MOTORCYCLE GUARD

• US 20150145232A1
• Filed: 11/27/2013
• Published: 05/28/2015
• Est. Priority Date: 11/27/2013
• Status: Active Grant

• Current Assignee: Zxibix Inc.
• Original Assignee: Zxibix Inc.
• Inventors: Carreira, Bernard K.
• Granted Patent: US 9,415,827 B2
• Time in Patent Office: Days
• US Class Current: 280/304.3
• CPC Class Codes: B62J 23/00 Other protectors specially adapted for cycles
• CPC Class Codes: B62K 21/02 Front wheel forks or equivalent, e.g. single tine
• CPC Class Codes: B62K 25/02 for mounting axles rigidly on cycle frame or fork, e.g. adjustably
• CPC Class Codes: Y10T 29/49948 Multipart cooperating fastener [e.g., bolt and nut]

Abstract

A plurality of protective cover assemblies and methods for protecting the front brake-side axle clamp and the front non-brake-side axle clamp of a motorcycle. A brake-side plastic cover plate is shaped to cover the brake-side axle clamp and brake caliper support and is coupled to the brake-side axle clamp utilizing existing brake-side axle clamp pinch bolt holes. A non-brake-side plastic cover plate is shaped to cover the non-brake-side axle clamp and is coupled to the non-brake-side axle clamp utilizing existing non-brake-side axle clamp pinch bolt holes. The cover assemblies deflect and absorb impact forces that would otherwise impact the axle clamps and the brake caliper support.

Claims

1. A protective cover system for an axle clamp, wherein the axle clamp is coupled to a front fork of a motorcycle, comprising:

a cover plate shaped to cover and conform to at least a portion of an axle clamp outer surface, the axle clamp having a first pinch bolt hole and a second pinch bolt hole, the axle clamp outer surface portion located generally perpendicular to a motorcycle front wheel, the cover plate including an impact face facing outward from the axle clamp when the cover plate is coupled to the axle clamp,

the cover plate having a first bolt hole located so that when the cover plate is coupled to the axle clamp, the first bolt hole is concentric to the first pinch bolt hole,

the cover plate having a second bolt hole located so that when the cover plate is coupled to the axle clamp, the second bolt hole is concentric to the second pinch bolt hole,

the cover plate comprising a resilient and flexible material,

the cover plate including a cover plate width generally equal to an axle clamp width of the axle clamp in a direction generally perpendicular to the motorcycle front wheel when the cover plate is coupled to the axle clamp,

the cover plate including a thickness configured for resisting breakage of the cover plate and protecting the axle clamp from damage when the cover plate sustains impact during use of the motorcycle,

a first spacer, of generally cylindrical shape, and comprising a rigid material, with a first spacer longitudinal axis coinciding with a first bolt hole longitudinal axis, a first spacer upper portion extending through at least a portion of the first bolt hole and coupled to the cover plate, the first spacer including a first spacer length greater than the thickness, whereby a cover plate interior face at the first spacer is separated from an axle clamp outer face by a first spacer distance equal to the first spacing length when the first spacer is coupled to the axle clamp at the first pinch bolt hole;

a second spacer, of generally cylindrical shape, and comprising a rigid material, with a second spacer longitudinal axis coinciding with a second bolt hole longitudinal axis, a second spacer upper portion extending through at least a portion of the second bolt hole and coupled to the cover plate, at the second hole location, and the second spacer including a second spacer length greater than the thickness, whereby the cover plate interior face at the second spacer is separated from the axle clamp outer face by a second spacer distance equal to the second spacing length when the second spacer is coupled to the axle clamp at the second pinch bolt hole;

a first bolt including a first bolt head and a threaded first bolt shaft, the first bolt shaft passing through the cover plate at the first bolt hole, the first spacer, and the first pinch bolt hole, wherein the first bolt head is mounted on a first spacer end proximate to the impact face of the cover plate, and the first bolt is threadably coupled to a first axle clamp top pinch bolt hole and a first axle clamp bottom pinch bolt hole;

