Handguard for bikes, and method for manufacturing

Abstract

The invention relates to a handguard for a motorcycle. The handguard is formed from a moldable plastic and has a body that has a convex outer surface and a concave inner surface. The body extends between a proximal end and distal end via a middle part. The middle part comprises an attachment unit for connecting to the motorcycle. The attachment unit can be a through-hole or a clamping part. The body and the attachment unit are integrally formed.

Description

HANDGUARD FOR BIKES, AND METHOD FOR MANUFACTURINGBACKGROUND OF THE INVENTION1. Field of the Invention

[0001] The invention relates generally to a handguard for bikes, such as motorcycles or electric motorcycles. The invention also relates to bikes, motorcycles, motor bikes and electric motor bikes with a handguard. The invention also relates to manufacturing a handguard for a bike or motor bike.2. Description of the Related Art

[0002] The handguard is a very useful motorcycle accessory which protects you from branches, bushes, projectiles and bad weather. It also protects elements present on the handlebars, such as the brake lever, the clutch lever and / or the handgrip. In addition, the handguard has a wind proof effect and can protect you from cold and rain.

[0003] Handguards are fixed to the steering handlebar close to the handgrip. The handguard has the protective surface that extends from a proximal end to the distal end over the handgrip and a mounting part that connects the protective surface to a part of the steering handlebar. The protective surface and mounting part are expensive and fragile. The handguard adds weight to the steering handlebar

[0004] Thus, there is a need for reducing the cost of a handguard. There is a need to create a simpler handguard. There is a need to create a stronger handguard. A further goal is reducing the weight of the handguard.BRIEF SUMMARY OF THE INVENTION

[0005] The present invention addresses at least one of these problems by providing a handguard for a motorcycle, the handguard formed from a moldable plastic having a synclastic body with a first radius and a second radius, wherein the second radius is smaller than the first radius, the synclastic body having a convex outer surface and a concave inner surface. The synclastic body can form the protective surface of the handguard. The synclastic body provides structural strength to the body, increasing the protective function of the handguard.

[0006] In embodiments, the synclastic body extends between a proximal end and distal end via a middle part. The synclastic body extends towards the distal end of the handgrip, when the handguard is mounted on the steering handlebar.

[0007] In embodiments, the middle part comprises two wings at opposite sides of the synclastic body, wherein each wing has at least one through-hole for connecting to the motorcycle. The through-hole is pre-formed, e.g. during molding. This reduces the steps needed for attaching the handguard to the steering handlebar.

[0008] According to embodiments of the invention, the synclastic body and the wings are integrally formed. By forming the synclastic body and wings into a single molded body, the costsare reduced. Not only the manufacturing costs are reduced, but also the time and costs for fixing the handguard to the steering handlebar. Also, the CO2 mark is reduced by using a single molded component. The integrally formed handguard can be formed using less material, while making it also lighter and higher performance, e.g. with higher resistance against breakage.

[0009] In embodiments, the first radius increases towards the distal end. This provides a rounding off of the curvature towards the distal end. The reduced curving results in more flexibility of the distal end allowing it to bend in case of a collision. The synclastic body has preferably a length that allows the distal end thereof to extend beyond the distal tip of the handgrip that it protects.

[0010] In embodiments, the second radius increases towards the distal end. This too reduces the structural integrity of the handguard towards the distal end, allowing it give in in case of a collision.

[0011] In embodiments, near a rim of the synclastic body extending in a longitudinal direction between distal and proximal end is anticlastic with respect to the first radius. The synclastic body has a first radius that follows the inner convex and outer concave shape of the synclastic body. The rim has a curvature with a third radius that is position anticlastic. In embodiments, the rim has a third radius that is smaller than the second radius. This allows for a short rim providing extra structural integrity to the rim along the body of the handguard.

