Suspension fork assembly

Abstract

This invention discloses a suspension fork assembly, which may include a fork comprising a steering tube, a spring assembly tube having a cap insert and an insert assembly, a shock absorber assembly tube having a cap insert and an insert assembly, a leg for the spring assembly configured for mounting within the spring assembly tube of the fork, and a leg for the shock absorber assembly configured for mounting within the shock absorber assembly tube of the fork. The fork may include a composite material, such as a carbon fiber material, whose components are attached by an adhesive bond. The suspension fork assembly may include an inverted fork, wherein the leg for the spring assembly is embedded in the spring assembly tube, and the leg for the shock absorber assembly is embedded in the shock absorber assembly tube. A cartridge may be suspended within the leg for the shock absorber assembly; the shock absorber assembly may include a piston assembly; the piston assembly may include a floating piston, a seal, and a slip ring; the slip ring may be configured to provide a seal through a fluid path of the piston assembly. The piston assembly may include a first / compression piston and a second / rebound piston. The piston washer controls fluid flow; a piston may have the slip ring to provide a seal through a fluid path between the first piston and the second piston. The fork may include a pneumatic profile. The invention also discloses a method of manufacturing the suspension fork assembly, and tools for installing / removing a piston assembly from the suspension fork assembly.

Description

Technical Field [

Cross-reference to related applications

[0001] This application claims priority to and incorporates in its entirety the following patent application: U.S. Provisional Patent Application No. 63 / 358,805, filed on July 6, 2022, entitled “Suspension Fork Assembly.”

[0002] The present invention relates to a suspension front fork assembly for a bicycle. Prior Art

[0003] It is generally known in the prior art to provide a suspension front fork assembly for a bicycle.

[0004] It would be desirable to provide an improved suspension front fork assembly constructed from a composite material, such as carbon fiber.

[0005] It would be best to provide an improved suspension front fork assembly made of a carbon fiber material and to provide a configuration to enhance performance.

[0006] It would be desirable to provide an improved suspension front fork assembly including an improved piston assembly configuration.

[0007] It would be desirable to provide an improved suspension front fork assembly comprised of a carbon fiber material and configured to enhance mechanical performance.

[0008] It would be desirable to provide an improved suspension front fork assembly constructed of a carbon fiber material and configured to enhance aerodynamic performance.

[0009] It would be best to provide a method for manufacturing an improved suspension front fork assembly made of a carbon fiber material.

[0010] It would be desirable to provide a tool for inserting / adjusting and removing a piston assembly in a modified suspension fork assembly. Summary of the Invention

[0011] The present invention relates to a suspension front fork assembly, which may include a front fork including a steer tube, a spring assembly tube having a cap insert and an insert assembly, and a damper assembly tube having a cap insert and an insert assembly; a spring assembly can be configured to fit within a leg provided by the spring assembly tube of the front fork; a damper assembly is configured to fit within the leg provided by the damper assembly tube of the front fork; and the front fork may include a composite material, such as a carbon fiber material.

[0012] The suspension fork assembly may include an inverted fork, wherein the leg for the spring assembly is embedded in the spring assembly tube, and the leg for the shock absorber assembly is embedded in the shock absorber assembly tube. The steering tube may include a carbon fiber material. The steering tube may have a tapered inner wall. The steering tube may have a tapered inner wall and a tapered outer wall. The steering tube may be attached to the front fork via an adhesive bond. The leg for the spring assembly may include a tube. The leg for the shock absorber assembly may include a tube. The cap insert may include a metal material; the cap insert may include an aluminum material. The cap insert may be bonded to the front fork. The cap insert for the spring assembly tube may be attached to the front fork via an adhesive bond. The cap insert for the shock absorber assembly tube may be attached to the front fork via an adhesive bond. The adhesive bond may include an adhesive that is cured to form the adhesive bond. The cap insert for the spring assembly tube may be attached to the front fork via an adhesive bond; the cap insert for the shock absorber assembly tube may be attached to the front fork via an adhesive bond. The steering tube may include a steerer. The insert assembly may include a bushing. The insert assembly may include a seal. The seal may include a dust seal. The insert assembly may include a bushing and a dust seal. The insert assembly may include an upper bushing, a lower bushing, a foam ring, and a dust seal. The suspension front fork assembly may include a shock absorber assembly within the shock absorber assembly tube and having a piston assembly. The piston assembly may be retained within the shock absorber assembly tube by friction. The piston assembly may include a first piston and a second piston. The piston assembly may include a piston spacer and a glide ring. A piston may have a glide ring; the glide ring may be configured to provide a seal for a fluid path through the two pistons. The first piston may be a compression piston, the second piston may be a rebound piston, and the spring assembly tube may include an aerodynamic profile configured to provide less aerodynamic drag than a circular profile.

[0013] The present invention relates to a suspension fork assembly comprising a leg and a shock absorber assembly including a cartridge within the leg. The cartridge may be attached to the leg for the shock absorber assembly at one end and unattached at the other end. The leg may include a shock absorber assembly tube. The cartridge may be suspended within the leg for the shock absorber assembly. The cartridge may be suspended within the leg for the shock absorber assembly at a top end. The suspension fork assembly may include a spring assembly. The spring assembly may include an air spring. The shock absorber assembly may include a piston assembly. The shock absorber assembly may include a floating piston. The floating piston may include a seal. The piston assembly may include a slip ring. The slip ring may be configured to provide a seal for a fluid path through the piston assembly. The piston assembly may include a first piston and a second piston. The first piston may be a compression piston. The second piston may be a rebound piston. The piston gasket may control fluid retention. A flow control element for the shock absorber assembly may include at least one shim. A piston may have a slip ring. The slip ring can be configured to provide a seal for a fluid path through the first piston and the second piston. The cartridge of the shock absorber assembly can be configured for a piston assembly including an internal floating piston; the cartridge can include a cartridge tube.

[0014] The present invention relates to a piston assembly for a shock absorber assembly of a suspension front fork assembly, comprising a first piston, a second piston, a piston gasket, and a slip ring. Each piston may have a slip ring. The slip ring may be configured to provide a seal for a fluid path through the two pistons. The first piston may be a compression piston. The second piston may be a rebound piston. The piston gasket may control the fluid path. A flow control element for the shock absorber assembly may include at least one gasket.

[0015] The present invention relates to a method for assembling a suspension front fork assembly, wherein the suspension front fork assembly includes a carbon fiber front fork, the carbon fiber front fork including a steering tube, a spring assembly tube with a cap insert, a shock absorber assembly tube with a cap insert, a spring assembly with a leg configured to be mounted within the spring assembly tube of the front fork, and a shock absorber assembly with a leg configured to be mounted within the shock absorber assembly tube of the front fork. The assembly method includes the steps of preparing each cap insert for bonding, applying adhesive to each cap insert to form an adhesive bond, installing each cap insert on the front fork, and curing each adhesive bond for each cap insert.