a second bolt including a second bolt head and a threaded second bolt shaft passing through the cover plate at the second bolt hole, the second spacer, and the second pinch bolt hole, wherein the second bolt head is mounted on a second spacer end proximate to the impact face of the cover plate, and the second bolt is threadably coupled to a second axle clamp top pinch bolt hole and a second axle clamp bottom pinch bolt hole,

whereby the cover plate is coupled to the axle clamp so that the impact face is adjacent to the axle clamp outer surface, whereby the cover plate sustains an impact and flexes to absorb the impact and contact the axle clamp to distribute the impact over an axle clamp contact surface, whereby impact damage to the axle clamp is reduced.

2. The protective cover system for the axle clamp according to claim 1, wherein the first spacer includes a first flange at the first spacer end proximate to the impact face and the second spacer includes a second flange at the second spacer end proximate to the impact face.

3. The protective cover system for the axle clamp according to claim 1, wherein the first spacer includes a first annular notch in a first spacer outer face portion coupled to the cover plate and the second spacer includes a second annular notch in a second spacer outer face portion coupled to the cover plate.

4. The protective cover system for the axle clamp according to claim 3, wherein the first annular notch extends to the first spacer end proximate to the impact face and the second annular notch extends to the second spacer end proximate to the impact face.

5. The protective cover system for the axle clamp according to claim 1, including an access hole located and configured to provide access to a motorcycle compression damping adjustment when the cover plate is coupled to the axle clamp.

6. The protective cover system for the axle clamp according to claim 1, wherein the cover plate covers an front disc brake support underside.

7. The protective cover system for the axle clamp according to claim 6, wherein the cover plate width varies to match a front disc support width of the front disc brake support underside.

8. The protective cover system for the axle clamp according to claim 1, further comprising a wheel guard distance between an edge of the cover plate proximate to the motorcycle front wheel and the motorcycle front wheel, whereby a wheel guard may be installed on the motorcycle front wheel between the edge of the cover plate proximate to the motorcycle front wheel and the motorcycle front wheel.

9. The protective cover system for the axle clamp according to claim 1, further comprising a wheel guard fin integrally coupled to at least a cover plate edge portion proximate to the motorcycle front wheel and extending towards a front wheel tire parallel to a motorcycle front wheel plane.

10. The protective cover system for the axle clamp according to claim 1, wherein the impact face includes a first annular recess at the first bolt hole and a second annular recess at the second bolt hole, whereby the first bolt head is snugly mounted in the first annular recess and the second bolt head is snugly mounted in the second annular recess when the cover plate is coupled to the axle clamp.

11. The protective cover system for the axle clamp according to claim 1, wherein the axle clamp includes a first bolt head recess and a second bolt head recess, and wherein a first spacer end proximate to the axle clamp includes an outer diameter equal to the first bolt head recess, and wherein a second spacer end proximate to the axle clamp includes an outer diameter equal to the second bolt head recess, whereby the first spacer is snugly mounted in the first bolt head recess and the second spacer is snugly mounted in the second bolt head recess.

12. The protective cover system for the axle clamp according to claim 1, further comprising an integral tab coupled to the cover plate and a motorcycle lower brake caliper mounting bolt.

13. The protective cover system for the axle clamp according to claim 1, further comprising a spacer connector, a first end of the spacer connector coupled to a side of the first spacer, and a second end of the spacer connector coupled a side of the second spacer, whereby the first spacer and the second spacer are coupled in a configuration suitable for coupling to the axle clamp.