[0012] In embodiments, a cross-section of the synclastic body at the middle part through the wings comprises a concave outer surface. In embodiments, the cross-section has two concave outer surfaces. The concave outer surface provides further structural integrity to the body, in particular near the wings. This allows transferring larger forces onto the connection with the steering handlebar.

[0013] In embodiments, the two concave outer surfaces connect at a ridge that extends along a longitudinal direction of the synclastic body. The ridge is formed on the outer surface of the synclastic body. It extends in the longitudinal direction by extending over some distance between proximal and distal end. In a preferably embodiment, the ridge transitions into a rim of the synclastic body towards the distal end.

[0014] In embodiments, the handguard has a thickness between outer surface and inner surface that decreases towards the distal end. This lowers the structural integrity of the body towards the more flexing distal end.

[0015] In an embodiment, each wing has a through-hole. The through-holes are generally aligned. This allows connecting those wings around a body, such as a control lever unit or brake unit. The connection can be made on opposite sides of the control lever unit. In embodiments, one wing has a second through-hole. By providing two through-holes on one wing, a connection can be made that is rotation stable / can withstand rotation forces. All of the first and second through-holes configured for connecting to the motorcycle.

[0016] In an embodiment, the handguard has an inflection point near the distal end.

[0017] In an embodiment, a rim of the synclastic body is monotonic curved in a transition connecting the wing to the middle part of the body of the handguard. This prevents sharp edgesthat could cause injury to the hand. In embodiments, each of the transitions connecting the wings to the middle part are monotonically curved.

[0018] According to a further aspect that can be combined with any of the features discloses in relation to the handguard of the first aspect, a handguard for a motorcycle is provided, wherein the handguard is formed from a moldable plastic having a body, the body having a convex outer surface and a concave inner surface, wherein the body extends between a proximal end and distal end via a middle part, wherein the middle part comprises an attachment unit for connecting to the motorcycle, and wherein the body and the attachment unit are integrally formed. The handguard formed as a single mold is less expensive, while having a higher structural integrity than prior art handguards.

[0019] The handguard according to any of the aspect disclosed herein is a single-piece mold, which eliminates the need for multi-component assembly, reducing production costs and reduces the points of failure. Also, improved strength and durability can be obtained, as the one- piece design enhances structural integrity, making the handguard more resistant to impacts and wear. With a single-piece mold, the production process is simplified, and cost efficiency is achieved.

[0020] According to a further aspect a motorcycle with a steering handlebar is provided. A hand grip is provided at a distal end of the steering handlebar. The handguard according to any of embodiments disclosed here can be mounted on the steering handlebar, preferably proximal from the hand grip.

[0021] In embodiments of the motorcycle, a handguard mount is fixed onto the steering handlebar to which the handguard is connected. The handguard mount can be connected to a frame part, such as tube, of the steering handlebar.

[0022] In embodiments of the motorcycle, a control lever unit is provided on the steering handlebar. The control lever unit can be a brake unit or clutch unit. The control lever unit is mounted to the steering handlebar proximal from the handgrip. The control lever unit has a lever connected via a first axis to the control lever unit, wherein the handguard is connected to the control lever unit.

[0023] In embodiments of the motorcycle, the first through holes of the handguard receive connectors, such as screws or bolts, that are connected to the first axis of the control lever unit. The preformed through-holes are used for connecting the wings of the single-piece handguard to the steering handlebar, and in particular to the brake unit.

