Fork Chassis Air Bleeder

Abstract

The fork assembly (100) includes a linearly fixed tube (110) and a linearly moving stanchion (116). The air bleed mechanism (128) is located within the upper portion of the fork assembly (100), preferably within the chassis crown (106) of the fork assembly (100). The air bleed mechanism (128) is configured to allow for the equalization of pressure between an internal cavity (306) located within the linearly fixed tube (110) and / or the linearly moving stanchion (116).

Description

Technical Field

[0001] This application generally relates to a suspension system for vehicles, and more specifically, but not limited to, an air bleed door assembly located in the upper portion of a bicycle fork.

Background Art

[0002] Bicycles generally include a suspension system. These suspension systems can enhance rider comfort and enable more effective power transmission to the ground, similar to those known in automotive suspensions. Air-sprung suspension systems are commonly used in mountain bikes. The front suspension system of a bicycle often includes a telescopic fork having two legs spanning the front wheel of the bicycle.

[0003] The wheel rotates around an axle connected to the lower portion of the telescopic fork. The telescopic fork includes internal components that absorb shock and typically includes at least one damper and a spring. Prior art forks often have the damper located in one leg and the spring in the other leg.

[0004] When the wheel encounters bumpy terrain, the force from the axle is transmitted to a sliding stance (e.g., a telescopic tube). These stances are operably connected to the spring and damper. The spring and damper serve to reduce the harshness of these forces and are typically structured to maintain the wheel firmly grounded to the ground, enabling efficient power transmission. As the wheel moves up and down over a ground elevation, the sliding stance moves linearly in and out from the stationary tube of the fork, and the spring and damper provide shock absorption and damping.

[0005] Current fork designs include an internal cavity, which is sealed to retain lubricating fluid and remove debris that could contaminate the suspension system. Known conventional forks, such as right-side up forks or standard forks, and inverted forks, include such sealed internal cavities.

[0006] Manufacturers may incorporate air springs within the spring leg. This can be achieved by incorporating a partition and plunger within the spring leg. In this design, the plunger divides the internal cavity into a spring cavity on a first side of the plunger and a non-spring cavity on a second side of the plunger. An air adjustment port may be used to adjust the pressure inside the spring cavity, and thus the spring effect provided by the plunger acts on the air spring cavity. The non-spring cavity is typically considered to contain sealed air.

[0007] The pressure within the non-spring cavity (also known as the sealed air cavity) affects the overall spring constant. The non-spring cavity can negatively impact the suspension characteristics of the fork, depending on the air pressure trapped inside. Significant changes in temperature or height, compared to a sealed manufacturing facility, affect the pressure within the non-spring cavity. The pressure within the sealed air cavity can be positive (i.e., higher than atmospheric pressure) or negative (i.e., lower than atmospheric pressure).

[0008] The positive pressure contained within the non-spring cavity is further compressed as the stanchion moves into the fixed tube, as happens when encountering a bump during travel. This pressure increase within the non-spring cavity exerts an increased force on the slide seal located between the stanchion and the stationary tube. This increased force compressing the seal typically increases friction between the stanchion and the fixed tube, thereby degrading the overall system performance.

[0009] To minimize such undesirable system performance and characteristics, riders of earlier systems with fork designs featuring tool-free air adjustment ports often adjust the pressure in the spring cavity to compensate for changes in pressure in the non-spring cavity. In fork designs without tool-free adjustment components, riders often do not adjust the air and have to deal with this undesirable spring constant and / or suspension characteristics.

[0010] U.S. Patents 9,739,331, 10,746,250, and 11,293,513 instruct the integration of bleeder valves into the downward-moving portion of the fork assembly. Fox Factory, ROCKSHOX / Sram, and MRP currently offer mountain bike forks with bleeder valves located in the downward portion of the fork. These bleeder valves extend outward from the downward tube and function via a push-to-bleed system (for example, the user presses a button down, opening the valve and releasing air).

[0011] While these earlier-technical bleeder valves function in a handcrafted way to release pressure from a sealed cavity inside the fork, these designs have numerous drawbacks. For example, these earlier-technical bleeder valves are known to unnecessarily leak oil from the assembly as air escapes.

[0012] Furthermore, these prior-technology bleeder valves are frequently damaged by contact with obstacles and debris on the trail, and are often accidentally activated. It is known that riders can inadvertently block the bleed passage when pressing down the bleed button, because the rider's finger extends over the bleed passage while pressing down the bleed button.

[0013] Some motorcycles include a bleeder valve located in the upper seal cap of the fork. These bleeder valves often require tools to operate. This bleeder location is considered suitable for motorcycles due to the large diameter of the telescopic tubing and the overall large fork size. However, this bleeder location is undesirable on bicycles, which have an adjustment knob on top of the seal cap, because the adjustment knob would have to be significantly smaller to accommodate the bleed valve in the limited space available on top of the seal cap of a typical bicycle, so the adjustment knob would likely be too small to operate easily. [Overview of the Initiative] [Problems that the invention aims to solve]

[0014] Therefore, further technological development is desired. [Means for solving the problem]

[0015] One embodiment of this application is directed to a fork assembly including an air bleeder located in the upper stationary portion of the fork assembly. The air bleeder is configured to allow enclosed air to escape from a sealed cavity located inside the fork assembly. The air bleeder may be located within the chassis crown. A first air bleeder may be located within the chassis crown at the first leg of the fork, and a second air bleeder may be located within the chassis crown at the second leg of the fork.

[0016] A further embodiment of this application is directed to an air bleeder assembly. This air bleeder assembly is configured such that when a bleeder control member, such as a knob, is pulled outward, air can be released from a sealed cavity within a fork assembly. This air bleeder assembly may include a plunger located within a fluid passage.

[0017] The plunger can slide between a first position and a second position within the fluid passage. The air blower assembly can be configured to be closed when the proximal end of the sliding plunger slides inward to a first position where this proximal end blocks the fluid passage.

[0018] An air bleeder assembly can be configured in an open configuration (e.g., a bleed configuration) by sliding the plunger outward to a second position where the plunger cannot completely block the fluid passage, thereby allowing air to move through the fluid passage. An air bleeder assembly may include an auto-bleed configured to release air from a sealed internal cavity without user intervention.