14. A method of making a protective cover system for an axle clamp, wherein the axle clamp is coupled to a front fork of a motorcycle, comprising the steps of:

forming a cover plate comprising a resilient and flexible material, in a shape covering and conforming to at least a portion of an axle clamp outer surface, the axle clamp outer surface portion being generally perpendicular to a motorcycle front wheel, the cover plate including a first bolt hole and a second bolt hole, the cover plate comprised of a resilient and flexible material, the cover plate including a cover plate width generally equal to an axle clamp width of the axle clamp outer surface portion, the cover plate including a cover plate thickness configured for resisting breakage of the cover plate and protecting the axle clamp from damage when the axle clamp sustains impact during use of the motorcycle, the cover plate including an impact face facing outward from the axle clamp when the cover plate is coupled to the axle clamp;

coupling a first spacer, wherein the first spacer is generally cylindrical, to the first bolt hole so that a first spacer portion extends through at least a portion of the first bolt hole, and a remainder of the first spacer extends outward from the cover plate face proximate to the axle clamp outer surface;

coupling a second spacer, wherein the second spacer is generally cylindrical, to the cover plate at the second hole so that a portion of the second cylindrical spacer extends through at least a portion of the first bolt hole, and a remainder of the second spacer extends outward from the face of the cover plate proximate to the axle clamp outer surface;

providing a first bolt including a first bolt head, and a first threaded bolt shaft, the axle clamp having a first pinch bolt hole and a second pinch bolt hole, the first bolt configured to be inserted in the first pinch bolt hole and threadably coupled to a first axle clamp top pinch bolt hole and a first axle clamp bottom pinch bolt hole, whereby the cover plate and the first spacer are coupled to the axle clamp;

providing a second bolt including a second bolt head and a second threaded bolt shaft, the second bolt configured to be inserted in the second pinch bolt hole and threadably coupled to a second axle clamp top pinch bolt hole and a second axle clamp bottom pinch bolt hole, whereby the cover plate and the second spacer are coupled to the axle clamp, whereby the cover plate covers the axle clamp outer surface portion and flexes, whereby an at least one impact from an external source is resisted by resilience and flexure of the cover plate as it contacts the axle clamp outer surface portion.

15. The method of making the protective cover system for the axle clamp according to claim 14, wherein the cover plate is formed by a method of forming selected from the group consisting of molding, thermoforming, and casting.

16. The method of making the protective cover system for the axle clamp according to claim 14, wherein the first spacer and the second spacer are comprised of metal.

17. The method of making the protective cover system for the axle clamp according to claim 14, wherein the first spacer includes a first flange at a first spacer end proximate to the impact face and the second spacer includes a second flange at a second spacer end proximate to the impact face.

18. The method of making the protective cover system for the axle clamp according to claim 14, wherein the first spacer includes a first annular notch in a first spacer outer face portion coupled to the cover plate and the second spacer includes a second annular notch in a second spacer outer face portion coupled to the cover plate.

19. The method of making the protective cover system for the axle clamp according to claim 18, wherein the first annular notch extends to a first spacer end proximate to the impact face and the second annular notch extends to a second spacer end proximate to the impact face.

20. The method of making the protective cover system for the axle clamp according to claim 14, wherein the cover plate includes an access hole located and configured to provide access to a motorcycle compression damping adjustment when the cover plate is coupled to the axle clamp.

21. The method of making the protective cover system for the axle clamp according to claim 14, wherein the cover plate covers an underside of a front disc brake caliper support when the cover plate is coupled to the axle clamp.

22. The method of making the protective cover system for the axle clamp according to claim 21, wherein the cover plate width varies to match a front disc brake caliper support width of the front disc brake caliper support.

23. The method of making the protective cover system for the axle clamp according to claim 14, wherein the cover plate includes a front brake disc guard fin integrally coupled to at least an axle clamp edge portion proximate to the motorcycle front wheel, the front brake disc guard fin extending towards a front wheel tire in a direction parallel to a motorcycle front wheel plane.

24. The method of making the protective cover system for the axle clamp according to claim 14, wherein the impact face includes a first annular recess at the first bolt hole and a second annular recess at the second bolt hole, whereby the first bolt head is snugly mounted in the first annular recess and the second bolt head is snugly mounted in the second annular recess when the cover plate is coupled to the axle clamp.

25. The method of making the protective cover system for the axle clamp according to claim 24, wherein the axle clamp includes a first bolt head recess and a second bolt head recess, and wherein a first spacer end proximate to the axle clamp includes an outer diameter equal to the first bolt head recess, and wherein a second spacer end proximate to the axle clamp includes an outer diameter equal to the second bolt head recess, whereby the first spacer is snugly mounted in the first bolt head recess and the second spacer is snugly mounted in the second bolt head recess.