[0016] The assembling method may include placing the front fork in a fixture and removing the front fork from the fixture. The assembling method may include placing the front fork in a fixture after installing each cap insert on the front fork, and removing the front fork from the fixture after curing each adhesive bond for each cap insert. Installing each cap insert on the front fork may include installing the cap insert of the spring assembly tube into the spring assembly tube using the adhesive bond. Installing each cap insert on the front fork may include installing the cap insert of the shock absorber assembly tube into the shock absorber assembly tube using the adhesive bond. Installing each cap insert on the front fork may include installing the cap insert of the spring assembly tube into the spring assembly tube using the adhesive bond, and installing the cap insert of the shock absorber assembly tube into the shock absorber assembly tube using the adhesive bond. The assembling method may include inserting a leg of the spring assembly into the spring assembly tube. The assembling method may include inserting a leg of the shock absorber assembly into the shock absorber assembly tube. The assembly method may include preparing the steering tube for bonding to the front fork and applying adhesive to the steering tube to form an adhesive bond. The assembly method may include attaching the steering tube to the front fork with the adhesive bond. The assembly method may include curing the adhesive bond on the steering tube. The assembly method may include placing the front fork in a fixture after attaching the steering tube. The assembly method may include removing the front fork from the fixture after curing the adhesive bond on the steering tube. The steering tube may include a carbon fiber material. The steering tube may include a steering gear. The front fork may include an insert assembly.

[0017] The assembly method may include preparing the insert assembly for bonding to the front fork and applying adhesive to the insert assembly to form an adhesive bond. The assembly method may include attaching the insert assembly to the front fork using the adhesive bond. The assembly method may include curing the adhesive bond for the insert assembly. The assembly method may include placing the front fork in a jig after attaching the insert assembly. The assembly method may include removing the front fork from the jig after curing the adhesive bond for the insert assembly. Installing each insert assembly in the front fork may include installing the insert assembly of the spring assembly tube into the spring assembly tube using the adhesive bond. Installing each insert assembly in the front fork may include installing the insert assembly of the shock absorber assembly tube into the shock absorber assembly tube using the adhesive bond. Installing each insert assembly in the front fork may include installing the insert assembly of the spring assembly tube into the spring assembly tube using the adhesive bond and installing the insert assembly of the shock absorber assembly tube into the shock absorber assembly tube using the adhesive bond. The fixture can be configured to calibrate the cap inserts in the steering tube and the spring combination tube. The fixture can be configured to calibrate the combination of inserts in the steering tube and the spring combination tube. The fixture can be configured to calibrate the cap insert in the spring combination tube and the combination of inserts in the spring tube. The fixture can be configured to calibrate the cap insert in the spring combination tube and the cap insert in the shock absorber combination tube. The fixture can be configured to calibrate the combination of inserts in the spring combination tube and the combination of inserts in the shock absorber combination tube. The fixture can be configured to calibrate the cap insert in the spring combination tube, the cap insert in the shock absorber combination tube, the combination of inserts in the spring combination tube, and the combination of inserts in the shock absorber combination tube. The fixture can be configured to calibrate the steering tube, the cap insert in the spring combination tube, the cap insert in the shock absorber combination tube, the combination of inserts in the spring combination tube, and the combination of inserts in the shock absorber combination tube. The combination of inserts can include a bushing. The combination of inserts can include a seal. The seal may include a dust seal. The insert assembly may include a shaft sleeve and a dust seal. The insert assembly may include an upper shaft sleeve, a lower shaft sleeve, a foam ring, and a dust seal.

[0018] The present invention relates to a suspension front fork assembly comprising a spring assembly tube and a shock assembly tube. The spring assembly tube may include a profile; the profile may include an aerodynamic profile configured to provide less aerodynamic drag than a toroidal profile. The shock assembly tube of the front fork may include a profile; the profile may include an aerodynamic profile configured to provide less aerodynamic drag than a toroidal profile. The aerodynamic profile may include a generally D-shaped profile. The aerodynamic profile may include a Kamm tail. At 30 miles per hour, the aerodynamic profile of the spring assembly tube generates less than 75% of the drag generated by a toroidal profile tube. At 30 miles per hour, the aerodynamic profile may provide a drag force of less than 1N.

[0019] The present invention relates to a tool configured to engage a piston assembly of a shock absorber assembly with a leg of a suspension fork assembly. The tool comprises a base, a first end configured to engage the piston assembly, a second end configured to engage the piston assembly, and a collar configured to be mounted on a body having an indicia, the indicia being configured to mark the collar's position on the body. The piston assembly can be retained within the leg of the shock absorber assembly by friction. The collar can be fixed to the body to determine the position of the piston assembly installed within the leg. The indicia can be used to mark the installation position of the piston assembly within the leg. The tool may comprise a body including the base, the first end, and the second end. The first end may include a projection and a recess. The first end may be configured to retain the piston assembly to be installed within the leg. The second end may include a projection and a recess. The second end may include a feature configured to engage the piston assembly to remove it from the leg. The second end may include a feature configured to attach to the piston assembly to remove it from the leg. The second end of the tool may be configured to attach to the piston by rotation. The collar may be secured to the body with a fastener. The marking may include a scale.

[0020] The present invention relates to a suspension front fork assembly comprising a front fork including a steering tube, a spring assembly tube having a cap insert and an insert assembly, and a shock absorber assembly tube having a cap insert and an insert assembly. A spring assembly may be provided with a leg configured to be mounted within the spring assembly tube of the front fork; a shock absorber assembly may be provided with a leg configured to be mounted within the shock absorber assembly tube of the front fork. The front fork may comprise a composite material. The suspension front fork assembly may comprise an inverted front fork, wherein the leg for the spring assembly is embedded in the spring assembly tube, and the leg for the shock absorber assembly is embedded in the shock absorber assembly tube. The composite material comprises a carbon fiber material. Simple diagram description

[0021] Figure 1 is a perspective schematic diagram of a bicycle according to an exemplary embodiment of the present invention;

[0022] Figure 2 is a perspective schematic diagram of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0023] Figures 3A and 3B are schematic front views of a suspension fork assembly according to an exemplary embodiment of the present invention;

