SMITH TIMOTHY J (US)
| US4599913A | 1986-07-15 | |||
| US4023653A | 1977-05-17 | |||
| US5564311A | 1996-10-15 |
| 1. | A barrel adjuster for bicycle cableactuated assemblies comprising: an elongated member having a through bore defining an axis, the bore receiving a control cable therethrough, a first end of the control cable operatively connected to a first one of an actuating assembly and a responding assembly, a first end of said elongated member adjacent a first end of a cable housing, a second end of the cable housing adjacent a frame segment of a bicycle, the cable housing surrounding a segment of the control cable, a second end of said elongated member operatively connected to a first one of the actuating assembly and the responding assembly and configured to be reciprocally displaceable along the axis, said elongated member including: an insertion hole formed in a plane substantially parallel to the axis and located between the first and second ends of said elongated member, the insertion hole configured to receive the first end of the control cable therethrough; and an insertion slot extending from the insertion hole to the first end of said elongated member, the insertion slot configured to receive a segment of the control cable therethrough. |
| 2. | A barrel adjuster according to claim 1, wherein said elongated member is substantially cylindrical and has a knurled outer gripping surface. |
| 3. | A barrel adjuster according to claim 1, wherein a threaded portion disposed adjacent the second end of said elongated member is configured to rotatably cooperate with a complementarilythreaded member formed in a first one of the actuating and responding assemblies. |
| 4. | A barrel adjuster according to claim 3, wherein the second end of said elongated member comprises a threaded male portion configured to rotatably cooperate with a complementarilythreaded female member formed in a first one of the actuating and responding assemblies. |
| 5. | A barrel adjuster according to claim 3, wherein the second end of said elongated member comprises a threaded female portion configured to rotatably cooperate with a complementarilythreaded male member formed in a first one of the actuating and responding assemblies. |
| 6. | A barrel adjuster for Bowden cableactuated assemblies comprising: an elongated member having a through bore defining an axis, the bore receiving a control cable therethrough, a first end of the control cable operatively connected to a first one of an actuating assembly and a responding assembly, said elongated member having first and second ends and including: a bearing surface formed in the bore of said elongated member along a plane substantially perpendicular to the axis, the bearing surface having a slot therein configured to receive the control cable therethrough; an insertion hole formed in a plane substantially parallel to the axis and located between the bearing surface and the second end of said elongated member, the insertion hole configured to receive the first end of the control cable therethrough; and an insertion slot extending from the insertion hole to the first end of said elongated member, the insertion slot configured to receive a segment of the control cable therethrough, the bearing surface adaptable to a first end of a cable housing, the cable housing radially enclosing a segment of the control cable, the second end of said elongated member operatively connected to a first one of the actuating assembly and the responding assembly and configured to reciprocally displace said elongated member along the axis. |
| 7. | A barrel adjuster according to claim 6, wherein said elongated member is substantially cylindrical and has a knurled outer gripping surface. |
| 8. | A barrel adjuster according to claim 6, wherein the second end of said elongated member comprises a threaded portion configured to rotatably cooperate with a complementarilythreaded member formed in a first one of the actuating and responding assemblies. |
| 9. | A barrel adjuster according to claim 8, wherein the second end of said elongated member comprises a threaded male portion configured to rotatably cooperate with a complementarilythreaded female member formed in a first one of the actuating and responding assemblies. |
| 10. | A barrel adjuster according to claim 8, wherein the second end of said elongated member comprises a threaded female portion configured to rotatably cooperate with a complementarilythreaded male member formed in a first one of the actuating and responding assemblies. |
| 11. | A bicycle cableactuated control system comprising: an actuating assembly; a responding assembly; a control cable operatively connected to said actuating assembly at a first cable end and operatively connected to said responding assembly at a second cable end; a control cable housing disposed around a segment of said control cable; and a barrel adjuster disposed around a segment of said control cable, a first end of said cable housing disposed proximate a first end of said barrel adjuster, a second end of said cable housing abutting a frame segment of the bicycle, a second end of said barrel adjuster operatively connected to a first one of said actuating and responding assemblies and configured to reciprocally displace said barrel adjuster along the cable length, said barrel adjuster including: an insertion hole located between the first end of said cable housing as assembled in said system and the second end of said barrel adjuster, the insertion hole configured to receive a first one of said first and second cable ends; and an insertion slot extending from the insertion hole to the first end of said barrel adjuster, the insertion slot configured to receive a segment of said control cable therethrough. |