[0024] According to yet further aspects of the invention a method for manufacturing a single-piece handguard is provided. The method comprises providing a moldable plastic and a mold having a single cavity shaped to form the handguard including the synclastic body and the two wings, casting the plastic in the mold, and curing the plastic.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to describe the manner in which the above-recited and other advantages and features of the disclosure can be obtained, a more particular description of the principlesbriefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only exemplary embodiments of the disclosure and are therefore not to be considered to be limiting of its scope, the principles herein are described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0026] FIG. 1a is a schematic perspective view of a motorcycle that can equipped with an intergrally formed handguard according to embodiments of the invention;

[0027] FIG. 1 b is a schematic perspective view of a steering handlebar that can equipped with an intergrally formed handguard according to embodiments of the invention;

[0028] FIG. 2 is a detailed view of an embodiment of a handguard according to an embodiment of the invention;

[0029] FIG. 3 is a detailed view of a furter embodiment of a handguard according to an embodiment of the invention;

[0030] FIG. 4 is a sectional view of the handguard of FIG. 3 along line IV-IV in FIG. 3; and

[0031] FIG. 5 is a further perspective view of a detail of an integrally formed handguard.DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0032] The following is a description of certain embodiments of the invention, given by way of example only and with reference to the drawings. The drawings are not necessarily to the actual scale and only serve the purpose of illustrating necessary teachings for implementing the present invention.

[0033] Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. Thus, the following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, well-known or conventional details are not described in order to avoid obscuring the description. A reference to an embodiment in the present disclosure can be a reference to the same embodiment or any other embodiment. Such references thus relate to at least one of the embodiments herein.

[0034] Reference to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others.

[0035] The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used.Alternative language and synonyms may be used for any one or more of the terms discussedherein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only and is not intended to further limit the scope and meaning of the disclosure or of any example term.Likewise, the disclosure is not limited to various embodiments given in this specification.

[0036] Without intent to limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions will control.

[0037] Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims or can be learned by the practice of the principles set forth herein.

[0038] The following is a description of certain embodiments of the invention, given by way of example only and with reference to the drawings. Referring to Fig. 1 a perspective view of a saddle-type vehicle 10 is shown. The saddle-type vehicle 10 particularly is a motorcycle.Typically, the motorcycle 10 comprises a front wheel 17, a rear wheel 19 and a seat 14. In various embodiments, the motorcycle 10 comprises a wheel fork 16 supporting the front wheel 17. The wheel fork 16 and the front wheel 17 are configured to rotate a rotational axis of the front wheel 17 with respect to a rotational axis of the rear wheel 19 in order to steer the motorcycle 10.

[0039] In various embodiments the motorcycle 10 comprises a structural frame 12 supporting the seat 14 and the engine 13. In various embodiments the rotational axis of the rear wheel 19 has a fixed orientation with respect to the structural frame 12. In various embodiments the wheel fork 16 is connected to the structural frame 12 by means of a steering joint. The steering joint preferably has a rotational axis perpendicular to both, the rotational axis of the front wheel 17 and to the rotational axis of the rear wheel 19.

[0040] The steering 15 is configured to rotate the wheel fork 16 about the steering joint with respect to the structural frame 12. By rotating the wheel fork 16 about the steering joint with respect to the structural frame 12, the rotational axis of the front wheel 17 is rotated with respect to the rotational axis of the rear wheel 19.

[0041] In various embodiments the wheel fork 16 comprises a front suspension such as a telescoping fork having a spring for elastic deflection and a damper for shock absorption. In various embodiments, the motorcycle 10 comprises a rear suspension 18 suspending the rearwheel 19 with respect to the structural frame 12. In various embodiments the rear suspension 18 comprises a spring for elastic deflection and a damper for shock absorption. In various embodiments the front and rear suspensions are adjustable by preloading the respective spring and / or manipulating the respective damper.

[0042] In various embodiments, the motorcycle comprises a bodywork 11 covering a portion of the structural frame 12 and preferably a portion of the engine 13. In various embodiments, the seat 14 is arranged on the body work 11 . In various embodiments the engine 13 comprises an energy source. In various embodiments the engine 13 is an electric engine and the energy source is a battery such as a secondary battery. In further embodiments the engine 13 is an internal combustion engine and the energy source is a fuel tank. In various embodiments, the engine 13 drives the rear wheel 19 by means of a chain drive, a belt drive or a shaft drive. In various embodiments, the engine is associated with a motorcycle data processing unit configured to centrally determine, process, and control at least portions of the operation of the motorcycle 10.