[0019] Further embodiments of this application include original bicycle fork air bleeding devices, systems, and methods. Further embodiments, inventions, forms, purposes, features, advantages, aspects, and benefits of this application are described or become apparent from the description and drawings contained herein.

[0020] The description in this specification refers to the accompanying drawings, where similar reference numerals indicate the same parts across multiple drawings. [Brief explanation of the drawing]

[0021] [Figure 1] A perspective view of an exemplary bicycle fork assembly according to the first embodiment of this application is shown. [Figure 2] A rearward perspective view of the upper portion of the fork assembly is shown, illustrating an exemplary bleed valve located on the chassis crown of the fork assembly. [Figure 3] Draw a cutaway diagram of an example spring leg for a fork assembly. [Figure 4A] A cross-sectional view of an exemplary air bleeder assembly according to a further embodiment of this application is shown, with the air bleeder assembly depicted in an open configuration. [Figure 4B]Draw a cross-sectional view of the air bleeder assembly of Figure 4A in a closed configuration. [Figure 5] Draw an enlarged view of the chassis crown of Figure 3, including a notch view of the spring leg. [Figure 6] Draw a perspective view of the fork assembly biased rearward of the chassis crown, depicting the damper leg in a partially cut-away chassis crown. [Figure 7] Draw a top view of the fork assembly of Figure 1. [Figure 8] A perspective view of an exemplary crown ring having a threaded hole. [Figure 9] Draw a perspective view of an exemplary plunger of the air bleeder assembly of Figures 4A - 4B. [Figure 10A] Draw a perspective view of an exemplary valve body of the air bleeder assembly. [Figure 10B] Draw a cross-sectional view of the valve body along the longitudinal axis of the valve body of Figure 10A. [Figure 11] A side cross-sectional view of a bicycle fork cut away at the bleeder. [Figure 12] A bottom cross-sectional view of a bicycle fork cut away at the bleeder. [Figure 13] A cross-sectional view of the fork emphasizing the damper cartridge.

Best Mode for Carrying Out the Invention

[0022] The accompanying drawings incorporated herein and constituting a part thereof illustrate various aspects and features of the present application. However, the present application should not be construed as limited to the specific embodiments depicted in the drawings.

[0023] For the purpose of facilitating an understanding of the principles of the present invention, embodiments shown in the drawings will be described with reference and using specific terminology. However, it will be understood that this is not intended to limit the scope of the invention. Rather, modifications and further alterations of the illustrated devices, as well as further applications of the principles of the invention as shown therein, are intended to be as commonly conceived by those skilled in the art to which the present invention relates.

[0024] As used herein, the terms “fixed,” “linearly fixed,” and “non-moving” in relation to various components are intended to include components that are substantially fixed with respect to linearly moving stanchions. Generally, these fixed components are considered fixed with respect to the shock absorption system of the fork assembly. However, it should be understood that such “fixed” and “linearly fixed” components can move during steering and may include a variety of movements depending on the forces acting on the fixed components, particularly those encountered when driving on uneven terrain.

[0025] Referring here to Figure 1, an exemplary bicycle fork assembly 100 includes a front surface 102, a rear surface 104, an upper portion 101, and a lower portion 103. The fork assembly 100 also includes a chassis crown 106, a steering tube 108, and two legs 124, 126. The first leg 124 extends substantially parallel to the second leg 126.

[0026] The axle 122 is configured to rotatably receive a wheel (not shown) on it. The axle 122 passes through the wheel hub (not shown), and the wheel can rotate around the axle 122. The axle may include a removable skewer (not shown). The axle 122 extends between and connects to a first leg 124 and a second leg 126. Near their distal or lower ends, the first leg 124 and the second leg 126 each include a fixed component 110 and a movable component 116. When fully assembled on a bicycle, the first leg 124 and the second leg 126 straddle both sides of a wheel (not shown).

[0027] The bicycle fork assembly 100 is depicted as having an inverted design. In this inverted design, the moving component 116 is located in the lower portion 103 of the fork assembly 100, and the fixed or immovable component 110 is located in the upper portion 101 of the fork assembly 100.

[0028] The fixed components 110 are depicted as taking the form of linearly fixed hollow tubes 110. Referring here to Figures 1, 3, and 5, each fixed tube 110 is depicted as extending between a proximal end 112 and a distal end 114. The proximal end 112 of each fixed tube 110 is fixedly connected to the chassis crown 106. The fixed tubes 110 can be fixedly connected to the chassis crown 106 via adhesive. However, it is also intended that the fixed tubes 110 can be fixedly connected to the chassis crown 106 through various joining techniques, including welding.

[0029] Furthermore, mechanical fasteners may be integrally formed with the chassis crown 106 and the like. The steering tube 108 may be fixedly connected to the chassis crown 106. Thus, the stationary upper portion 101 of the fork assembly 100 may include the chassis crown 106, the hollow tube 110, and the steering tube 108.

[0030] The linearly moving component 116 is depicted as taking the form of a hollow tube and is called a stanchion 116.

[0031] The tube is usually cylindrical, but it may also have other cross-sectional shapes such as oval or hexagonal. Referring here to Figures 1 and 12, the stanchion 116 extends between a proximal end 118 and a distal end 120 (Figure 3). The axle 122 is attached to the stanchion 116 at the distal end 120. The proximal end 118 of each stanchion 116 is depicted as being slidably received inward within the internal passage of the distal end 114 of a fixed tube 110.

[0032] As best shown in Figures 3 and 12, the outer diameter of the proximal end 118 of the stanchion 116 can be tightly received by the inner diameter of the hollow passage of the fixed tube 110. A slide seal (not shown) may be located where the stanchion 116 and the fixed tube 110 interact, and may be located between the linearly fixed inner wall of the tube 110 and the linearly moving outer wall of the tube 116. The stanchion 116 is configured to move inward and outward relative to the fixed tube 110 along axis 121, which can be described as a linear reciprocating motion with irregular timing and distance intervals.

