Methods and apparatus for structural reinforcement of vehicle suspension members

Abstract

A method and apparatus for assembling a suspension. In one embodiment, a method includes altering a temperature of a first suspension component and then pressing the first suspension component and a second suspension component into engagement while the temperature remains substantially altered.

What we claim is: 
     
         1 . A vehicle suspension fork comprising:
 a crown having a first fork tube opening and a second fork tube opening;   a first fork tube retained in said first fork tube opening wherein such retention creates a compressive hoop stress in said first fork tube and a tensile hoop stress in said first fork tube opening but creates no substantial axial stress in either of said first fork tube or said first fork tube opening;   a second fork tube retained in said second fork tube opening wherein such retention creates a compressive hoop stress in said second fork tube and a tensile hoop stress in said second fork tube opening but creates no substantial axial stress in either of said second fork tube or said second fork tube opening;   wherein said vehicle suspension fork is made by a process of:
 conditioning a first portion of said suspension fork to a non-ambient temperature; 
 precisely positioning said first portion relative to at least one second portion of said vehicle suspension fork while said non-ambient temperature remains substantially as conditioned; and 
 returning assembled portions to a substantially ambient temperature. 
   
     
     
         2 . The vehicle suspension fork of  claim 1 , wherein said first portion comprises said crown. 
     
     
         3 . The vehicle suspension fork of  claim 1 , wherein said at least one second portion comprises fork legs. 
     
     
         4 . The vehicle suspension fork of  claim 1 , wherein said at least one second portion of said vehicle suspension fork is conditioned at said substantially ambient temperature. 
     
     
         5 . The vehicle suspension fork of  claim 1 , wherein there exists a temperature difference between said first portion and said at least one second portion. 
     
     
         6 . The vehicle suspension fork of  claim 1 , wherein said first portion comprises said crown and said at least one second portion comprises said first fork tube and said second fork tube, and wherein while said crown remains conditioned to said non-ambient temperature, an inner diameter of each of said first fork tube opening and said second fork tube opening enlarges relative to an outer diameter of an end of said each of said first fork tube and said second fork tube, thereby enabling said first fork tube opening and said second fork tube opening to more easily receive said end of said each of said first fork tube and said second fork tube while said crown remains said conditioned. 
     
     
         7 . The vehicle suspension fork of  claim 1 , wherein after said returning assembled portions to said substantially ambient temperature and said assembled portions achieve an equal temperature, said assembled portions comprise a press-fit between a female portion of said first portion and a male portion of said at least one second portion. 
     
     
         8 . The vehicle suspension fork of  claim 1 , wherein said crown is located in a fixture, said fixture fixing said crown in a position relative to said first fork tube and said second fork tube whereby, when fixed, a centerline of a male portion of said vehicle suspension fork is aligned with a centerline of said first fork tube opening and said second fork tube opening in a female portion of said crown. 
     
     
         9 . The vehicle suspension fork of  claim 1 , and wherein when said first portion and said at least one second portion comprise the same temperature, said inner diameter of each of said first fork tube opening and said second fork tube opening is less than said outer diameter of said end of said each of said first fork tube and said second fork tube. 
     
     
         10 . The vehicle suspension fork of  claim 1 , wherein an outer surface of said at least one second portion is coated with a corrosion resistant material.