defined when viewed approximately parallel to a plane containing the longitudinal center axis of the first down tube (e.g., C-C passing through the right down tube 204) and the longitudinal center axis of the second down tube (e.g., B-B passing through the left down tube 218).

In one embodiment, the fork arch 100 has an aspect ratio greater than one (e.g., the ratio of the depth to the width of the torsion geometry 405 and/or the transverse geometry 407) with respect to the depths (e.g., depths 431, 433, and 435) and widths (e.g., widths 411, 412, 441, and 442) discussed herein. In one embodiment, the fork arch 100 has an aspect ratio equal to one (e.g., the ratio of the depth to the width of the torsion geometry 405 and/or the transverse geometry 407). In one embodiment, the fork arch 100 has an aspect ratio (e.g., a depth-to-width ratio of the torsion geometry 405 and/or the transverse geometry 407) that is less than one. In one embodiment, the fork arch 100 includes a torsion geometry 405 having an aspect ratio (depth-to-width ratio) greater than one and a transverse geometry 407 having an aspect ratio (depth-to-width ratio) less than one. In one embodiment, the fork arch 100 includes a torsional geometry 405 and a transverse geometry 407, wherein the torsional geometry 405 has at least one portion with an aspect ratio (depth to width ratio) greater than 1, and the transverse geometry 407 has at least one portion with an aspect ratio (depth to width ratio) less than 1.

Although an embodiment of the fork arch 100 is shown herein as having a torsion geometry 405 and a transverse geometry 407, this is shown as only one embodiment and for purposes of clarity. However, in other embodiments, different applications (e.g., different usage scenarios, vehicles, cost, marketing, etc.) will result in the fork arch 100 having different torsion geometries 405 and/or transverse geometries 407, and/or combinations thereof. Furthermore, different applications may result in variations in the width, shape, or one or more material removal areas 406 of the torsion geometry 405 and/or transverse geometry 407 of the fork arch 100. In one embodiment, optimization is performed using a computer-aided design (CAD) program.

Some examples of different vehicle geometries include, but are not limited to, travel, wheel size, bike type, weight target, stiffness target, the amount of space allowed in the camber, clearance with other fork sections, clearance with bike model, clearance with tire model, etc.

For example, there may be size and design differences depending on whether the fork arch 100 is metal, composite, etc. That is, each different material will likely result in a different shape, thickness, etc., to achieve the desired stiffness and stress threshold for the fork arch 100. For example, a composite material will have minimum weight and shape requirements to meet the stiffness and stress threshold, while aluminum will have another weight and shape requirement to meet the stiffness and stress threshold, magnesium will have yet another given weight and shape requirement to meet the stiffness and stress threshold, and so on.

In one embodiment, the fork arches 100 will include a variety of sizes, geometries, and shapes to cover a variety of marketing scenarios, as each fork arch 100 will have a material cost and a manufacturing cost (e.g., milling, extrusion, 3D printing, casting, forming, etc.). For example, the absolutely lightest fork arches 100 may be made from a material such as a graphene spiral. While the manufacturing costs may make the fork arches 100 impractical for mass production, specialized teams and the like will employ such fork arches 100. Conversely, an aluminum fork arch 100 will have a price point based on the manufacturing and material costs that place the aluminum fork arch 100 in a lower cost tier, while a magnesium fork arch 100 may be in a medium cost tier.

In one embodiment, the shape, thickness, one or more material removal areas 406, etc. of the fork arch 100 will be different for different categories of bicycles, such as road bicycles, gravel bicycles, mountain bikes, electric bicycles, etc., as different categories will have different torsional and/or lateral stiffness and stress thresholds. Furthermore, within any given category, there may be different riding configurations (e.g., solid frame, hardtail, full suspension, etc.), wheel sizes, rim sizes, brake types, clearances, etc.

For example, a fork arch 100 for a mountain bike may have fewer or no material removal areas 406 because weight reduction is not as high a priority as durability, stiffness, endurance, etc.

In contrast, a fork arch 100 for a road bicycle will have many areas of material removal 406, as reducing weight will take priority over any increase in stiffness, durability, endurance, etc.

The preceding detailed description is not intended to be exhaustive or to limit the embodiments to the precise forms described. Rather, example embodiments have been presented in the detailed description to enable one skilled in the art to make and use embodiments of the described subject matter. Furthermore, various embodiments have been described in various combinations. However, any two or more embodiments may be combined. Although some embodiments have been described in language specific to structural features and/or methodological acts, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed by way of illustration and as example forms of implementing the claims and their equivalents.