[0033] The fork assembly 100 has a suspension assembly operably connected between a linearly moving stanchion 116 and a fixed chassis crown 106. As shown in Figures 3, 5, and 6, the suspension assembly may include a spring assembly located in the hollow internal cavity of the first leg 124 and a damper assembly located in the hollow internal cavity of the second leg 126.

[0034] The first leg portion 124 will hereafter be referred to as the spring leg portion 124, and the second leg portion 126 will hereafter be referred to as the damper leg portion 126.

[0035] Referring again to Figure 1, as is well known, the damper adjustment knob 132 can be located above the damper leg 126, and the spring adjustment knob 134 can be located above the spring leg 124.

[0036] When the wheel encounters an obstacle such as a bump or uneven ground, a Y-axis force along the axle 121 is transmitted from the wheel to the axle 122 and then to the stanchion 116. As the movable stanchion 116 is pushed upward into the fixed tube 110, the suspension system, including the spring assembly in the spring leg 124 and the damper assembly in the damper leg 126, absorbs the severe impact or "shock," which helps keep the wheel firmly in place relative to the ground, provides efficient power transmission, and improves user comfort.

[0037] An inappropriate amount of air pressure within the sealed internal cavity of the fork assembly 100 can be caused by changes in temperature and / or height. Such inappropriate air pressure can adversely affect the suspension characteristics, particularly the spring constant. The air blower assemblies 128, 130 are configured to selectively allow fluid flow between the sealed internal cavity and the external atmosphere, thereby equalizing the pressure within the sealed internal cavity to atmospheric pressure.

[0038] The fork assembly 100 includes an air bleeder assembly 128 located on the stationary upper portion 101 of the fork assembly 100. The air bleeder assembly 128 may be located on the chassis crown 106.

[0039] Referring to Figures 1 and 3, the air bleeder assembly 128 is depicted as being located on the spring leg 124 and is configured to selectively allow air to escape from a sealed internal cavity of the spring leg 124 to the outside atmosphere. The sealed internal cavity can take the form of a non-spring-filled air cavity 306.

[0040] The air bleeder assembly 130 is located on the chassis crown 106 above the damper leg 126 and can selectively allow air to escape from the sealed internal cavity of the damper leg 126 to the outside atmosphere. The sealed internal cavity of the damper leg 126 can take the form of a sealed air cavity 602, as best shown in Figure 6.

[0041] The applicants discovered that by positioning the air bleeder assemblies 128, 130 within the chassis crown 106, oil leakage from there can be prevented. The applicants found that oil located inside the fork assembly 100 moves downward to the lower portion 103 of the legs 124, 126, and the air bleeder assemblies 128, 130 are positioned towards the upper part of the legs 124, 126. Furthermore, positioning the air bleeder assemblies 128, 130 within the chassis crown 106 provides the user with easier access to the bleeder assemblies 128, 130 and reduces the possibility of damage from contact with obstacles and debris during driving. This occurs because the height of the bleeder assemblies 128, 130 is increased compared to the bleeder assemblies of known prior art devices.

[0042] As best illustrated in Figure 2, the air bleeder assemblies 128 and 130 each include an externally accessible actuator 206. This actuator 206 is depicted as taking the form of a pull knob 206. The pull knob 206 is preferably located adjacent to the damper adjustment knob 132 and the spring adjustment knob 134 and oriented substantially perpendicular to them.

[0043] The location of the pull knob 206 is considered highly advantageous because users are familiar with the adjustment knobs 132 and 134 and can easily locate the nearby pull knob 206. This location of the pull knob 206 allows the damper adjustment knob 132 and the spring adjustment knob 134 to occupy the limited space within the chassis crown above the damper leg 126 and the spring leg 124, respectively.

[0044] The air blower assemblies 128, 130 may include an outer protective flare 202. The protective flare 202 projects outward from the chassis crown 106 toward the outer surface of the pull knob 206 and extends substantially around the outer diameter of the pull knob 206.

[0045] The protective flare 202 is configured to protect the pull knob 206 and the air bleeder assemblies 128, 130 from impacts and debris that may be encountered during use. The protective flare 202 includes finger grooves 204 on both sides of the pull knob 206. The finger grooves 204 are configured to allow the user to easily grip the pull knob 206.

[0046] Referring briefly to Figures 3 and 12, the spring leg 124 includes an air spring assembly comprising a shaft 308, a partition 304, a spring plunger 312, and a spring 310. An air spring cavity 314 is located below the spring plunger 312, and a sealed air non-spring cavity 306 is formed above the spring plunger 312. An air blower assembly 128 allows the user to equalize the pressure in the non-spring cavity 306 of the spring leg 124 with atmospheric pressure.

[0047] For example, if the air pressure inside the non-spring cavity 306 is higher than atmospheric pressure, it can negatively affect the suspension characteristics and increase friction in the suspension system. The air blower assembly 128 allows the user to vent air from the non-spring cavity 306 to the atmosphere, thereby releasing pressure from inside the non-spring cavity 306 and counteracting the negative effects.

[0048] It has been found that negative pressure within the non-spring cavity 306 relative to atmospheric pressure can be advantageous. This negative pressure can help offset the initial static friction of the system. Specifically, the vacuum generated within the non-spring cavity 306 can help pull the stanchion into the fixed tube. Furthermore, including negative pressure within the non-spring cavity 306 can be used to compensate for the pressure increase within the non-spring cavity 306 when the suspension is compressed.

[0049] A spring cavity filling port (not shown) can be fluidly connected to the air spring cavity 314. The user can adjust the pressure in the air spring cavity 314 by utilizing the air spring filling port and a suitable pressure source such as a bicycle pump, CO2 tubing, or air compressor.

[0050] This spring cavity filling port may be located near the spring adjustment knob 134. This exemplary spring leg 124 includes a spring cavity filling port that is in fluid communication with an air spring cavity 314. The air spring cavity 314 is shown as a spring plunger 312. The air blower assembly 128 is in fluid communication with a sealed air non-spring cavity 306, which is located and illustrated above the spring plunger 312.

[0051] The air bleeder assemblies 128 and 130 may allow the user to intentionally create a negative pressure (sub-atmospheric pressure) environment within the enclosed air cavity of the fork assembly 100. This can be achieved by the user activating one or more of the bleeder assemblies 128 and 130 after compressing the fork assembly 100.