[0024] Figures 4 and 5 are exploded perspective views of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0025] Figure 6 is a side view of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0026] Figure 7 is a side sectional schematic diagram of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0027] Figure 8 is a side view of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0028] Figure 9 is a side sectional schematic diagram of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0029] Figure 10 is an exploded perspective schematic diagram of an insert assembly of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0030] Figure 11 is a side view of an insert assembly of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0031] Figure 12 is a cross-sectional schematic diagram of an insert assembly of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0032] Figure 13 is a partial side view of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0033] Figure 13A is a partial top plan view of an aerodynamic shape of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0034] Figure 14 is a side sectional schematic diagram of a piston assembly of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0035] Figures 15A-15C are side cross-sectional schematic diagrams of a piston assembly of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0036] Figure 16A is a perspective schematic diagram of a piston assembly of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0037] Figure 16B is an exploded perspective schematic diagram of a piston assembly of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0038] Figure 17 is an exploded perspective schematic diagram of a piston assembly of a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0039] Figure 18 is a schematic side view of a tool for a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0040] Figures 19A and 19B are schematic cross-sectional views of a top view of a tool for a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0041] Figure 20 is a schematic side sectional view of a tool for a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0042] Figure 21A is a partial perspective schematic diagram of a piston assembly for a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0043] Figure 21B is a partially exploded perspective schematic diagram of a piston assembly for a suspension front fork assembly according to an exemplary embodiment of the present invention;

[0044] Figure 22A-22C is a schematic side sectional view of a tool for use in a suspension fork assembly according to an exemplary embodiment of the present invention;

[0045] Figure 23A-23D is a schematic side sectional view of a tool for use in a suspension fork assembly according to an exemplary embodiment of the present invention;

[0046] Figure 24A-24B is a partial side sectional schematic diagram of a tool for use in a suspension fork assembly according to an exemplary embodiment of the present invention;

[0047] Figures 25 and 26 are schematic diagrams of a process of manufacturing a suspension front fork assembly according to an exemplary embodiment of the present invention; Implementation Method

[0048] Referring to FIG. 1 , a bicycle B is shown according to an exemplary embodiment of the present invention, which provides a parts / assembly arrangement including a frame FR having a head tube T and a seat post SP (with a seat S), a set of wheels including a front wheel FW having a fork / suspension assembly F / 100, and a rear wheel RW coupled to the frame FR (via a suspension system), and a set of pedals; the bicycle provides a handlebar H (coupled to the front wheel FW via a stem ST and to the fork assembly F / 100 via the head tube T), a controller for a brake system BR (e.g., a shaft in / on each of the front wheel FW and rear wheel RW) coupled to a brake disc D, and a gear / shift control (coupled to a selectable gear system for the rear wheel RW).

[0049] According to an exemplary embodiment, a suspension system (e.g., a front fork for a bicycle B) is shown as including a suspension / fork combination F / 100, configured to provide suspension damping for the bicycle B when in motion.

[0050] As shown in Figures 2, 3A-3B, 4, 5, 6, 7, 8, and 9, according to an exemplary embodiment, the suspension front fork assembly F / 100 includes a set of legs 102 and 104, an axle 106, a crown steer unit 110 including a steering tube 118, and a tube configuration 112 having a spring assembly tube 112a and a shock assembly tube 112b. The spring assembly tube 112a is configured to receive the leg 102 having a spring assembly, shown as an air spring assembly 130, and is assembled with a cap insert 116, an air cap 132, and an insert assembly 120. The shock assembly tube 112b is configured to receive the leg 104 having a shock assembly 140, and is assembled with the cap insert 116, an adjuster knob 142, and the insert assembly 120. As shown in Figures 5, 6, 7, 8, and 9, the tube configuration 112 with the spring assembly tube 112a and the shock absorber assembly tube 112b may include a composite material CM, such as a carbon fiber material; the cap insert 116, the steering tube 118, and the insert assembly 120 may be attached to the tube configuration 112 by an adhesive material AD.

[0051] As shown in Figures 4, 5, 7, 8, 9, 10, 11, and 12, an insert assembly 120 may include an insert 122, and a set of sleeves including an upper sleeve 124 and a lower sleeve 125, and a ring 126, and a seal shown as a dust seal 128.

[0052] As shown in Figures 4, 14, 15A-5C, and 16A-16B, the shock absorber assembly tube 112b with the shock absorber assembly 140 may include a piston assembly 150, which includes a cartridge / tube 141 and a group of pistons including a compression piston 156 and a rebound piston 158, and has a piston washer 152, a spring shown as a compression / wave spring 155, and a ring shown as a sliding ring 160; in addition to a nut 168, a flow control element shown as a group of gaskets can be provided to fix to a piston seat 144, which includes gasket 146, gasket 148, gasket 154, gasket 162, gasket 164, and gasket 166.

[0053] As shown in Figures 14, 15A-15C, and Diagram A, the shock absorber assembly 140 includes a fluid damping arrangement (e.g., including a hydraulic / suspension fluid). The operation of the shock absorber assembly 140 includes a compression state when the assembly is subjected to an input load (e.g., light or heavy), and a rebound state after the input load. The operational configuration of the shock absorber assembly 140 includes positioning a flow control element, shown as a central needle 140x, in the piston assembly into an open or closed state to configure a flow path / channel for the fluid. As shown in Figures 15A-15C and 16A-16B, the shock absorber assembly may include channels for fluid flow, shown as channels P1 / P2 / P3 / P4 / P5 / P6 / P7 / P8. A flow control arrangement for the shock absorber assembly may include a flow control element, such as at least one shim. See Diagram A.

[0054] As shown in Figures 1, 2, 3A-3B, and Figure A, the suspension front fork assembly F / 100 provides a suspension system for the bicycle B during operation. The shock absorber assembly 140 of the suspension front fork assembly F / 100 is configured to facilitate the flow of hydraulic / suspension fluid (e.g., a controlled flow rate of fluid) to provide suspension damping between a preset / extended state (see Figure 3A) and a compressed / contracted state (see Figure 3B) when the front wheel of the bicycle encounters road irregularities (e.g., bumps, obstacles, potholes, etc.). As shown in Figures 3A and 3B, in operation, when the suspension system having a suspension fork assembly with a shock absorber assembly is used to provide suspension damping in response to an input (e.g., from an irregular road surface encountered by the front wheel), the suspension fork assembly F / 100 will be compressed / contracted as shown in Figure 3B; after the input, the suspension fork assembly F / 100 will return to a default / extended state as shown in Figure 3A (e.g., ready to provide suspension damping when the front wheel encounters the input).