100: Fork arch

102: Front fork assembly

202: Right leg

204: Right lower tube

208: Upper right tube

210: Crown

212: Steering tube

214: Upper left tube

218: Left lower tube

220:Left leg

224,226: Exit Department

85:Front axle

Claims (17)

A suspension comprises: a first upper tube telescopically coupled to a first down tube; a second upper tube telescopically coupled to a second down tube; and a fork arch connecting the first down tube to the second down tube. The fork arch comprises a torsional geometry and a transverse geometry, the torsional geometry having a depth-to-width ratio greater than one, and the transverse geometry having a depth-to-width ratio less than one. The suspension of claim 1 , wherein at least a portion of the torsion geometry extends in a longitudinal direction of the bicycle. The suspension of claim 1 , wherein the depth and width of the fork arch are variable along the length of the fork arch. The suspension of claim 1 further comprising at least one material removal area, wherein the at least one material removal area is located in a position selected from the group consisting of: the torsion geometric portion, the transverse geometric portion, and a combination of the torsion geometric portion and the transverse geometric portion. A suspension as described in claim 4, wherein the at least one material removal area is selected from at least one component in the group consisting of: an opening, a thinned portion without an opening, a recessed portion without an opening, a protrusion without an opening, and a groove without an opening. The suspension of claim 1, wherein a depth of at least one portion of the torsion geometric portion is greater than a depth of at least one portion of the transverse geometric portion. A suspension as described in claim 1, wherein the first leg portion of the torsion geometric portion is asymmetric with the second leg portion of the torsion geometric portion. A suspension component comprises: a first down tube; a second down tube; and a fork arch connecting the first down tube to the second down tube, wherein the fork arch comprises a torsional geometric portion and a transverse geometric portion, wherein at least a portion of the torsional geometric portion has a depth-to-width ratio greater than one, and at least a portion of the transverse geometric portion has a depth-to-width ratio less than one. The suspension component of claim 8 further comprises at least one material removal area, wherein the at least one material removal area is located in a position selected from the group consisting of: the torsion geometric portion, the transverse geometric portion, and a combination of the torsion geometric portion and the transverse geometric portion. A suspension component as described in claim 9, wherein the at least one material removal area is selected from at least one component in the group consisting of: an opening, a thinned portion without an opening, a recessed portion without an opening, a protrusion without an opening, and a groove without an opening. A suspension component as described in claim 8, wherein a majority of the twisted geometric portion has a depth to width ratio greater than 1. A suspension comprising: a first fork leg including a first upper tube telescopically coupled to a first lower tube; a second fork leg including a second upper tube telescopically coupled to a second lower tube; and a fork arch connecting the first fork leg to the second fork leg, wherein the fork arch includes a torsional geometry and a lateral geometry, the torsional geometry having a depth-to-width ratio greater than one and the lateral geometry having a depth-to-width ratio less than one, and wherein at least one portion of the lateral geometry extends in a first direction and at least one portion of the torsional geometry extends in the first direction, wherein the at least one portion of the torsional geometry extends a greater distance than the at least one portion of the lateral geometry. The suspension of claim 12, wherein the first direction is a longitudinal direction of the bicycle. The suspension of claim 12, wherein a majority of the torsion geometry extends a greater distance in the longitudinal direction of the bicycle than a majority of the lateral geometry. A suspension as described in claim 12, wherein at least one of the torsional geometric portion and the transverse geometric portion includes at least one material removal area, and the at least one material removal area is selected from the group consisting of: an opening, a thinned portion without an opening, a recessed portion without an opening, a protrusion without an opening, and a groove without an opening. The suspension of claim 12, wherein the depth and width of the fork arch are variable along the length of the fork arch. The suspension of claim 12 further comprises: The transverse geometry comprises: A first leg portion coupled to the upper portion of the first lower tube, the first leg portion comprising: At least one portion extending distally relative to a vertical center plane; and At least one portion extending proximally toward the vertical center plane; and A second leg portion coupled to the upper portion of the second lower tube, the second leg portion comprising: At least one portion extending distally relative to the vertical center plane; and At least one portion extending proximally toward the vertical center plane; and The torsional geometry comprises: A first twisted geometric leg portion coupled to the upper portion of the first lower tube, partially coupled to the first leg portion and extending proximally toward the vertical center plane; and a second twisted geometric leg portion coupled to the upper portion of the second lower tube, partially coupled to the second leg portion and extending proximally toward the vertical center plane.