[0052] In this way, when the fork assembly 100 is compressed, air is discharged from the non-spring cavity 306 of the spring leg 124 and / or from the sealed air cavity 602 of the damper leg 126, depending on whether the user activates one or both of the bleeder assemblies 128 and 130. When the user stops compressing the fork assembly 100, the stanchion moves outward from the fixed tube, creating negative pressure in one or more sealed air cavities.

[0053] Referring to Figure 6, the damper leg 126 includes a damper assembly. This damper assembly may include a damper cartridge 604 located within the hollow internal cavity of the damper leg 126. This damper cartridge 604 is shown as a sealed oil containment unit. An exemplary cartridge assembly is depicted in U.S. Provisional Patent Application No. 63 / 417,527, filed October 19, 2022, entitled TORSION RESISTANT BICYCLE FORK, the disclosure of which is fully incorporated herein.

[0054] As shown in the figure, the sealed air cavity 602 is defined between the damper cartridge 604 and the fixed tube 110. The air blower assembly 130 allows the user to equalize the pressure in the sealed air cavity 602 with the external atmosphere. This equalization is achieved by exhausting air from the sealed air cavity 602 to the atmosphere via the damper leg 126, or by introducing air from the atmosphere into the sealed air cavity 602, depending on the pressure in the sealed air cavity 602 relative to atmospheric pressure.

[0055] The internal components of the air bleeder assembly 130 are substantially the same as those of the air bleeder assembly 128. The main difference between the air bleeder assembly 128 and the air bleeder assembly 130 lies in their mounting location. Specifically, the air bleeder assembly 128 is located on the spring leg 124 and is configured to allow for pressure equalization between the enclosed air and atmospheric pressure within the spring leg 124. In contrast, the air bleeder assembly 130 is located on the damper leg 126 and is configured to allow for pressure equalization between the enclosed air and atmospheric pressure within the damper leg 126.

[0056] An exemplary air bleeder assembly 128 is described here with reference to Figure 4A. The air bleeder assembly 128 is configured to selectively fluidize the enclosed air non-spring cavity 306 to the outside atmosphere. When the air bleeder assembly 128 is in an open configuration 436 (as depicted in Figure 4A), fluid flow is permitted between the non-spring cavity 306 and the outside atmosphere. Thus, the pressure inside the non-spring cavity 306 becomes equal to atmospheric pressure.

[0057] If the pressure inside the non-spring cavity 306 is higher than atmospheric pressure, air will flow from the non-spring cavity 306 into the atmosphere. If the pressure inside the non-spring cavity 306 is lower than atmospheric pressure, air will flow from the atmosphere into the non-spring cavity 306.

[0058] The air blower assembly 128 includes a valve body 408, a fluid passage 414, and a plunger 420. The valve body 408 is shown extending through the outer wall 302 of a linearly fixed tube 110 within the upper fork. The valve body 408 may be located on the chassis crown 106 of the fork assembly 100.

[0059] The valve body 408 extends between the first end 410 and the second end 412. The second end 412 of the valve body 408 is depicted as extending outward from the outer housing 402 of the chassis crown 106. The valve body 408 is depicted as extending through the outer housing 402 of the chassis crown 106 and the outer wall 302 of the linearly fixed tube 110.

[0060] The valve body 408 is removably connected to the fork assembly 100. The first end or inner end 410 of the valve body 408 is depicted as screw-engaging with a female threaded hole 406 extending through the side wall of the crown ring 404. Referring to Figures 4A, 8, and 10A–10B, the valve body 408 is depicted as including a male thread 1004 positioned adjacent to the first end 410. These threads 1004 are configured to screw-engage with the female threads of the threaded hole 406 in the crown ring 404, thereby securely fastening the valve body 408 within the fork assembly 100.

[0061] Referring here to Figures 4A and 8, the crown ring 404 is fixedly connected to the proximal end 112 of the linearly fixed tube 110. Preferably, the crown ring 404 is inserted into the hollow interior of the linearly fixed tube 110 at the proximal end 112, with the flange surface 804 extending radially outward below the crown ring 404 in contact with the proximal end 112.

[0062] The crown ring 404 can be fixedly attached to the linearly fixed tube 110 by various bonding techniques such as adhesives, welding, brazing, and / or mechanical fasteners. The crown ring 404 includes an internal female thread 802 configured to engage with the male thread of the upper seal cap 440.

[0063] Referring here to Figures 4A and 10A-10B, the air bleeder assembly 128 may include several sealing members, including a tube seal 435, a dust seal 433, and a main bleed seal 428. In one embodiment, the seals 435, 433, and 428 include O-rings formed of beech wood N. However, various other sealing members and materials may also be used.

[0064] The tube seal 435 is positioned to surround the outer surface of the valve body 408. When the valve body 408 is screwed into the hole 406 of the crown ring 404, the tube seal 435 is pressed tightly against the outside of the valve body 408 and the outer wall 302 of the fixed tube 110, and may also contact the outer housing 402 of the chassis crown 106.

[0065] The valve body 408 may include an external projection 1009 that can contact the tube seal 435, which presses the tube seal 435 against the seal receiving groove 437 in the outer wall 302. The dust seal 433 will be described later with reference to Figure 4B, and the main bleed seal 428 will be described later with reference to the plunger 420.

[0066] Referring here to Figures 4A and 10A–10B, the fluid passage 414 extends from the non-spring-sealed air cavity 306 to the atmosphere outside the fork assembly 100. The valve body 408 is depicted as having a substantially hollow interior, which at least partially defines the fluid passage 414. The fluid passage 414 is depicted as extending from the first end 410 to the second end 412 of the valve body 408.

[0067] The fluid passage 414 may include a first diameter 416 located relatively close to the first end 410, an outlet diameter 419 located relatively close to the second end 412, and an expanded diameter 418 located between the first diameter 416 and the outlet diameter 419. As shown in the figure, the expanded diameter 418 has a larger diameter and cross-sectional area than the first diameter 416. The outlet diameter 419 is depicted as having a smaller diameter and cross-sectional area than the first diameter 416.