[0043] In various embodiments the seat 14 is configured to accommodate the user. The steering 15 is configured to receive a user input for adjusting a motorcycle function and / or to display at least one state indicator of the motorcycle 10.

[0044] Fig. 1 b shows an embodiment of the steering 15. In various embodiments the steering 15 comprises a steering handlebar 21 with user interface units 23, 25 and 27. In various embodiments the steering handlebar 21 has a tubular shape with a hollow centre extending along the steering handlebar 21 .

[0045] In various embodiments the user interface unit comprises at least one of a throttle grip 23, a control interface unit 25, and a control lever 27. Additionally, a display can be present. Throttle grip 23 and handgrip 24 are mounted on the distal ends of the steering handlebar 21 . Throttle grip 23 and handgrip 24 can be mounted on the opposite ends.

[0046] In various embodiments operating the throttle grip 23 controls the power released by the engine 13 to the rear wheel 19. In various embodiments the control lever 27 is configured to operate the brakes or a clutch for disengaging a driving connection between the engine 13 and the rear wheel 19. In various embodiments the control interface unit 25 is configured to receive user input with reduced requirements for real-time operation for the motorcycle 10, such as switching on and off the motorcycle, switching and adjusting lights, a turn indicator, and / or a horn.

[0047] In various embodiments the steering 15 comprises a data distributer configured to receive at least one of a communication from the control interface unit 25, the throttle grip 23, the control lever 27. In various embodiments, the data distributer is configured for wireless communication with the display unit. In various embodiments, the data distributer can be connected electrically with the control interface unit 25, the throttle grip 23 and / or the control lever 27 across a signal line.

[0048] Mounted at the front (towards the front wheel 17) side of the handgrips 23,24 are handguards 43,44.

[0049] Handguard 43 is connected to the control lever 27. Lever 37 of control lever 27 is also protected by handguard 43 against objects such as branches.

[0050] A connector such as a bolt 50, connects the handguard to the control lever 27. That same bolt 50 forms the axis of the lever 27. As will be discussed in relation to other drawings, a single bolt can be received in two opposite through-holes in wings of the handguard 43 for connecting the handguard to the control lever 27. Control lever 27 is connected to the steering handlebar 22 via a clamp 47.

[0051] Handguard 44 is connected to a bracket 46 that is mounted on the steering handlebar 22. Bracket 46 is clamped using a suitable clamp 49 onto the bar of handlebar 22. Other attachments are possible too.

[0052] Both handguards 43 and 44 are connected to the handlebar 22 at a location that is proximal from the handgrip 23,24. The handgrips 23,24 are mounted distal. The handguards 43, 44 extend to the distal end in order to protect the hand of the user in any gripping position of the handgrip 23,24.

[0053] Bracket 46 provides similar connection options as the control lever 27. A bolt 57 is received in through-holes in wings of the handguard for connecting the handguard 44 to the bracket 46.

[0054] FIG.2 shows a detail of handguard 44. Bracket 46 connects the handguard via clamp 48 to handlebar 22 proximal from handgrip 24.

[0055] A bolt 57 forms a connector. Bolt 57 is received in a through-hole in wing 61 of handguard 44. Wing 61 is integrally formed with the body of handguard 44. Wing 61 is an integral part of middle part 69 of the body that has a proximal end 74 and distal end 64.

[0056] FIG.2 shows the outer surface of the handguard 44 that is convex shaped with a curvature 81. In FIG.2 the first radius 87 of the curvature 81 is shown by a dotted line. First radius 87 is the radius at the middle part 69. The curvature 81 can vary along the longitudinal length. The first radius 87 will increase towards the distal and proximal ends.