| 12. | A bicycle cableactuated system according to claim 11, wherein the first end of said cable housing abuts a bearing surface formed within said barrel adjuster substantially perpendicular to the length of said control cable and having a slot therein configured to receive said control cable therethrough. |
| 13. | A bicycle cableactuated system according to claim 11, wherein said actuating assembly comprises a first one of a brake actuating assembly and a gear actuating assembly and said responding assembly comprises a first one of a brake caliper assembly and a derailleur assembly. |
| 14. | A bicycle cableactuated system according to claim 11, wherein said barrel adjuster is substantially cylindrical and has a knurled outer gripping surface. |
| 15. | A bicycle cableactuated system according to claim 11, wherein the second end of said barrel adjuster comprises a threaded portion configured to rotatably cooperate with a complementarilythreaded member formed in a first one of the actuating and responding assemblies. |
| 16. | A bicycle cableactuated system according to claim 15, wherein the second end of said barrel adjuster comprises a threaded male portion configured to rotatably cooperate with a complementarilythreaded female member formed in a first one of the actuating and responding assemblies. |
| 17. | A bicycle cableactuated system according to claim 15, wherein the second end of said barrel adjuster comprises a threaded female portion configured to rotatably cooperate with a complementarilythreaded male member formed in a first one of the actuating and responding assemblies. |
| 18. | A method of control cable routing in bicycle cableactuated systems comprising: attaching a first one of an actuating assembly and a responding assembly to a portion of a bicycle; operatively connecting a second end of a barrel adjuster to the first one of the actuating and responding assemblies, the barrel adjuster second end configured to be reciprocally displaceable relative to the first one of the actuating and responding assemblies; abutting a second end of a cable housing against a frame portion of the bicycle, the cable housing radially enclosing a segment of a control cable; abutting a first end of the cable housing to a first end of the barrel adjuster; inserting a first end of the control cable through an insertion hole formed in the barrel adjuster in a plane substantially parallel to the length of the control cable, the insertion hole located between the first and second ends of the barrel adjuster; simultaneously inserting a portion of the control cable proximate the first cable end through an insertion slot formed in the barrel adjuster and extending from the insertion hole to the first end of the barrel adjuster, the insertion slot configured to receive a segment of the control cable therethrough; and operatively connecting the control cable to the first one of the actuating and responding assemblies. |
| 19. | A barrel adjuster for use with a Bowden cable actuation system, the Bowden cable including a flexible cable and a housing formed radially outwardly around the flexible cable and having an end, the flexible cable displaceable with respect to the housing along an axis and having an enlarged end, the barrel adjuster comprising: a body having a first end for disposal adjacent the end of the cable housing and a second end opposed to the first end for disposal adjacent a preselected one of an actuating member and a responding member; a bore from the first end of the body to the second end for receiving the flexible cable therethrough; a cable housing end bearing surface formed in the bore of the body; the body having a sidewall, a slot formed in the sidewall to extend from the first end of the body to a point beyond the cable housing end bearing surface, a slot formed in the cable housing end bearing surface which is in communication with the slot in the sidewall; the slot in the sidewall terminating in an insertion hole which is enlarged in comparison with the slot in the sidewall, the insertion hole and the slot in the sidewall communicating an exterior of the body to the bore, the slots in the cable housing end bearing surface and in the body sidewall being too small to pass the enlarged end of the flexible cable, the insertion hole being large enough to receive therethrough the enlarged end of the flexible cable; and means formed on the body for axially adjusting the position of the second end of the body relative to the preselected member. |