[0068] Referring to Figures 4A, 9, and 10B, the plunger 420 is slidably received within the passage 414. The plunger 420 functions as a valve, providing selective opening and closing of the passage 414. The plunger 420 has a substantially cylindrical form composed of multiple cylindrical segments having different outer diameters. However, the plunger 420 can take various forms and have various shapes, and can selectively block the passage 414 to prevent the passage of air.

[0069] The plunger 420 is sized and configured to extend between a proximal end 422 and a distal end 424. When the plunger 420 is assembled by being inserted into the passage 414 of the valve body 408, the proximal end 422 of the plunger 420 is positioned near the first end 410 of the valve body 408, and the distal end 424 of the plunger 420 is positioned near the second end 412 of the valve body 408.

[0070] The main bleed seal 428 can externally surround the plunger 420 near its proximal end 422. A reduced-diameter main bleed seal receiving groove 426 is formed at the proximal end 422 of the plunger 420, away from the distal end 424. The seal receiving groove 426 is depicted as being located between the expanded diameter portions 902.

[0071] The distal end 424 of the plunger 420 includes a diameter 906. The expanded diameter portion 902 is depicted as being larger in size and cross-sectional area than the diameter 906, and the diameter 906 is depicted as being larger in size and cross-sectional area than the diameter 904 of the seal receiving groove 426.

[0072] The pull knob 206 is attached to the distal end 424 of the plunger 420 and to the plunger 420 via a screw 432. Thus, movement of the pull knob 206 causes movement of the plunger 420. However, it is also intended that the pull knob 206 may be attached to the plunger 420 via various fasteners, adhesives, fixtures, etc. For example, the distal end 424 of the plunger 420 may be threaded so that the pull knob 206 is screwed into it, or an interference-type fit may be used.

[0073] Referring to Figures 4A and 4B, the pull knob 206 may have a cap-shaped appearance. The pull knob 206 has an outer surface 454, an inner surface 452, a dust cover 430 extending from the inner surface 452 away from the outer surface 454, and an inner cavity 431. The inner cavity 431 is defined between the inner surface 452 and the inner wall of the dust cover 430. A gripping rim 429 is positioned around the pull knob 206 toward the outer surface 454.

[0074] The plunger 420 is slidably received within the fluid passage 414. The plunger 420 slides along the axis 1008 between a first position in which the plunger 420 blocks the fluid passage 414 and a second position in which the plunger does not completely block the fluid passage 414.

[0075] When the plunger 420 is in the first position or the closed position, the air bleeder assembly 128 is in the closed configuration 450 shown in Figure 4B. In this first position, the proximal end 422 of the plunger 420 is located at the first end 410 of the valve body 408. In this first position, the plunger 420 completely blocks the fluid passage 414.

[0076] As shown in the figure, in this first position, the main bleed seal 428 is firmly pressed between the plunger 420 at the plunger diameter 904 and the inner surface 456 of the valve body 408, and is tightly engaged with them. In this way, the plunger 420 and the main bleed seal 428 completely fill and seal the first diameter of the passage 414, thereby preventing the flow of air through the passage 414.

[0077] When the plunger 420 is positioned in the second or open position, the air bleeder assembly 128 is placed in the open configuration 436 shown in Figure 4A. In this second position, the proximal end 422 of the plunger 420 slides away from the first end 410 of the valve body 408 toward the second end 412, creating a gap between the plunger 420 and the first end 410 of the valve body 408.

[0078] In this second position, the proximal end 422 of the plunger 420 is positioned within the enlarged diameter 418 of the passage 414, and the main bleed seal 428 is positioned spaced apart from the inner surface of the valve body. When positioned in this manner, the bleed seal does not contact the inner surface 456 of the valve body 408 and does not engage with it in a sealed manner because the diameter of the enlarged diameter portion 418 of the passage 414 is larger than the outer diameter of the main bleed seal 428.

[0079] When the plunger 420 is positioned in this second position, the passage 414 is not completely blocked. Rather, there is a passage 415 defined between the main bleed seal 428 and the inner surface 456 of the valve body 408. When the air bleeder assembly 128 is positioned in an open configuration 436 by sliding the plunger 420 to the second position, the trapped air in the non-spring cavity 306 can escape to the atmosphere through the passage 415.

[0080] The seal receiving groove 1006 may be located within the valve body 408, away from the first end 410 toward the second end 412. The dust seal 433 can be positioned within the dust seal groove 1006 to surround and enclose the valve body 408. When the air bleeder assembly 128 is positioned in the closed configuration 450 (Figure 4B), the inner surface 452 of the pull knob 206 can contact the second end 412 of the valve body 408, and the dust cover 430 of the pull knob 206 extends over and surrounds the dust seal 433. The dust seal 433 provides a sealed engagement between the inner surface of the dust cover 430 and the valve body 408. The dust seal 433 is configured to prevent debris from entering the air bleeder assembly 128 when the air bleeder assembly 128 is in the closed configuration 450.

[0081] Preferably, the air bleeder assembly 128 includes a compression spring 434 that biases the plunger 420 to a first (closed) position, in which the air bleeder assembly is in a closed configuration 450. The spring 434 is depicted as extending between a spring locking projection 908 on the plunger 420 and a spring locking projection 1002 inside the valve body 408. The spring 434 can maintain the air bleeder assembly 128 in the closed configuration 450 unless a force sufficient to overcome the spring 434 is applied.

[0082] If the user decides to release air from the non-spring cavity 306, the user reaches for the pull knob 206. The user can place one finger in each of the finger receiving grooves 204 and grasp the gripping rim 429 of the pull knob 206. The user pulls the pull knob 206 outward, away from the housing 402, and overcomes the spring 434.

[0083] When the user pulls the pull knob 206, the proximal end 422 of the plunger 420 slides toward the expanded diameter 418. The spring 434 is compressed as the plunger 420 moves outward toward the second position. Specifically, the spring 434 is compressed between a spring locking projection 908 on the plunger 420 and a spring locking projection 1002 inside the valve body 408.

[0084] The user continues to pull the pull knob 206 outward until the proximal end 422 of the plunger 420 reaches the expanded diameter 418 and the plunger 420 is positioned in the second open position. Once the user moves the plunger 420 to the second position, the plunger 420 and the main bleed seal 428 do not completely block the passage 414, leaving the air bleeder assembly 128 in an open configuration 436, which allows air to escape from the non-spring cavity 306 through the passage 415 into the atmosphere.