[0057] The body of the handguard 44 is synclastic having a second curvature 82 at middle part 69. The first radius 87 of curvature 81 is larger than the second radius of curvature 82 at the middle part 69. The synclastic form forms a protective cavity for the hand that grips the handgrip, and reinforces the body to maintain it shape. The synclastic form resists and deflects objects.

[0058] At the transition of the wing 61 to longitudinal rim 63, a monotonically curved corner 62 (shown with a dotted line) is formed to reinforce the connection of the wing 61 with the middle part 69 and the rest of the body of the handguard 44. Corner 72 is formed similar to corner 62.

[0059] Also, close along the longitudinal rim 63, the body is shaped anticlastic. In some embodiments, the body of the handguard has an inflection points near the distal end.

[0060] FIG.3 shows handguard 43 mounted to control lever 27 that is fixed to the handlebar 22 via a clamp 47 proximal from handgrip 23.

[0061] A bolt 50 is received in a through-hole in wing 95 of the integral body of the handguard 43. The through-hole is formed during molding of the handguard 43,44. The invention provides an integrally formed by moulding handguard that has the synclastic body, has two wings 95 and through-holes formed therein.

[0062] Wing 95 is an integral part of the molded body of handguard 43. The wing 95 is integrally connected with a middle part 99 of the molded body positioned between distal end 97 and proximal end 96. Middle part 99 has synclastic curvatures 91 and 92. First radius 119 of the first curvature is larger than the second radius of the second curvature. The second curvature has a smaller radius than the first curvature. The shortest radius of the first curvature is positioned in the middle part, where the wing 95 is formed to the body.

[0063] The molded body is formed from a hard plastic. The molded body has a synclastic shape with the first curvature 91 extending the longitudinal direction between distal end 97 and proximal end 96 and a second curvature perpendicular thereto that extends between the two wings 95 of the body.

[0064] The inner surface 103 is, as a result of the first curvature generally concave shaped between the distal and proximal end. Handguard 43 has similar transitions 93,94 between the wing 95 and the rim of the handguard.

[0065] FIG.4 shows the handguard 43 in cross section across line IV-IV shown in FIG.3 having distal end 97.

[0066] Outer surface 121 of the middle part 99 is shown in cross-section with the second curvature having generally a second radius 131 . Inner surface 122 is similarly formed with the second curvature. The first curvature extends in and out of the paper.

[0067] The body of the handguard 43 is integrally formed with first wing 95 and second wing 109 that extends parallel along wing 95. Wings 95,109 both have a through-hole and the through- holes are provided such at a single bolt 130 can extend through those through-holes so that the handguard can be connected to the control lever 27. The bolt 130 also forms the axis of the lever 37.

[0068] Also shown in the cross-section is ridge 128 that extends in the longitudinal direction of the synclastic body from the middle part 99 towards the distal end. Ridge 128 transitions into the rim 102 towards the distal end 97. Ridge 128 is formed by the outer surface (and inner surface) of the body having two concave 126,127 (convex) shaped parts that merge into the ridge. The ridge provides additional rigidity. Also, on the inner side of the body, extra space is created for the user’s hand.

[0069] FIG.5 shows middle part 160 of the synclastic handguard body. Middle part 160 has wing 109. Two connectors connect wing 109 to control lever 37. The end of the bolt pin 140 forms the axis of lever 37. Connector 150 is also received in a second through-hole formed in wing 109. Although connectors 50 and 140 will already connect the integrally formed handguard to the control lever 27, connector 150 will provide a further connection that prevents rotation of the handguard with respect to the control lever 27.

[0070] In yet a further embodiment, the handguard 44 is integrally formed to include the bracket 46 and a part of clamp 48. Then, a handguard is provided from a single piece, completely integrally formed. This reduces the costs, reducing the production time.