| 20. | A bicycle brake lever, comprising: a stationary member adaptable to be affixed to a bicycle handlebar, the stationary member having a first end and a second end, a bore from the first end to the second end for the passage therethrough of a flexible cable of a Bowden cable assembly, the bore having a diameter sufficiently large to receive therethrough an enlarged end of the flexible cable, the bore of the stationary member not being slotted; a lever hingedly affixed to the stationary member, a cable pull seat formed in the lever for receiving the enlarged end of the flexible cable; a barrel adjuster, a body of the barrel adjuster having a first end for disposal adjacent the end of the cable housing and a second end opposed to the first end and disposed adjacent the first end of the stationary member; a bore from the first end of the barrel body to the second end for receiving the flexible cable therethrough; a cable housing end bearing surface formed in the bore of the body; the body having a sidewall, a slot formed in the sidewall to extend from the first end of the body to a point beyond the cable housing end bearing surface, a slot formed in the cable housing end bearing surface which is in communication with the slot in the sidewall; the slot in the sidewall terminating in an insertion hole which is enlarged in comparison with the slot in the sidewall, the insertion hole and the slot in the sidewall communicating an exterior of the body to the bore, the slots in the cable housing end bearing surface and in the body sidewall being too small to pass the enlarged end of the flexible cable, the insertion hole being large enough to receive therethrough the enlarged end of the flexible cable; and means formed on the body for axially adjusting the position of the second end of the body relative to the first end of the stationary member. AMENDED CLAIMS [received by the International Bureau on 19 August 1998 (19.08.98); original claims 1,6,11 and 1820 amended; remaining claims unchanged (6 pages)] 1. A barrel adjuster for bicycle cableactuated assemblies comprising: an elongated member having a through bore defining an axis, the bore receiving a control cable therethrough, a first end of the control cable operatively connected to a first one of an actuating assembly and a responding assembly, a first end of said elongated member adjacent a first end of a cable housing, a second end of the cable housing adjacent a frame segment of a bicycle, the cable housing surrounding a segment of the control cable, a second end of said elongated member operatively connected to a first one of the actuating assembly and the responding assembly and configured to be reciprocally displaceable along the axis, said elongated member including: an insertion hole formed in a plane substantially parallel to the axis and located between the first and second ends of said elongated member, the insertion hole and the through bore proximate the second end of said elongated member configured to receive the first end of the control cable therethrough; and an insertion slot extending from the insertion hole to the first end of said elongated member, the insertion slot configured to receive a segment of the control cable therethrough. |
| 21. | 2 A barrel adjuster according to claim 1, wherein said elongated member is substantially cylindrical and has a knurled outer gripping surface. |
| 22. | 3 A barrel adjuster according to claim 1, wherein a threaded portion disposed adjacent the second end of said elongated member is configured to rotatably cooperate with a complementarilythreaded member formed in a first one of the actuating and responding assemblies. |
| 23. | 4 A barrel adjuster according to claim 3, wherein the second end of said elongated member comprises a threaded male portion configured to rotatably cooperate with a complementarilythreaded female member formed in a first one of the actuating and responding assemblies. |
| 24. | 5 A barrel adjuster according to claim 3, wherein the second end of said elongated member comprises a threaded female portion configured to rotatably cooperate with a complementarilythreaded male member formed in a first one of the actuating and responding assemblies. |
| 25. | 6 A barrel adjuster for Bowden cableactuated assemblies comprising: an elongated member having a through bore defining an axis, the bore receiving a control cable therethrough, a first end of the control cable operatively connected to a first one of an actuating assembly and a responding assembly, said elongated member having first and second ends and including: a bearing surface formed in the bore of said elongated member along a plane substantially perpendicular to the axis, the bearing surface having a slot therein configured to receive the control cable therethrough; an insertion hole formed in a plane substantially parallel to the axis and located between the bearing surface and the second end of said elongated member, the insertion hole and the through bore proximate the second end of said elongated member configured to receive the first end of the control cable therethrough; and an insertion slot extending from the insertion hole to the first end of said elongated member, the insertion slot configured to receive a segment of the control cable therethrough, the bearing surface adaptable to a first end of a cable housing, the cable housing radially enclosing a segment of the control cable, the second end of said elongated member operatively connected to a first one of the actuating assembly and the responding assembly and configured to reciprocally displace said elongated member along the axis. |
| 26. | 7 A barrel adjuster according to claim 6, wherein said elongated member is substantially cylindrical and has a knurled outer gripping surface. |
| 27. | 8 A barrel adjuster according to claim 6, wherein the second end of said elongated member comprises a threaded portion configured to rotatably cooperate with a complementarilythreaded member formed in a first one of the actuating and responding assemblies. |