[0055] As shown in Figures 1, 2, 3A-3B, 4, 14, 15A-15C, and Figure A, during operation, the suspension fork assembly F / 100 used in one of the suspension systems of the bicycle B will encounter various input loads, such as very light / slight, light, heavy, etc.; the suspension fork assembly F / 100 with the shock absorber assembly 140 is designed and configured, and has adjustment / configuration of flow control elements (such as needle body positioning, spacer elements, etc.) to provide efficient and effective suspension damping / response for each input load. [ , Exemplary Embodiments , ]

[0056] According to an exemplary embodiment shown in Figures 2, 3A-3B, 4, 5, 6, 7, 8, 9, 10, 11, 12, 14, 15A-15C, and 16A-16B, a suspension front fork assembly F / 100 may include a front fork, the front fork including a steering tube 118, a spring assembly tube 112a having a cap insert 116 and an insert assembly 122, and a shock absorber assembly tube 112b having a cap insert 116 and an insert assembly 122; a spring assembly may be configured to be mounted within a support provided by the spring assembly tube 112a of the front fork; a shock absorber assembly 140 is configured to be mounted within a support provided by the shock absorber assembly tube 112b of the front fork; the front fork may include a composite material, such as a carbon fiber material.

[0057] According to an exemplary embodiment shown in Figures 2, 3A-3B, 4, 5, 6, 7, 8, 9, 10, 12, 14, 15A-15C, and 16A-16B, the suspension front fork assembly F / 100 may include an inverted front fork, wherein the legs for the spring assembly are embedded in the spring assembly tube 112a, and the legs for the shock assembly 140 are embedded in the shock assembly tube 112b. The steering tube 118 may include a carbon fiber material. The steering tube 118 may have a tapered inner wall. The steering tube 118 may have a tapered inner wall and a tapered outer wall. The steering tube 118 may be attached to the front fork via an adhesive bond AD. As shown in Figures 13 and 13A, the legs of the spring assembly tube 112a may include an aerodynamic shape configured to provide less aerodynamic drag than a toroidal shape.

[0058] According to an exemplary embodiment shown in Figures 2, 3A-3B, 4, 5, 6, 7, 8, 9, 10, 11, 12, 14, and 16A-16B, the leg 102 for the spring assembly may include a tube; the leg 104 for the shock absorber assembly 140 may include a tube; the cap insert 116 may include a metal material; the cap insert 116 may include an aluminum material; the cap insert 116 may be bonded to the front fork; the cap insert 116 of the spring assembly tube 112a may be attached to the front fork via an adhesive bond AD; the cap insert 116 of the shock absorber assembly tube 112b may be attached to the front fork via an adhesive bond AD; the adhesive bond A D may include an adhesive that, after curing, forms the adhesive bond AD. The cap insert 116 for the spring assembly tube 112a may be attached to the front fork via the adhesive bond AD. The cap insert 116 for the shock assembly tube 140 may be attached to the front fork via the adhesive bond AD. The steering tube 118 may include a steering gear. The insert assembly 122 may include a sleeve. The insert assembly 122 may include a seal. The seal may include a dust seal. The insert assembly 122 may include a sleeve and a dust seal 128. The insert assembly 122 may include an upper sleeve 124, a lower sleeve 125, a foam ring 126, and a dust seal 128. See Figures 10, 11, and 12.

[0059] According to an exemplary embodiment shown in Figures 2, 3A-3B, 4, 14, 15A-15C, and 16A-16B, the suspension front fork assembly F / 100 may include a shock assembly 140 within the shock assembly tube 112b, including a piston assembly 150. The piston assembly 150 may be retained within the shock assembly tube 112b by friction. The piston assembly 150 may include a first piston and a second piston. The piston assembly 150 may include a piston washer 152 and a sliding ring 160. A piston may include a sliding ring 160. The sliding ring 160 may be configured to provide a seal for a fluid path through the two pistons. The first piston may be a compression piston 156, and the second piston may be a rebound piston 158.

[0060] As shown in Figures 4, 14, 15A-15C, and 16A-16B, the shock absorber assembly 140 with the piston assembly 150 may include channels for fluid flow, shown as channels P1 / P2 / P3 / P4 / P5 / P6 / P7 / P8. A flow control device for the shock absorber assembly 140 may include a flow control element, such as a needle 140x, and / or at least one shim. The element may include a shim assembly / set. The element / shim may include shim 146, and / or shim 148, and / or shim 154, and / or shim 162, and / or shim 164, and / or shim 166. See Figure A.

[0061] As shown in Figures 2, 3A-3B, 4, 14, 15A-15C, and 16A-16B, a suspension fork assembly F / 100 may include a leg 104 and a shock absorber assembly 140 within the leg 104, which includes a cartridge 141; the cartridge 141 may be attached to the leg 104 for the shock absorber assembly 140 at one end and not attached at the other end. The cartridge 141 may be suspended within a foot 104 for the shock absorber assembly 140; the cartridge 141 may be suspended at a top end within a foot 104 for the shock absorber assembly 140; the suspension front fork assembly F / 100 may include a spring assembly; the spring assembly may include a spring, such as an air spring; the shock absorber assembly 140 may include a piston assembly 150; the piston assembly 150 may include a slip ring 160; the slip ring 160 may be configured to provide a seal for a fluid path through the piston assembly 150; the piston assembly 150 may include a first piston and a second piston; the first piston may be a compression piston 156; the second piston may be a rebound piston 158; the piston gasket 152 may control fluid retention. A piston may include a slip ring 160; the slip ring 160 may be configured to provide a seal for a fluid path through the first piston and the second piston; the cartridge of the shock absorber assembly may be configured for a piston assembly including an internal floating piston; the cartridge 141 may include a cartridge tube configured for a piston assembly 150. According to an exemplary embodiment shown in Figures 4 and 21A-21B, the shock absorber assembly may include a cartridge 141 with a cartridge tube configured for a piston assembly including an internal floating piston assembly 180; the shock absorber assembly may include the internal floating piston assembly 180; the internal floating piston assembly may include an internal floating piston 182 and a seal 186 secured by a screw 184. See also Figures 22A-22C and 23A-23D.

[0062] According to an exemplary embodiment shown in Figures 2, 3A-3B, 4, 14, 15A-15C, and 16A-16B, the suspension fork assembly may include an inverted front fork, wherein the spring assembly leg 102 is embedded in the spring assembly tube 112a / CF, while the shock assembly leg 104 is embedded in the shock assembly tube 112b / CF. A cartridge 141 may be suspended within the leg 104 of the shock assembly 140. The shock assembly 140 may include a piston assembly 150. The piston assembly 150 may include a seal and a slip ring 160. The slip ring 160 may be configured to provide a seal for a fluid path through the piston assembly 150. The piston assembly 150 may include a first / compression piston and a second / rebound piston. The piston gasket 152 may control fluid retention; a piston may include the slip ring 160 to provide a seal for a fluid path through the first and second pistons.