26. The method of making the protective cover system for the axle clamp according to claim 14, further comprising an integral tab coupled to the cover plate and to a motorcycle lower brake caliper mounting bolt.

27. The method of making the protective cover system for the axle clamp according to claim 14, further comprising a spacer connector, a first end of the spacer connector coupled to a side of the first spacer, and a second end of the spacer connector coupled a side of the second spacer, whereby the first spacer and the second spacer are coupled in a configuration suitable for coupling to the axle clamp.

28. The method of making the protective cover system for the axle clamp according to claim 14, wherein the cover plate is formed using computer numerical control.

29. A method of using a protective cover system for an axle clamp, wherein the axle clamp is coupled to a front fork of a motorcycle, and the axle clamp includes an axle clamp outer surface, comprising the steps of:

coupling the protective cover system including a resilient and flexible cover plate, the cover plate having a first bolt hole and a second bolt hole and including a cover plate width, and the protective cover system including a first spacer and a second spacer, to the axle clamp, the axle clamp having a first pinch bolt hole and a second pinch bolt hole, wherein a first bolt including a first bolt head and an threaded first bolt shaft is threadably coupled to a first axle clamp top pinch bolt hole and a first axle clamp bottom pinch bolt hole after the first bolt is passed through the first bolt hole, the first spacer, and a second bolt including a second bolt head and a second threaded bolt shaft is threadably coupled to a second axle clamp top pinch bolt hole and a second axle clamp bottom pinch bolt hole after the first bolt is passed through the second bolt hole, the second spacer, whereby the axle clamp outer surface is covered by the cover plate, the cover plate generally following the axle clamp outer surface and including an impact face facing outward from the axle clamp when the cover plate is coupled to the axle clamp;

sustaining an at least one external impact to the cover plate while operating the motorcycle, whereby the impact is absorbed by the cover plate flexing, whereby a cover plate surface portion proximate to the axle clamp contacts an axle clamp outer surface portion, whereby the impact is sustained without damage to the axle clamp.

30. The method of using the protective cover system for the axle clamp according to claim 29, wherein the cover plate covers a front disc brake support underside when the cover plate is coupled to the axle clamp.

31. The method of using the protective cover system for the axle clamp according to claim 30, wherein the cover plate width varies to match a front disc brake caliper support width of the front disc brake caliper support underside.

32. The method of using the protective cover system for the axle clamp according to claim 29, wherein the cover plate includes a front brake disc guard fin integrally coupled to at least a portion of an axle clamp edge proximate to the motorcycle front wheel, the front brake disc guard fin extending towards a front wheel tire in a direction parallel to a motorcycle front wheel plane.

33. The method of using the protective cover system for the axle clamp according to claim 29 wherein the impact face includes a first annular recess at the first bolt hole and a second annular recess at the second bolt hole, whereby the first bolt head is snugly mounted in the first annular recess and the second bolt head is snugly mounted in the second annular recess when the cover plate is coupled to the axle clamp.

34. The method of using the protective cover system for the axle clamp according to claim 29, wherein the axle clamp includes a first bolt head recess and a second bolt head recess, and wherein a first spacer end proximate to the axle clamp includes an outer diameter equal to the first bolt head recess, and wherein a second spacer end proximate to the axle clamp includes an outer diameter equal to the second bolt head recess, whereby the first spacer is snugly mounted in the first bolt head recess and the second spacer is snugly mounted in the second bolt head recess.

35. The method of using the protective cover system for the axle clamp according to claim 29, further comprising an integral tab coupled to the cover plate and to a motorcycle lower brake caliper mounting bolt.

36. The method of using the protective cover system for the axle clamp according to claim 29, further comprising a spacer connector, a first end of the spacer connector coupled to a side of the first spacer, and a second end of the spacer connector coupled a side of the second spacer, whereby the first spacer and the second spacer are coupled in a configuration suitable for coupling to the axle clamp.