| 28. | 9 A barrel adjuster according to claim 8, wherein the second end of said elongated member comprises a threaded male portion configured to rotatably cooperate with a complementarilythreaded female member formed in a first one of the actuating and responding assemblies. |
| 29. | 10 A barrel adjuster according to claim 8, wherein the second end of said elongated member comprises a threaded female portion configured to rotatably cooperate with a complementarilythreaded male member formed in a first one of the actuating and responding assemblies. |
| 30. | 11 A bicycle cableactuated control system comprising: an actuating assembly; a responding assembly; a control cable operatively connected to said actuating assembly at a first cable end and operatively connected to said responding assembly at a second cable end; a control cable housing disposed around a segment of said control cable; and a barrel adjuster disposed around a segment of said control cable, a first end of said cable housing disposed proximate a first end of said barrel adjuster, a second end of said cable housing abutting a frame segment of the bicycle, a second end of said barrel adjuster operatively connected to a first one of said actuating and responding assemblies and configured to reciprocally displace said barrel adjuster along the cable length, said barrel adjuster including: an insertion hole located between the first end of said cable housing as assembled in said system and the second end of said barrel adjuster, the insertion hole and the second end of said barrel adjuster configured to receive a first one of said first and second cable ends therethrough; and an insertion slot extending from the insertion hole to the first end of said barrel adjuster, the insertion slot configured to receive a segment of said control cable therethrough. |
| 31. | 12 A bicycle cableactuated system according to claim 11, wherein the first end of said cable housing abuts a bearing surface formed within said barrel adjuster substantially perpendicular to the length of said control cable and having a slot therein configured to receive said control cable therethrough. |
| 32. | 13 A bicycle cableactuated system according to claim 11, wherein said actuating assembly comprises a first one of a brake actuating assembly and a gear actuating assembly and said responding assembly comprises a first one of a brake caliper assembly and a derailleur assembly. |
| 33. | 14 A bicycle cableactuated system according to claim 11, wherein said barrel adjuster is substantially cylindrical and has a knurled outer gripping surface. |
| 34. | 15 A bicycle cableactuated system according to claim 11, wherein the second end of said barrel adjuster comprises a threaded portion configured to rotatably cooperate with a complementarilythreaded member formed in a first one of the actuating and responding assemblies. |
| 35. | 16 A bicycle cableactuated system according to claim 15, wherein the second end of said barrel adjuster comprises a threaded male portion configured to rotatably cooperate with a complementarilythreaded female member formed in a first one of the actuating and responding assemblies. |
| 36. | 17 A bicycle cableactuated system according to claim 15, wherein the second end of said barrel adjuster comprises a threaded female portion configured to rotatably cooperate with a complementarilythreaded male member formed in a first one of the actuating and responding assemblies. |
| 37. | 18 A method of control cable routing in bicycle cableactuated systems comprising: attaching a first one of an actuating assembly and a responding assembly to a portion of a bicycle; operatively connecting a second end of a barrel adjuster to the first one of the actuating and responding assemblies, the barrel adjuster second end configured to be reciprocally displaceable relative to the first one of the actuating and responding assemblies; abutting a second end of a cable housing against a frame portion of the bicycle, the cable housing radially enclosing a segment of a control cable; abutting a first end of the cable housing to a first end of the barrel adjuster; inserting a first end of the control cable through an insertion hole formed in the barrel adjuster in a plane substantially parallel to the length of the control cable, the insertion hole located between the first and second ends of the barrel adjuster; simultaneously inserting a portion of the control cable proximate the first cable end through an insertion slot formed in the barrel adjuster and extending from the insertion hole to the first end of the barrel adjuster, the insertion slot configured to receive a segment of the control cable therethrough; inserting the first end of the control cable through the barrel adjuster second end; and operatively connecting the control cable to the first one of the actuating and responding assemblies. |