[0063] According to an exemplary embodiment shown in Figures 2, 3A-3B, 4, 14, 15A-15C, and 16A-16B, a piston assembly 150 for a shock absorber assembly 140 of a suspension front fork assembly F / 100 may include a first piston, a second piston, a piston washer 152, and a sliding ring 160. Each piston may include a sliding ring 160; the sliding ring 160 may be configured to provide a seal for a fluid path through the two pistons; the first piston may be a compression piston; the second piston may be a rebound piston; and the piston washer 152 may control the fluid path.

[0064] The suspension fork assembly may include components constructed from a composite material, such as a carbon fiber, glass fiber, or organic fiber of a polymer structure. [Combination method]

[0065] According to an exemplary embodiment shown in Figures 5, 26, and 27, a method for assembling a suspension fork assembly F / 100 including a composite material (e.g., a carbon fiber) CM fork may include preparing components for assembly and assembling the components, including bonding / attaching them with an adhesive, such as Adhesive AD. See also Figures 1, 2, 3A-3B, 4, 6, 7, 8, and 9.

[0066] According to an exemplary embodiment shown in Figures 5, 26 and 27, a suspension front fork assembly F / 100 includes a front fork having a steering tube 118 / CM and a tube 112 / CM, and is constructed of a composite material. The tube 112 / CM includes a spring assembly tube 112a / CM having a cap insert 116, and a spring assembly tube 112a / CM having a cap insert 116, wherein a leg 102 for the spring assembly 130 is configured to be mounted within the spring assembly tube 112a of the front fork, and a leg 102 for the shock absorber assembly 140 is configured to be mounted within the shock absorber assembly tube 112b of the front fork. The manufacturing method of the suspension front fork assembly F / 100 may include preparing an insert assembly 120 and each cap insert 116 for bonding, applying adhesive to each cap insert 116 to form an adhesive bond AD, installing each cap insert 116 on the front fork, and curing each adhesive bond AD for each cap insert 116. See also Figures 2, 3A-3B, 4, 6, 7, 8, 9, 10, 11, 12, 14, and 16A-16B.

[0067] According to an exemplary embodiment shown in Figures 26 and 27, the steps of the assembly method may include placing the front fork into a fixture and removing the front fork from the fixture; the steps of the assembly method may include placing the front fork into a fixture after installing each cap insert 116 to the front fork, and removing the front fork from the fixture after curing each adhesive bond AD for each cap insert 116; the step of installing each cap insert 116 for the front fork may include attaching the cap insert 116 of the spring assembly tube 112a / CM to the spring assembly tube 112a / CM with the adhesive bond AD. 16 is installed into the spring assembly tube 112a / CM; the step of installing each cap insert 116 on the front fork may include installing the cap insert 116 of the shock absorber assembly tube 112b / CM into the shock absorber assembly tube 112b / CM with the adhesive; the step of installing each cap insert 116 on the front fork may include installing the cap insert 116 of the spring assembly tube 112a / CM into the spring assembly tube 112a / CM with the adhesive, and installing the cap insert 116 of the shock absorber assembly tube 112b / CM into the spring assembly tube 112a / CM with the adhesive. The cap insert 116 is installed into the shock assembly tube 112b / CM; the steps of the assembly method may include providing the support leg 102 for the spring assembly 130 and inserting it into the spring assembly tube 112a / CM; the steps of the assembly method may include providing the support leg 104 for the shock assembly 140 and inserting it into the shock assembly tube 112b / CM; the steps of the assembly method may include preparing the steering tube 118 for bonding it to the front fork, and applying adhesive to the steering tube 118 to perform an adhesive bond AD; the assembly The method may include attaching the steer tube 118 to the front fork with the adhesive bond AD; the method may include curing the adhesive bond AD on the steer tube 118; the method may include placing the front fork in a jig after attaching the steer tube 118; the method may include removing the front fork from the jig after curing the adhesive bond AD on the steer tube 118; the steer tube 118 may include a carbon fiber material; the steer tube 118 may include a steerer; and the front fork may include an insert assembly 120. See also Figures 2, 3A-3B, 4, 5, 6, 7, 8, 9, 10, 11, 12, 14, and 16A-16B.

[0068] According to an exemplary embodiment shown in Figures 5, 10, 26, and 27, the assembly method may include preparing the insert assembly 120 for bonding to the front fork, applying adhesive to the insert assembly 120 to form an adhesive bond AD, attaching the insert assembly 120 to the front fork using the adhesive bond AD, and curing the adhesive bond AD for the insert assembly 120. See also Figures 2, 3A-3B, 4, 5, 6, 7, 8, 9, 11, 12, 14, and 16A-16B.

[0069] According to an exemplary embodiment shown in Figures 5, 10, 26, and 27, the steps of the assembly method may include placing the front fork into a fixture after attaching the insert assembly 120; the steps of the assembly method may include removing the front fork from the fixture after curing the adhesive bond AD for the insert assembly 120; the step of installing each insert assembly 120 for the front fork may include installing the insert assembly 120 of the spring assembly tube 112a / CM into the spring assembly tube 112a / CM with the adhesive bond AD; installing each insert assembly 120 for the front fork The step of attaching an insert assembly 120 may include attaching the insert assembly 120 of the shock absorber assembly tube 112b / CM to the shock absorber assembly tube 112b / CM using the adhesive bond AD. The step of attaching each insert assembly 120 to the front fork may include attaching the insert assembly 120 of the spring assembly tube 112a / CM to the spring assembly tube 112a / CM using the adhesive bond AD, and attaching the insert assembly 120 of the shock absorber assembly tube 112b / CM to the shock absorber assembly tube 112b / CM using the adhesive bond AD. Please also refer to Figures 2, 3A-3B, 4, 5, 6, 7, 8, 9, 11, 12, 14, and 16A-16B.