[0085] When the plunger 420 is in the second position and released by the user, the spring 434, which was compressed at this time, expands linearly outward, moving the plunger linearly proximal back to the first position and returning the air bleeder assembly 128 to the closed configuration 450. In this way, the air bleeder assembly 128 can be operated without tools. Furthermore, the pull-out-to-bleed design of the air bleeder assembly 128 significantly reduces the possibility of the user's fingers blocking the bleed passage, as can occur with the push-in bleed design of prior art.

[0086] In one exemplary embodiment, the air bleeder assembly 128 may be configured to include an automatic bleed function configured to release air from the non-spring cavity 306 without user intervention. As previously mentioned, an increase in the pressure inside the non-spring cavity 306 compared to atmospheric pressure can result in undesirable suspension characteristics. When the air pressure inside the non-spring cavity 306 increases compared to atmospheric pressure, a force ("pneumatic force") is applied to the proximal end 422 of the plunger 420. A compression spring 434 is configured to exert an expandable force ("spring force") on the plunger 420, which counteracts the pneumatic force. This spring 434 can bias the air bleeder assembly 128 into a closed configuration.

[0087] The automatic bleed function is activated by selecting a spring 434 configured to exert a spring force on the plunger 420 that is less than or equal to the pneumatic force exerted on the plunger 420 when bleeding may be desirable. For example, a bleed threshold pressure may be determined, which is the pressure at which the user is likely to want to bleed the non-spring cavity 306. Once the bleed threshold pressure is determined, the pneumatic force on the plunger 420 may be determined. A compression spring 434 may then be selected that exerts a spring force less than or equal to the pneumatic force at the bleed threshold pressure.

[0088] Thus, when the air pressure in the non-spring cavity 306 rises to the bleed threshold pressure, the pneumatic force overcomes the spring force and compresses the spring, causing the plunger 420 to move linearly distally to a second position, and the air bleeder assembly 128 to an open configuration 436. The bleeder assembly 128 remains in this open configuration 436 until the pressure inside the non-spring cavity 306 drops to a level where the spring force exerted on the plunger 420 by the spring 434 exceeds the pneumatic force exerted on the proximal end 422 by the pneumatic force. When the spring force exceeds the pneumatic force, the plunger 420 moves linearly proximal to return the plunger 420 to the first position, and the air bleeder assembly is placed in a closed configuration 450.

[0089] The fork assembly 100 has been described herein as including a spring leg 124 to which an air bleeder assembly 128 is attached, and a damper leg 126 to which an air bleeder assembly 130 is attached. However, depending on the specific design parameters and fork structure, the air bleeder may be located on only one leg, and the other leg may not include an air bleeder.

[0090] Alternatively, both legs may include a single air bleeder, or one or more legs may include multiple air bleeders. A spring 434 of varying forces may be provided with the air bleeder assembly 128, allowing the user to induce automatic bleeding in response to various internal pressures.

[0091] The threads 1004 allow the air bleeder assembly 128 to be easily removed from the fork assembly 100, enabling the user to replace the spring 434. This removableness, in addition to easy repairability, affects the adjustability of the device. Furthermore, the air bleeder assembly 128 may be supplied as a standalone component that can be retrofitted to various forks, or it may be supplied together with the fork assembly 100.

[0092] Exemplary materials are described here. The chassis crown 106, linearly fixed tube 110, stanchion 116, axle 122, pull knob 206, valve body 408, crown ring 404, and steering tube 108 may be manufactured from aluminum. The plunger 420 may be formed from brass, and the sealing members (e.g., 433, 435, 428) may have a polymer structure.

[0093] The chassis crown 106 may be made of 6061-T6511 aluminum, and the fixed tube 110 may be made of 7075-T6 aluminum. The stanchion 116 may be formed of 7075-T6 aluminum. The crown ring 404 may be formed of 6061-T6 aluminum.

[0094] The valve body 408 may be made of 6061-T6 aluminum. The pull knob 206 may be made of 6061-T6 aluminum, and the plunger 420 may be formed from alloy 360 brass. The sealing member may be made of Buna N, a synthetic copolymer made of acrylonitrile and butadiene, which is very commonly used for O-rings.

[0095] This specification has discussed specific, non-limiting, exemplary materials and dimensions for the bleeder valve assemblies 128, 130 and the fork assembly 100 as a whole. However, it is intended that the assemblies and components described herein may include a variety of dimensions and material configurations.

[0096] For example, many of the components discussed herein include aluminum structures, as such structures were found to offer an acceptable strength-to-weight ratio at a reasonable cost. However, a variety of other materials may be used, such as composite materials (e.g., carbon fiber, Kevlar, etc.), titanium, magnesium, steel, and their alloys.

[0097] The dimensions discussed herein and shown in the fully incorporated provisional application may be modified depending on the specific application and design parameters. Although the fork assembly 100 is described herein as a bicycle fork assembly 100, it is intended that this unique fork assembly 100 and air bleeder assemblies 128, 130 may also be used in other vehicles having a fork chassis / suspension. For example, the fork assembly 100 could be used in bicycles, motorcycles, various three-wheeled trike-type vehicles, and so on.

[0098] While the present invention has been described in relation to what is considered to be the most practical and preferred embodiment at present, it should be understood that the present invention is not limited to the disclosed embodiments. Conversely, the present invention is intended to encompass a variety of modifications and equivalent configurations that fall within the spirit and scope of the appended claims, the scope of which is most broadly interpreted to include all modifications and equivalent configurations as permitted by law.

[0099] The use of the words preferred, desirable, or preferred in the above description indicates that the features described in this way may be more desirable, but they are not necessarily required, and any embodiment lacking them may be intended to fall within the scope of the invention as defined by the subsequent claims. The term “fluid” should be interpreted in its broadest sense to include all fluid substances, whether gaseous or liquid.