| 38. | 19 A barrel adjuster for use with a Bowden cable actuation system, the Bowden cable including a flexible cable and a housing formed radially outwardly around the flexible cable and having an end, the flexible cable displaceable with respect to the housing along an axis and having an enlarged end, the barrel adjuster comprising: a body having a first end for disposal adjacent the end of the cable housing and a second end opposed to the first end for disposal adjacent a preselected one of an actuating member and a responding member; a bore from the first end of the body to the second end for receiving the flexible cable therethrough; a cable housing end bearing surface formed in the bore of the body; the body having a sidewall, a slot formed in the sidewall to extend from the first end of the body to a point beyond the cable housing end bearing surface, a slot formed in the cable housing end bearing surface which is in communication with the slot in the sidewall; the slot in the sidewall terminating in an insertion hole which is enlarged in comparison with the slot in the sidewall, the insertion hole and the slot in the sidewall communicating an exterior of the body to the bore, the slots in the cable housing end bearing surface and in the body sidewall being too small to pass the enlarged end of the flexible cable, the insertion hole and the bore at the second end of the body being large enough to receive therethrough the enlarged end of the flexible cable; and means formed on the body for axially adjusting the position of the second end of the body relative to the preselected member. |
| 39. | 20 A bicycle brake lever, comprising: a stationary member adaptable to be affixed to a bicycle handlebar, the stationary member having a first end and a second end, a bore from the first end to the second end for the passage therethrough of a flexible cable of a Bowden cable assembly, the bore having a diameter sufficiently large to receive therethrough an enlarged end of the flexible cable, the bore of the stationary member not being slotted; a lever hingedly affixed to the stationary member, a cable pull seat formed in the lever for receiving the enlarged end of the flexible cable; a barrel adjuster, a body of the barrel adjuster having a first end for disposal adjacent the end of the cable housing and a second end opposed to the first end and disposed adjacent the first end of the stationary member; a bore from the first end of the barrel body to the second end for receiving the flexible cable therethrough; a cable housing end bearing surface formed in the bore of the body; the body having a sidewall, a slot formed in the sidewall to extend from the first end of the body to a point beyond the cable housing end bearing surface, a slot formed in the cable housing end bearing surface which is in communication with the slot in the sidewall; the slot in the sidewall terminating in an insertion hole which is enlarged in comparison with the slot in the sidewall, the insertion hole and the slot in the sidewall communicating an exterior of the body to the bore, the slots in the cable housing end bearing surface and in the body sidewall being too small to pass the enlarged end of the flexible cable, the insertion hole and the bore proximate the second end of the barrel body being large enough to receive therethrough the enlarged end of the flexible cable; and means formed on the body for axially adjusting the position of the second end of the body relative to the first end of the stationary member. Statement Under Article 19 These amendments are submitted to clarify that the cable end enters the barrel adjuster through the insertion hole and exits through the threaded end of the barrel. These amendments are not made to overcome the cited prior art references, but merely to clarify what Applicants regard as their invention. |
Technical Field of the Invention This invention relates in general to cable-actuated bicycle assemblies, and more particularly to assemblies having barrel adjusters for adjusting the length of cable travel.
Background of the Invention Bicycle brake systems comprise an actuating assembly or brake lever, operatively connected by a control cable within a housing (i.e. Bowden cable) to a responding assembly such as brake calipers or cantilever brakes. Actuation of the brake lever by a rider causes brake shoes attached to the brake calipers to clamp down on the rirn of a bicycle wheel located between the calipers, thereby slowing the bicycle. Likewise, bicycle gear shifting systems comprise an actuating assembly or shifter, operatively connected by a Bowden cable to a responding assembly, typically a derailleur. Actuation of the shifter by a rider causes the derailleur to urge a drive chain between various sprockets of a freewheel at the rear derailleur or chainrings at the front derailleur, thereby effecting a gear shift. Barrel adjusters are used on both bicycle braking and shifting systems at the actuating or responding assemblies to adjust the length of cable travel between the actuating and responding assemblies. The present invention is an improvement to barrel adjusters.
FIGURE 1 is a side view of a brake lever assembly 10 operatively connected by a brake cable 30 to a brake caliper assembly 50, cable 30 sliding within a cable housing 31. As shown, deflection of a pivoting brake lever 14 by a rider's hand toward the bicycle handlebar pulls the brake cable 30, thereby causing brake shoes 52, mounted on brake calipers 54, to clamp down on a bicycle wheel 60. A barrel adjuster 34, operatively connected to either the brake lever or caliper assembly and abutting the adjoining cable housing end, permits adjustment of the length of cable travel by effectively lengthening or shortening the effective cable housing length.
FIGURE 2 is an exploded isometric view of the components comprising a conventional brake lever assembly. A brake housing 11 receives and is clamped to a bicycle handlebar through a bore 12. Brake lever 14 is pivotally connected at a hinge 16 to brake housing 11. A threaded shaft 22 of a barrel adjuster 20 is received by a threaded bore 18 of brake housing 11.