[0070] According to an exemplary embodiment as shown in Figures 5, 10, 26, and 27, a fixture can be configured to calibrate the steering tube 118 / CM and the cap insert 116 in the spring combination tube 112a / CM; the fixture can be configured to calibrate the steering tube 118 / CM and the insert combination 120 in the spring combination tube 112a / CM; the fixture can be configured to calibrate the cap insert 116 in the spring combination tube 112a / CM and the insert combination 120 in the spring combination tube 112a / CM; the fixture can be configured to calibrate the cap insert 116 in the spring combination tube 112a / CM and the cap insert 116 in the shock absorber combination tube; the fixture can be configured to calibrate the insert combination 120 in the spring combination tube 112a / CM and the insert combination 120 in the shock absorber combination tube 112b / CM; the fixture can be configured to calibrate the cap insert in the spring combination tube 112a / CM The fixture can be configured to calibrate the steering tube 118 / CM, the cap insert 116 in the spring assembly tube 112a / CM, the cap insert 116 in the shock absorber assembly tube 112b / CM, the spring assembly tube 112a / CM, and the insert assembly 120 in the shock absorber assembly tube 112b / CM; the fixture can be configured to calibrate the steering tube 118 / CM, the cap insert 116 in the spring assembly tube 112a / CM, the cap insert 116 in the shock absorber assembly tube 112b / CM, the spring assembly tube 1 The insert assembly 120 in 12a / CM and the insert assembly 120 in the shock-absorbing assembly tube 2b / CM; the insert assembly 120 may include a sleeve; the insert assembly 120 may include a seal; the seal may include a dust seal; the insert assembly 120 may include a sleeve and a dust seal; the insert assembly 120 may include an upper sleeve 124, a lower sleeve 126, a foam ring 160, and a dust seal 128. Please also refer to Figures 2, 3A-3B, 4, 6, 7, 8, 9, 11, 12, 14, and 16A-16B. Aerodynamic shape

[0071] According to an exemplary embodiment shown in Figures 1, 2, 3A-3B, 5, 13, and 13A, a suspension front fork assembly F / 100 may include a spring assembly tube 112a and a shock assembly tube 112b (i.e., each tube is formed of an engineered / composite material CM such as carbon fiber, and is provided as a component); the spring assembly tube 112a may include a shape; the shock assembly tube 112b may include a shape; the shape may include an aerodynamic shape configured to provide less aerodynamic drag than a toroidal shape; the shock assembly tube 112b of the front fork may include a shape; the shape may include an aerodynamic shape configured to provide less aerodynamic drag than a toroidal shape; the aerodynamic shape may include a generally D-shaped shape; the aerodynamic shape may include a cam tail; at 30 miles per hour, the aerodynamic shape may provide a drag that is less than 75% of the drag provided by a toroidal shape; at 30 miles per hour, the aerodynamic shape may provide a drag that is less than 1N. Tool for installing / removing piston assemblies

[0072] According to an exemplary embodiment as shown in Figures 17, 18, 19A-19B, 20, 21A-21B, 22A-22C, 23A-23D, and 24A-24B, a tool / tool ​​combination 170 is configured to engage an internal floating piston assembly 180 of a shock assembly 140 to a cartridge 141 for a suspension fork assembly F / 100 leg; as shown, the tool 170 can be configured to be mounted within the shock assembly tube 112b to facilitate installation / positioning of the internal floating piston assembly 180 within the shock assembly 140 / cartridge 141 (see Figures 22A-22C) and to facilitate removal of the internal floating piston assembly 180 from the shock assembly 140 / cartridge 141 (see Figures 23A-23D). The internal floating piston assembly 180 can be retained within the support for the shock absorber assembly 140 by friction / interference (e.g., allowing installation, placement, positioning, and removal).

[0073] As shown in Figures 22A-22B, 23A-23D, and 24A-24B, the piston assembly 150 of the shock absorber assembly 140 may include an internal floating piston assembly 180, which provides an internal floating piston 182 with a flat surface 182a and a protrusion 182b, a seal 186, and a screw 184; the flat surfaces 182a and the protrusion 182b may be configured to engage the tool 170; the tool 170 may include a body / base, a first end with a flat surface 172b and a pocket 172c, configured to retain / disengage the flat surface 182a and the protrusion 182b of the internal floating piston assembly 180 by rotation (for example, to remove it), and a second end with a flat surface 172a, configured to engage the flat surface 182a of the internal floating piston assembly 180 (for example, to install it).

[0074] As shown in Figures 17 and 18 , the tool 170 may include an O-ring 178 and a collar 174 configured to be assembled with the body and secured to the body via a screw 176. The body may include markings configured to indicate the position of the collar 174 on the body. See also Figure 22B . The collar 174 may be secured along the body to determine and / or set an installation position for the internal floating piston assembly 180 within the leg. The markings may indicate the installation position of the internal floating piston assembly 180 within the leg. The markings may indicate instructions for use of the tool (e.g., by providing markings on the end of the tool indicating an "installation" end or a "removal" end).

[0075] As shown in Figures 17, 18, 19A-19B, 20, 21A-21B, 22A-22C, 23A-23D, and 24A-24B, the tool 170 may include a body comprising the base, the first end, and the second end; the first end may include a protrusion and a recess; the first end may be configured to retain the piston assembly to be installed within the leg; the second end may include a protrusion and a recess; the second end may include a feature configured to engage the piston assembly to remove it from the leg; the second end may include a feature configured to attach to the piston assembly to remove it from the leg; the second end of the tool may be configured to attach to the piston by rotation; the collar may be secured to the body with a fastener; the marking may include a scale; the marking may be used to identify the position of the collar and / or piston assembly within the leg / tube.

[0076] It is worth noting that the present invention (e.g., the inventive concept, etc.) has been described in the specification of this patent document and / or illustrated in the drawings based on exemplary embodiments; the embodiments of the present invention are merely exemplary and do not limit the scope of the present invention. The component construction and / or arrangement of the inventive concept specifically presented in the present invention described in the specification and / or illustrated in the drawings are for illustration only. Although the exemplary embodiments of the present invention have been described in detail in this patent document, a person of ordinary skill in the art to which the present invention relates will understand that the subject matter of these exemplary embodiments and alternative embodiments may be modified into equivalents, modifications, variations, etc., and can be considered to be within the scope of the present invention; all such subject matter (e.g., modifications, variations, specific implementations, combinations, equivalents, etc.) are within the intended scope of the present invention. It should also be noted that various / other modifications, variations, substitutions, equivalents, changes, omissions, etc. may be implemented in the configuration and / or arrangement of the exemplary embodiments thereof (e.g., concepts, designs, structures, devices, shapes, combinations, constructions, means, functions, systems, processes / methods, steps, order of process / method steps, execution, execution conditions, operations, materials, compositions, combinations, etc.) without departing from the scope of the present invention. All such patent subject matter (e.g., modifications, variations, implementations, combinations, equivalents, etc.) are intended to be within the scope of the present invention. The scope of the present invention is not limited to the subject matter described in the specification and / or illustrated in the drawings of this patent document (e.g., details, structures, functions, materials, effects, steps, sequences, systems, results, etc.). The scope of the patent application in this patent document is intended to be appropriately interpreted as covering the full scope of the subject matter of the present invention (e.g., including any and all such modifications, variations, implementations, combinations, equivalents, etc.); the technical terms used in this patent document should be understood to be used to describe the subject matter of the exemplary embodiments, not to limit the scope of the present invention.