[0100] When interpreting the claims, if words such as “one (a),” “one (an),” “at least one,” “multiple,” or “at least a portion” are used, unless otherwise stated in the claim, it is intended that the claim is not intended to be limited to just one item or one specific quantity of an item. Unless otherwise stated in the claim, the expression “at least one of X, Y, and Z” should be interpreted as including both conjunctive and separable forms.

[0101] Specifically, the expression "at least one of X, Y, and Z" is intended to include the following permutations of X, Y, and Z: X only; Y only; Z only; X and Y; X and Z; Y and Z; and X, Y, and Z. Furthermore, where the expressions "at least a portion" and / or "a portion" are used, the items may include a portion and / or the entire item, unless otherwise stated.

[0102] [Implementation Method] (1) An air bleed system, A fork (100) including a linearly fixed component (110), wherein the linearly fixed component includes a linearly fixed tube (110), and the fork (100) A linearly moving component (110) including a linearly moving tube (110), wherein the linearly moving tube (110) extends downward from the linearly fixed tube (110), the proximal end (118) of the linearly moving tube (116) slides into engagement with the linearly fixed tube (110), the linearly moving tube (116) is configured to move linearly relative to the linearly fixed component (110), and the distal end (120) of the linearly moving tube (116) is configured to hold a wheel, An internal cavity (306) defined inside the linearly fixed tube (110) and / or the linearly moving tube (116), An air bleed assembly (128) located on the linearly fixed component (110), wherein the air bleed assembly (128) is configured to selectively fluidize the internal cavity (306) with the external atmosphere, depending on the open configuration of the air bleed assembly (128), An air bleed system, including... (2) The air bleed system according to Embodiment 1, further comprising a spring cavity (314) filling port that is in fluid communication with the air spring cavity (306). (3) The air bleed system according to Embodiment 1, wherein a portion of the air bleed assembly (128) extends through the outer wall (302) of the linearly fixed tube (110), and the air bleed assembly (128) is in fluid communication with the sealed air non-spring cavity (306). (4) The air bleed system according to Embodiment 3, wherein the air bleed assembly (128) extends through the chassis crown (106). (5) The air bleed system according to Embodiment 1, wherein the air bleed assembly (128) further includes a control knob (206), at least a portion of which extends outward from a linearly fixed tube (110), and when the control knob (206) is moved outward away from the internal cavity (306), the air bleed assembly (128) transitions to the open configuration.

[0103] (6) The air bleed assembly (128) A valve body (408) extending between a first end (410) and a second end (412), the valve body defining a fluid passage (414) extending between the first end (410) and the second end (412), A plunger (420) having a proximal end (422) and a distal end (424), wherein the plunger (420) is arranged to slide inside the fluid passage (414), and the control knob (206) is operably connected to the distal end (424) of the plunger (420), Includes, The air bleed system according to Embodiment 5, wherein the proximal end (422) of the plunger (420) is configured to block the fluid passage (414) when the air bleed assembly (128) is in a closed configuration, and fluid communication between the internal cavity (306) and the atmosphere is prevented when the air bleed assembly (128) is in the closed configuration. (7) The air bleed system according to Embodiment 6, wherein the plunger (420) further includes a seal (428) having a periphery and extending around the periphery of the plunger (420) near the proximal end (422) of the plunger (420), the seal (428) being configured to engage tightly between the plunger (420) and the valve body (408) when the air bleed assembly (128) is in the closed configuration. (8) The air bleed system according to Embodiment 7, wherein the proximal end (118) of the linearly moving tube (116) is slidably received internally by the distal end (114) of the linearly fixed tube (110), and a slide seal is located between the inner wall of the linearly fixed tube (110) and the outer wall of the linearly moving tube (116). (9) The air bleed system according to Embodiment 1, wherein the internal cavity (306) includes a sealed air cavity located within the damper leg, and the air bleed assembly (128) further includes a second air bleed assembly (128) located in the chassis crown (106) of the damper leg (126) and in the chassis crown (106) of the spring leg (124), the second air bleed assembly (128) being configured to selectively release air from the sealed air cavity of the spring leg (124). (10) The air bleed system according to Embodiment 9, wherein the fork (100) includes a bicycle fork, further including an air adjustment knob (134) located above the non-spring cavity (306) of the spring leg, and further including a damper adjustment knob (132) located above the damper leg (126).

[0104] (11) A bicycle air bleed assembly, A bicycle fork assembly (110) including an internal cavity (306), A valve body (408) extending between the first end (410) and the second end (412), A fluid passage (414) extending into the interior of the valve body (408), wherein the passage (414) is in fluid communication with the internal cavity (306) toward the first end (410) of the valve body (408), and the passage (414) is in fluid communication with the outside atmosphere toward the second end (412) of the valve body (408), A plunger (420) having a proximal end (422) and a distal end (424), wherein the proximal end (422) of the plunger (420) is slidably disposed within the fluid passage (414) inside the valve body (408), and the plunger (420) is configured to slide between a first closed position and a second bleed position, wherein when the plunger (420) is in the first position, fluid flow through the passage (414) is blocked, and when the plunger (420) is in the second position, fluid flow through the passage (414) is permitted between the internal cavity (306) and the external atmosphere, Includes a bicycle air bleed assembly. (12) The bicycle air bleed system according to Embodiment 11, wherein in the first position, the proximal end (422) of the plunger (420) is slid inward toward the first end (410) of the valve body (408), and in the second position, the proximal end (422) of the plunger is slid toward the second end (412) of the valve body (408). (13) The bicycle air bleed system according to Embodiment 12, wherein the upper portion of the fork includes a chassis crown (106) and the valve body (408) extends through the chassis crown (106). (14) The bicycle air bleed system according to Embodiment 12, further comprising a spring (434) configured to act on the plunger (420) and bias the plunger (420) to the first position. (15) The bicycle air bleed system according to embodiment 14, further including automatic bleeding.

[0105] (16) The bicycle air bleed system according to Embodiment 15, wherein the plunger (420) moves from the first position to the second position without user intervention when the force exerted on the proximal end (422) of the plunger by the pressure in the internal cavity (306) exceeds the force exerted on the plunger by the spring (434). (17) The bicycle air bleed system according to Embodiment 11, further comprising a main bleed seal (428) extending around the plunger (420), wherein when in the first position, the plunger (420) and the main bleed seal (428) cooperate to block the passage. (18) The bicycle air bleed system according to Embodiment 12, further comprising a dust seal (433) extending around the valve body (408) toward the second end (412) of the valve body (408), wherein, when in the first position, a cooperative sealing engagement between the dust seal (433), the valve body (408), and the dust cover (430) prevents fluid flow through the passage (414).