[0071] Any of the embodiments disclosed herein can be formed by molding. In embodiments, injection molding is used. The handguard, specifically the synclastic body withwings, can be formed by providing a moldable plastic and a mold having a single cavity. The plastic is casted in the mold and cures. The body is formed with recess in the wings so that the handguard can be connected to either a bracket or a control lever. In other embodiments the handguard body is formed with a portion of clamp 46,47 for direct connection to the handlebar 22.

[0072] Further modifications in addition to those described above may be made to the structures and techniques described herein without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, these are examples only and are not limiting upon the scope of the invention.

Claims

CLAIMS1. A handguard for a motorcycle, the handguard formed from a moldable plastic having a synclastic body with a first radius and a second radius, wherein the second radius is smaller than the first radius, the synclastic body having a convex outer surface and a concave inner surface, wherein the synclastic body extends between a proximal end and distal end via a middle part, wherein the middle part comprises two wings at opposite sides of the synclastic body, wherein each wing has at least one through-hole for connecting to the motorcycle, and wherein the synclastic body and the wings are integrally formed.

2. Handguard according to claim 1 Handguard according to any of the preceding claims, wherein each wing has a through-hole that is generally aligned, and wherein one wing has a second through-hole, the first and second through-holes configured for connecting to the motorcycle.

3. Handguard according to any of the preceding claims, wherein near a rim of the synclastic body extending in a longitudinal direction between distal and proximal end is anticlastic with respect to the first radius, wherein preferably the anticlastic rim has a third radius that is smaller than the second radius.

4. Handguard according to any of the preceding claims, wherein a cross-section of the synclastic body at the middle part comprises a concave outer surface, preferably two concave outer surfaces,5. Handguard according to claim 4, wherein the two concave outer surface connect at a ridge that extends along a longitudinal direction of the synclastic body, wherein preferably the ridge transitions into a rim of the synclastic body towards the distal end.

6. Handguard according to any of the preceding claims, wherein the first and / or the second radius increases towards the distal end.

7. Handguard according to any of the preceding claims, wherein each wing has a through-hole that is generally aligned, and wherein one wing has a second through-hole, the first and second through-holes configured for connecting to the motorcycle.

8. Handguard according to any of the preceding claims, wherein an inflection point of the first radius is positioned near the distal end.

9. Handguard according to any of the preceding claims, wherein a rim of the synclastic body is monotonic curved in a transition connecting the wing to the middle part of the body, wherein preferably each of the transitions connecting the wings to the middle part are monotonically curved.

10. A handguard for a motorcycle, the handguard formed from a moldable plastic having a body, the body having a convex outer surface and a concave inner surface, wherein thebody extends between a proximal end and distal end via a middle part, wherein the middle part comprises an attachment unit for connecting to the motorcycle, and wherein the body and the attachment unit are integrally formed wherein preferably the attachment unit comprises wings with through-holes for mounting the handguard directly or indirectly to the steering handlebar.11 . Motorcycle with a steering handlebar and a hand grip at a distal end of the steering handlebar, wherein the handguard according to any of the previous claims is mounted proximal from the hand grip.

12. Motorcycle according to claim 11 , wherein a handguard mount is fixed onto the steering handlebar to which the handguard is connected.

13. Motorcycle according to claim 11 or 12, wherein a control lever unit, such as a brake unit, is mounted to the steering handlebar proximal from the handgrip, wherein the control lever unit has a lever connected via a first axis to the control lever unit, wherein the handguard is connected to the control lever unit.

14. Motorcycle according to claim 13, wherein the first through holes of the handguard receive connectors, such as screws or bolts, that form a first axis of the control lever unit, wherein preferably at least one wing of the handguard has a second through-hole that also receives a connector for connecting the handguard to the control lever unit, wherein the second through-hole and connector are arranged to rotation lock the handguard to the control lever unit.

15. Method for manufacturing a handguard according to any of the claims 1-10, the method comprising providing a moldable plastic and a mold having a single cavity shaped to form the handguard including the synclastic body and the two wings; casting the plastic in the mold; and curing the plastic.

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