[0077] It is also worth noting that, according to exemplary embodiments, the present invention may include conventional technologies (e.g., technologies implemented and / or combined in exemplary embodiments, modifications, variations, combinations, equivalents, etc.), or may include any other applicable technologies that are suitable for and / or capable of performing the functions and processes / operations described in this specification and / or illustrated in the drawings. All such technologies (e.g., technologies implemented in embodiments, modifications, variations, combinations, equivalents, etc.) are considered to fall within the scope of the invention of the present patent document. [Chart B] [Component Symbol Table] [Component symbol] [element], [part], [or component] B: Bicycle BR: Braking system D: Brake disc / shaft (brake) F:Front fork assembly FR: frame H: handlebar FW: front wheel RW: rear wheel S: Seat SP: Seat pillar ST: Turning handle T:Head tube CM: Composite materials (such as carbon fiber) AD: Adhesive 100: Suspension front fork 102: Support legs 104: Support legs 106: Axle 110: Top steering unit 112: Pipe fittings 112a: Spring combination tube / spring combination tube 112b: shock-absorbing combination tube / shock-absorbing combination tube 116: Cap insert 118: Steering tube 120:Insert combination [Chart B] [Component Symbol Table] [Component symbol] [element], [part], [or component] 122:Lower insert 124: Upper sleeve 125: Lower sleeve 126: Ring 128: Dust seal 130: Air spring assembly 132: Gas Cap 140: shock absorption combination 140x: needle body 141: Cartridge / Cartridge Tube 142: Adjustment knob 144: Piston seat 146: Gasket 148: Gasket 150:Piston assembly 152:Piston gasket 154: Gasket 155: Spring 156:Compression piston 158: Rebound piston 160: Rings / Slip Rings 162: Gasket 164: Gasket 166: Gasket 168: Nut 170: Tool Kit 172: Shaft (with flat surface 172a, flat surface 172b, and pocket 172c) 174: Collar [Chart B] [Component Symbol Table] [Component symbol] [element], [part], [or component] 176: Screw 178:O-ring 180: Internal floating piston assembly 182: Internal floating piston (with flat surface 182a and convex portion 182b) 184: Screw 186: Seal ***

Claims

1. A suspension fork assembly, comprising: A fork includes a steering tube, a spring assembly tube having a cap insert and an insert assembly, and a shock absorber assembly tube having a cap insert and an insert assembly; a leg for a spring assembly configured for mounting within the spring assembly tube of the fork; and a leg for a shock absorber assembly configured for mounting within the shock absorber assembly tube of the fork; wherein the spring assembly tube includes an aerodynamic profile configured to provide less aerodynamic drag than an annular profile.

2. The suspension fork assembly as described in claim 1, wherein the shock absorber assembly tube includes an aerodynamic profile configured to provide less aerodynamic drag than an annular profile.

3. The suspension fork assembly as described in claim 1, wherein the aerodynamic profile includes a generally D-shaped profile.

4. The suspension fork assembly as described in claim 1, wherein the aerodynamic profile includes a cam tail.

5. The suspension fork assembly as described in claim 1, wherein the aerodynamic shape of the spring assembly tube produces less than 75% of the drag produced by an annular tube at 30 miles per hour.

6. The suspension fork assembly as described in claim 1, wherein the aerodynamic profile provides a drag of less than 1 N at 30 mph.

7. The suspension fork assembly as described in claim 1, wherein the fork includes a composite material.

8. The suspension fork assembly as described in claim 7, wherein the composite material is a carbon fiber material.

9. The suspension fork assembly as described in claim 1, comprising an inverted fork.

10. A suspension fork assembly, comprising: A spring-loaded combination tube; And a shock-absorbing combination pipe; The spring assembly tube includes an outer shape; The shape includes an aerodynamic shape configured to provide less aerodynamic drag than a ring-shaped shape.

11. The suspension fork assembly as described in claim 10, wherein the shock absorber assembly tube of the fork includes an outline; wherein the outline includes an aerodynamic shape configured to provide less aerodynamic drag than an annular shape.

12. The suspension fork assembly as described in claim 10, wherein the aerodynamic profile includes a generally D-shaped profile.

13. The suspension fork assembly as described in claim 10, wherein the aerodynamic profile includes a cam tail.

14. The suspension fork assembly as described in claim 10, wherein the aerodynamic shape of the spring assembly tube produces less than 75% of the drag produced by an annular tube at 30 miles per hour.

15. The suspension fork assembly as described in claim 10, wherein the aerodynamic profile provides a drag of less than 1 N at 30 mph.

16. The suspension fork assembly as described in claim 10, comprising an inverted fork.

17. The suspension fork assembly as described in claim 10, wherein the fork includes a composite material.

18. The suspension fork assembly as described in claim 17, wherein the composite material comprises a carbon fiber material.

19. The suspension fork assembly as described in claim 17, wherein the composite material comprises an engineered material.

20. A suspension fork assembly, comprising: One leg; A shock-absorbing assembly within the support leg includes a housing; wherein the housing has an upper end and a lower end; The casing is attached to a support leg for the shock absorption assembly at one of its upper or lower ends, while the other end of the upper or lower end is not attached.

21. The suspension fork assembly as described in claim 20, wherein the outrigger includes a shock-absorbing assembly tube.

22. The suspension fork assembly as described in claim 20, wherein the cartridge is suspended within a foot for the shock absorption assembly.

23. The suspension fork assembly as described in claim 20, wherein the cartridge is suspended at one upper end within a foot for the shock absorption assembly.

24. The suspension fork assembly as described in claim 20 further includes a spring assembly.

25. The suspension fork assembly as described in claim 24, wherein the spring assembly includes an air spring.

26. The suspension fork assembly as described in claim 20, wherein the shock absorption assembly includes a piston assembly.

27. The suspension fork assembly as described in claim 20, wherein the shock absorption assembly includes a floating piston.

28. The suspension fork assembly as described in claim 27, wherein the floating piston includes a seal.

29. The suspension fork assembly as described in claim 26, wherein the piston assembly includes a slip ring.

30. The suspension fork assembly as described in claim 29, wherein the slip ring system is configured to provide a seal for a fluid path through the piston assembly.

31. The suspension fork assembly as described in claim 26, wherein the piston assembly includes a first piston and a second piston.

32. The suspension fork assembly as described in claim 31, wherein the first piston is a compression piston.

33. The suspension fork assembly as described in claim 32, wherein the second piston is a rebound piston.

34. The suspension fork assembly as described in claim 26, comprising a piston washer for controlling fluid retention.

35. The suspension fork assembly as described in claim 31, wherein only one piston has a slip ring.

36. The suspension fork assembly as described in claim 35, wherein the slip ring system is configured to provide a seal through a fluid path between the first piston and the second piston.