As installed, brake cable 30 runs through barrel adjuster 20 and bore 18 of brake housing 11 and is operatively connected to brake lever 14 at a seat 15 which receives a cable end 32 (FIGURE 2a). Cable end 32 has an enlarged diameter in comparison with the diameter of cable 30 and typically consists of a cylindrical or disk-shaped metal
casting (a disk-shaped end 32 is shown). Seat 15 is a receptacle sized and shaped to receive cable end 32. Brake cable 30 is inserted into barrel adjuster 20 through slot 24, into a lock nut 28, through slot 29 and into brake housing or base 11 through slot 19. In conventional barrel adjusters slots 24, 29 and 19, slightly wider than the diameter of brake cable 30, necessarily run the entire length of the barrel adjuster 20, lock nut 28 and brake housing 11 because the enlarged cable end 32 cannot be fed through the barrel adjuster itself nor can it be fed through bore 18 of brake housing 11. A bearing surface 26 is formed as a transition between a bore 23, which receives a housing end 33 of cable housing 31, and a deep channeled portion of slot 24, which forms the remainder of the path for cable 30 through adjuster 20. Bearing surface 26 of the barrel adjuster 20 blocks the entry of cable end 32 at one end of the barrel adjuster while the restricted diameters of bores 23 and 18 of the barrel adjuster 20 and brake housing 11, respectively, further bar the routing of cable end 32 through them. Therefore, in conventional brake lever assemblies, cable 30 must be "lowered" into the barrel adjuster 20 and brake housing 11 through their respective slots 24, 29 and 19, first ensuring that slot 29 of the lock nut 28 is aligned with slot 24 of the barrel adjuster 20.
In operation, as barrel adjuster 20 is rotated, bearing surface 26 of the barrel adjuster abuts cable housing end 33, displacing cable housing 31 and thereby effectively increasing or decreasing the length of cable travel along the cable housing.
Slot 24 of the barrel adjuster 20 severely reduces the torsional stiffness of the barrel adjuster, requiring it to be made out of metal instead of a lighter-weight, easier-to- manufacture plastic material. Slot 29 of lock nut 28, likewise, severely compromises the radial or hoop stiffness of the lock nut such that attempts to secure a plastic lock nut against the brake housing 11 will cause it to pry open and "slip" to the next thread.
Finally, slot 19 of brake housing 11 significantly reduces the impact strength of the brake housing by allowing it to be pried open by lever 14 under side loading.
FIGURE 3 is an exploded isometric view of the components comprising an improved prior art brake lever assembly. In the improved system, brake housing is only partially slotted, receiving cable end 32 (FIGURE 3a) through an insertion hole 17 located at the end of a slot 13. Although exhibiting increased flexural stiffness, the improved brake housing 11 of FIGURE 3 does not eliminate the need for full-length slots along the barrel adjuster 20 and lock nut 28.
Summary of the Inventions It is an object of the present invention to provide a brake lever assembly having a brake lever housing that is free of cable insertion holes and slots thereby significantly increasing the torsional and flexural characteristics of the brake housing. It is another object of the present invention to provide a brake lever assembly including an unslotted lock nut and a partially slotted barrel adjuster, to likewise significantly increase the hoop and flexural strength of these components. It is a further object of the present invention to provide a brake lever assembly comprising a brake housing, lock nut and barrel adjuster manufactured from lighter-weight plastic materials without compromising the overall stiffness of these components.
According to this invention, a brake lever assembly is provided with a partially slotted barrel adjuster having an insertion hole sized to receive a cable end or bead thereby eliminating the need for a slot in the lock nut or a slot and insertion hole in the brake housing. Further, according to this invention, the bore of the barrel adjuster and the bore of the brake housing receiving the barrel adjuster are sufficiently sized to receive the cable end therethrough.
Brief Description of the Drawings Further aspects of the invention will be discerned in the following detailed description when taken in conjunction with the drawings, in which like characters denote like parts and in which: FIGURE 1 is a front view of a prior art brake actuating system including brake lever and brake caliper assemblies.
FIGURES 2 and 2a are expanded isometric views of the components comprising a conventional brake lever assembly.
FIGURES 3 and 3a are expanded isometric views of the components comprising a additional conventional brake lever assembly.
FIGURES 4 and 4a are expanded isometric views of the components comprising a brake lever assembly according to the invention.
FIGURE 4b is an isometric view of an additional barrel adjuster embodiment according to the invention.
FIGURE 5 is an elevational view of a brake caliper employing the invention.
FIGURE 6 is a side view of a brake lever and barrel adjuster according to another embodiment the invention.
FIGURE 7 is a side view of a bicycle gear speed shifter employing the invention.
FIGURE 8 is a side view of a derailleur employing the invention.