Claims

1. Air bleed system, A fork (100) including a linearly fixed component (110), wherein the linearly fixed component includes a linearly fixed tube (110), and A linearly moving component (110) including a linearly moving tube (110), wherein the linearly moving tube (110) extends downward from the linearly fixed tube (110), the proximal end (118) of the linearly moving tube (116) slides into engagement with the linearly fixed tube (110), the linearly moving tube (116) is configured to move linearly relative to the linearly fixed component (110), and the distal end (120) of the linearly moving tube (116) is configured to hold a wheel, An internal cavity (306) defined inside the linearly fixed tube (110) and / or the linearly moving tube (116), An air bleed assembly (128) located on the linearly fixed component (110), wherein the air bleed assembly (128) is configured to selectively fluidize the internal cavity (306) to the external atmosphere, depending on the open configuration of the air bleed assembly (128), An air bleed system, including...

2. The air bleed system according to claim 1, further comprising a spring cavity (314) filling port that is in fluid communication with an air spring cavity (306).

3. The air bleed system according to claim 1, wherein a portion of the air bleed assembly (128) extends through the outer wall (302) of the linearly fixed tube (110), and the air bleed assembly (128) is in fluid communication with a sealed air non-spring cavity (306).

4. The air bleed system according to claim 3, wherein the air bleed assembly (128) extends through the chassis crown (106).

5. The air bleed system according to claim 1, wherein the air bleed assembly (128) further includes a control knob (206), at least a portion of which extends outward from a linearly fixed tube (110), and when the control knob (206) is moved outward away from the internal cavity (306), the air bleed assembly (128) transitions to the open configuration.

6. The air bleed assembly (128) is A valve body (408) extending between a first end (410) and a second end (412), wherein the valve body defines a fluid passage (414) extending between the first end (410) and the second end (412), A plunger (420) having a proximal end (422) and a distal end (424), wherein the plunger (420) is positioned to slide within the fluid passage (414), and the control knob (206) is operably connected to the distal end (424) of the plunger (420), Includes, The air bleed system according to claim 5, wherein the proximal end (422) of the plunger (420) is configured to block the fluid passage (414) when the air bleed assembly (128) is in a closed configuration, and fluid communication between the internal cavity (306) and the atmosphere is prevented when the air bleed assembly (128) is in the closed configuration.

7. The air bleed system according to claim 6, wherein the plunger (420) further includes a seal (428) having a periphery and extending around the periphery of the plunger (420) near the proximal end (422) of the plunger (420), the seal (428) being configured to engage tightly between the plunger (420) and the valve body (408) when the air bleed assembly (128) is in the closed configuration.

8. The air bleed system according to claim 7, wherein the proximal end (118) of the linearly moving tube (116) is slidably received internally by the distal end (114) of the linearly fixed tube (110), and a slide seal is located between the inner wall of the linearly fixed tube (110) and the outer wall of the linearly moving tube (116).

9. The air bleed system according to claim 1, wherein the internal cavity (306) includes a sealed air cavity located within the damper leg, and the air bleed assembly (128) further includes a second air bleed assembly (128) located in the chassis crown (106) of the damper leg (126) and in the chassis crown (106) of the spring leg (124), the second air bleed assembly (128) being configured to selectively release air from the sealed air cavity of the spring leg (124).

10. The air bleed system according to claim 9, wherein the fork (100) includes a bicycle fork, further including an air adjustment knob (134) located above the non-spring cavity (306) of the spring leg, and further including a damper adjustment knob (132) located above the damper leg (126).

11. A bicycle air bleed assembly, A bicycle fork assembly (110) including an internal cavity (306), A valve body (408) extending between the first end (410) and the second end (412), A fluid passage (414) extending into the interior of the valve body (408), wherein the passage (414) is in fluid communication with the internal cavity (306) toward the first end (410) of the valve body (408), and the passage (414) is in fluid communication with the outside atmosphere toward the second end (412) of the valve body (408), A plunger (420) having a proximal end (422) and a distal end (424), wherein the proximal end (422) of the plunger (420) is slidably disposed within the fluid passage (414) inside the valve body (408), and the plunger (420) is configured to slide between a first closed position and a second bleed position, wherein when the plunger (420) is in the first position, fluid flow through the passage (414) is blocked, and when the plunger (420) is in the second position, fluid flow through the passage (414) is permitted between the internal cavity (306) and the external atmosphere, Includes a bicycle air bleed assembly.

12. The bicycle air bleed system according to claim 11, wherein in the first position, the proximal end (422) of the plunger (420) is slid inward toward the first end (410) of the valve body (408), and in the second position, the proximal end (422) of the plunger is slid toward the second end (412) of the valve body (408).

13. The bicycle air bleed system according to claim 12, wherein the upper portion of the fork includes a chassis crown (106), and the valve body (408) extends through the chassis crown (106).

14. The bicycle air bleed system according to claim 12, further comprising a spring (434) configured to act on the plunger (420) and bias the plunger (420) to the first position.

15. The bicycle air bleed system according to claim 14, further comprising automatic bleeding.

16. The bicycle air bleed system according to claim 15, wherein the plunger (420) moves from the first position to the second position without user intervention when the force exerted on the proximal end (422) of the plunger by the pressure in the internal cavity (306) exceeds the force exerted on the plunger by the spring (434).

17. The bicycle air bleed system according to claim 11, further comprising a main bleed seal (428) extending around the plunger (420), wherein when in the first position, the plunger (420) and the main bleed seal (428) cooperate to block the passage.

18. The bicycle air bleed system according to claim 12, further comprising a dust seal (433) extending around the valve body (408) toward the second end (412) of the valve body (408), wherein, when in the first position, a cooperative sealing engagement between the dust seal (433), the valve body (408), and the dust cover (430) prevents fluid flow through the passage (414).

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