37. The suspension fork assembly as described in claim 20, wherein the shock absorber assembly's cartridge system is configured for a piston assembly including an internal floating piston.

38. A shock absorber assembly for a suspension fork, comprising a piston assembly; wherein the piston assembly includes a first piston having a slip ring and a second piston not having a slip ring.

39. The damping assembly as described in claim 38, wherein the slip ring system is configured to provide a seal through a fluid path between the first piston and the second piston.

40. The damping assembly as described in claim 39, wherein the piston assembly includes a piston washer for controlling fluid flow.

41. The damping assembly as described in claim 40, wherein the piston gasket controls the fluid path.

42. The damping assembly as described in claim 41, wherein the first piston includes a compression piston and the second piston includes a rebound piston.

43. A suspension fork assembly, comprising: One leg; A shock-absorbing assembly within the support leg includes a cartridge; wherein the shock-absorbing assembly includes a piston assembly. The piston assembly includes a first piston with a slip ring and a second piston without a slip ring.

44. The suspension fork assembly as described in claim 43, wherein the slip ring system is configured to provide a seal for a fluid path through the piston assembly.

45. The suspension fork assembly as described in claim 43, wherein the first piston is a compression piston.

46. ​​The suspension fork assembly as described in claim 45, wherein the second piston is a spring-loaded piston.

47. The suspension fork assembly as described in claim 46, wherein the piston assembly includes a piston washer for controlling fluid flow.

48. The suspension fork assembly as described in claim 47, wherein the slip ring system is configured to provide a seal through a fluid path between the first piston and the second piston.

49. The suspension fork assembly as described in claim 48, wherein the piston washer controls the fluid path.

50. The suspension fork assembly as described in claim 43, wherein the piston assembly comprises only one slip ring.

51. A piston assembly for use in a shock absorber assembly of a suspension fork assembly, comprising: A first piston with a slip ring; a second piston without a slip ring; And a piston washer.

52. The piston assembly as described in claim 51, wherein the slip ring system is configured to provide a seal through a fluid path between the first piston and the second piston.

53. The piston assembly as described in claim 51, wherein the first piston is a compression piston; and wherein the second piston is a springback piston.

54. The piston assembly as described in claim 52, wherein the piston washer controls the fluid path.

55. The piston assembly as described in claim 52, wherein the fluid path passes through the first piston, the washer, and the second piston.

56. The piston assembly as described in claim 51, wherein only one piston has a slip ring.

57. The piston assembly as described in claim 51, which comprises only one slip ring.

58. A method of assembling a suspension fork assembly, wherein the suspension fork assembly includes components comprising a steering tube, a spring assembly tube having a cap insert, a shock absorber assembly tube having a cap insert, a leg for mounting a spring assembly within the spring assembly tube of the fork, and a leg for mounting a shock absorber assembly within the shock absorber assembly tube of the fork; the method comprising the steps of: preparing each cap insert for bonding; applying an adhesive to each cap insert for adhesive bonding; mounting each cap insert onto the fork; calibrating at least two of the components in a clamp; and curing each adhesive bond for each cap insert.

59. The method as described in claim 58, wherein the step of installing each cap insert for the fork includes installing the cap insert of the spring assembly tube into the spring assembly tube with the adhesive, and installing the cap insert of the shock absorber assembly tube into the shock absorber assembly tube with the adhesive.

60. The method as described in claim 58 further includes the steps of preparing a steering tube for bonding to the fork, applying an adhesive to the steering tube to form an adhesive bond, attaching the steering tube to the fork with the adhesive bond before placing the fork into the clamp, and curing the adhesive bond to the steering tube before removing the fork from the clamp.

61. The method as described in claim 60, wherein the steering tube comprises a composite material.

62. The method as described in claim 58, wherein the fork further includes an insert assembly, and the method further includes the steps of preparing the insert assembly for bonding to the fork, applying an adhesive to the insert assembly to form an adhesive bond, attaching the insert assembly to the fork with the adhesive bond before placing the fork into the clamp, and curing the adhesive bond of the insert assembly before removing the fork from the clamp.

63. The method as described in claim 62, wherein the step of attaching each insert assembly to the fork includes using the adhesive to install the insert assembly of the spring assembly tube into the spring assembly tube, and using the adhesive to install the insert assembly of the shock absorber assembly tube into the shock absorber assembly tube.

64. The method as described in claim 63, wherein the clamp is configured to calibrate the steering tube, the insert assembly in the spring assembly tube, and the insert assembly in the damping assembly tube.

65. The method as described in claim 63, wherein the clamp is configured to calibrate the cap insert in the spring assembly tube and the insert assembly in the spring assembly tube.

66. The method as described in claim 63, wherein the clamp is configured to calibrate the cap insert in the shock-absorbing assembly tube and the insert assembly in the shock-absorbing assembly tube.

67. The method as described in claim 59, wherein the clamp is configured to calibrate the cap insert in the spring assembly tube and the cap insert in the shock-absorbing assembly tube.

68. The method as described in claim 63, wherein the clamp is configured to calibrate the insert assembly in the spring assembly tube and the insert assembly in the damping assembly tube.

69. The method as described in claim 63, wherein the clamp is configured to calibrate the cap insert in the spring assembly tube, the cap insert in the damping assembly tube, the insert assembly in the spring assembly tube, and the insert assembly in the damping assembly tube.

70. The method as described in claim 63, wherein the clamp is configured to calibrate the steering tube, the cap insert in the spring assembly tube, the cap insert in the damping assembly tube, the insert assembly in the spring assembly tube, and the insert assembly in the damping assembly tube.

71. The method as described in claim 62, wherein the insert assembly includes a bushing and a seal.

72. The method as described in claim 62, wherein the insert assembly includes an upper bushing, a lower bushing, a foam ring, and a dust seal.

73. A suspension fork assembly manufactured by the method described in claim 58, comprising an inverted fork.

74. A suspension fork assembly manufactured by the method described in claim 58, comprising a composite material.

75. The suspension fork assembly as described in claim 74, wherein the composite material is a carbon fiber material.

76. A suspension fork assembly, comprising: A fork includes a steering tube, a spring assembly tube having a cap insert and an insert assembly, and a shock absorber assembly tube having a cap insert and an insert assembly; a leg for the spring assembly configured for mounting within the spring assembly tube of the fork; and a leg for the shock absorber assembly configured for mounting within the shock absorber assembly tube of the fork; wherein, upon adhesive bonding curing, the steering tube, the cap insert for the spring assembly tube, the cap insert for the shock absorber assembly tube, the insert assembly for the spring assembly tube, and the insert assembly for the shock absorber assembly tube are aligned.

77. The suspension fork assembly as described in claim 76, wherein the fork includes a composite material.

Images