Detailed Description of the Invention FIGURES 4 and 4a depict the partially slotted barrel adjuster of the invention. By relocating insertion hole 17 (Figure 3) from the brake housing 11 to a location 21 on the barrel adjuster 40 itself and sizing the threaded portion 22 of bore 23 of adjuster 40 and bore 18 of brake housing 11, respectively, to receive cable end 32 (FIGURE 4a), slot 13 of the brake housing 11 (FIGURE 3) and slot 29 in lock nut 28 are eliminated and the full length slot 24 of the barrel adjuster 20 is replaced by a partial slot 41 in the body of adjuster 40. Slot 41 starts at an open end 56 of bore 23, passes beyond bearing surface 26 and terminates in an enlarged insertion hole 21. Neither the slot 41 nor slot 82 in the bearing surface 26 are large enough to permit the passage of cable end 32. So configured, the brake housing 11, lock nut 27 and the barrel adjuster 40 exhibit substantially increased hoop strength, torsional and flexural properties, allowing them to be manufactured of lighter-weight plastic and composite materials and the like, thereby significantly reducing the overall weight of the brake lever assembly. Additionally, the barrel adjuster of the invention eliminates the need to machine or tool slots or insertion holes in the brake housing 11 or lock nut 27, thereby reducing manufacturing costs.
According to the invention, during installation of brake cable 30, as cable end 32 is inserted into insertion hole 21 of the barrel adjuster 40 (thereby bypassing bearing surface 26), brake cable 30 is simultaneously received by slots 41 and 82. Cable end 32 is then routed through threaded portion 22 of bore 23 of the barrel adjuster 40 and through bore 18 of brake housing 11, and is finally inserted into seat 15 of the brake lever 14.
The present invention permits a barrel adjuster to be manufactured of materials exhibiting a torsional or flexural strength lower than steel or aluminum alloys. One such material is Grivory", a tough glass-filled nylon.
In an alternative embodiment, as shown in FIGURE 4b, the exterior surface of the barrel adjuster 80 can be knurled (shown at 57) for easy finger grip adjustment.
Further, because the barrel adjuster of the invention is preferably made of plastic, it will be lighter per unit volume. The radius of the adjuster can be made larger than that of a corresponding metal conventional barrel adjuster, permitting more leverage to be employed by the hand of a rider in twisting the adjuster, without any increase in
weight as compared with a conventional device. Thus, the present invention enables the manufacture of brake lever and gear shifting components that are considerably lighter and stiffer than those of conventional brake lever assemblies.
While the present invention has been illustrated principally in conjunction with a handlebar-mounted brake lever, it has use in other Bowden control cable assemblies.
One such alternative embodiment is illustrated in FIGURE 5. In this embodiment, a slotted barrel adjuster 84 according to the invention is mounted before a barrel 85 of the brake caliper component 54. An end of the Bowden cable housing 31 abuts an end of the slotted barrel shifter 84.
FIGURE 6 is yet another embodiment of the invention, this time again used with a brake lever. In this embodiment, the female bore of the brake lever base 11 in FIGURE 4 is replaced with male threads 88. The barrel adjuster 40 has a female threaded connection 86 that includes internal female threads 90.
FIGURE 7 is yet another embodiment of the invention, this one used with a handlebar mounted gear shifter 90. The gear shifter 90 has a "noodle" 92 through which the cable 30 passes. A slotted barrel adjuster 94 according to the invention is disposed between an end of the "noodle" 92 and an end of the Bowden cable housing 31.
FIGURE 8 is a side view of rear derailleur employing the invention. A derailleur indicated generally at 100 includes a plate 102 through which a derailleur control cable 30' is threaded. The derailleur control cable includes a Bowden housing 31' having an end which terminates inside of a respective bore of a barrel adjuster 104. The barrel adjuster 104 is constructed in a manner similar to the other embodiments of the invention and includes a slot 106 running from an end of the adjuster 104 to an insertion hole 108 that is sufficiently large to receive an enlarged cable end of the control cable 30'. The barrel adjuster is threadly inserted into a respective bore of the plate 102.
While the form of apparatus herein described constitutes preferred embodiments of the invention, it should be understood that the invention is not limited to this disclosed form of apparatus, and that changes may be made therein without departing from the scope of the invention, which is defined by the appended claims.
Next Patent: UNDULATING PROPELLER USING THE ENERGY GENERATED BY PITCHING OF THE VESSEL