U.S. patent application number 09/781402 was filed with the patent office on 2001-07-26 for fluid cooled disc brake for bicycle.
Invention is credited to Nakamura, Yasushi.
Application Number | 20010009213 09/781402 |
Document ID | / |
Family ID | 22332852 |
Filed Date | 2001-07-26 |
United States Patent
Application |
20010009213 |
Kind Code |
A1 |
Nakamura, Yasushi |
July 26, 2001 |
Fluid cooled disc brake for bicycle
Abstract
A bicycle disc brake caliper is provided with a cooling system
that transfers heat away from the actuating fluid. Basically, the
bicycle disc brake caliper has a housing and a piston unit, with a
coolant member of the cooling system attached to the housing. The
housing has a frame mounting member sized to be coupled to a
portion of a bicycle frame. The piston unit is movably coupled to
the housing between a release position, in which the piston unit is
spaced from a brake disc mounted to a wheel of a bicycle, and a
braking position, in which the piston unit engages the brake disc
of the bicycle wheel. The coolant member has a coolant area for
receiving coolant to create a coolant heat sink that transfers heat
from the housing. The housing has an actuating passage in fluid
communication with the piston unit to move the piston unit via an
actuating fluid. In one embodiment, the cooling system includes a
pump and a reservoir. In another embodiment, a coolant or water
bottle is attached to the coolant member for manually adding
coolant thereto. In another embodiment, the coolant member is
filled with a high specific heat gel.
Inventors: |
Nakamura, Yasushi;
(Itami-shi, JP) |
Correspondence
Address: |
SHINJYU GLOBAL IP COUNSELORS, LLP
1233 20TH STREET, NW, SUITE 700
WASHINGTON
DC
20036-2680
US
|
Family ID: |
22332852 |
Appl. No.: |
09/781402 |
Filed: |
February 13, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09781402 |
Feb 13, 2001 |
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09110408 |
Jul 6, 1998 |
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6202802 |
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Current U.S.
Class: |
188/26 ;
188/71.6; 280/288.4 |
Current CPC
Class: |
F16D 55/228 20130101;
F16D 2055/0091 20130101; B62L 1/00 20130101; F16D 2066/001
20130101; B62L 3/023 20130101; F16D 2065/783 20130101; B60T 5/00
20130101; F16D 2065/784 20130101; F16D 65/853 20130101; B62L 3/02
20130101; B62L 1/005 20130101; F16D 2065/787 20130101; F16D
2065/781 20130101 |
Class at
Publication: |
188/26 ;
188/71.6; 280/288.4 |
International
Class: |
F16D 055/22; B62L
005/00 |
Claims
What is claimed is:
1. A bicycle disc brake caliper, comprising: a housing with a frame
mounting member sized to be coupled to a portion of a bicycle
frame; a piston unit movably coupled to said housing between a
release position in which said piston unit is spaced from a brake
disc mounted to a wheel of a bicycle and a braking position in
which said piston unit engages the brake disc of the bicycle wheel;
and a coolant member coupled to said housing, said coolant member
having a coolant area for receiving coolant to create a coolant
heat sink that transfers heat from said housing, said housing
including an actuating passage in fluid communication with said
piston unit to move said piston unit via an actuating fluid.
2. A bicycle disc brake caliper according to claim 1, wherein said
housing has a disc receiving slot extending through said piston
unit to receive the brake disc therein, said slot has an upstream
end and a downstream end such that the brake disc rotates from said
upstream end to said downstream end, said coolant member being
located adjacent said downstream end of said slot.
3. A bicycle disc brake caliper according to claim 1, wherein said
coolant member includes a first opening and a second opening with
an external conduit path extending therebetween.
4. A bicycle disc brake caliper according to claim 1, wherein said
coolant area includes an internal conduit path extending through
said housing.
5. A bicycle disc brake caliper according to claim 1, wherein said
coolant member is integrally formed as a unitary part of said
housing.
6. A bicycle disc brake caliper according to claim 3, wherein said
conduit path includes a radiator to dissipate heat from coolant
passing therethrough.
7. A bicycle disc brake caliper according to claim 6, wherein said
conduit path further includes a pump for circulating coolant
through said coolant area and said radiator.
8. A bicycle disc brake caliper according to claim 3, wherein said
conduit path further includes a pump for circulating coolant
through said coolant area.
9. A bicycle disc brake caliper according to claim 8, wherein said
pump includes a switch for selectively activating and deactivating
said pump.
10. A bicycle disc brake caliper according to claim 8, wherein said
pump includes a temperature sensor mounted to said housing for at
least partially controlling activation and deactivation of said
pump.
11. A bicycle disc brake caliper according to claim 8, wherein said
pump includes a three position switch for selecting an on position,
a temperature sensing position and an off position.
12. A bicycle disc brake caliper according to claim 8, wherein said
pump is driven by an electric motor.
13. A bicycle disc brake caliper according to claim 12, wherein
said electric motor is battery operated.
14. A bicycle disc brake caliper according to claim 3, further
comprising a fluid conduit extends directly between said first and
second openings with at least a portion of said conduit being
transparent.
15. A bicycle disc brake caliper according to claim 14, wherein
said coolant member further includes a third opening in fluid
communication therewith, said third opening having a pressure
release valve therein.
16. A bicycle disc brake caliper according to claim 1, wherein said
piston unit includes at least first and second pistons.
17. A bicycle disc brake caliper according to claim 1, wherein said
housing includes a first housing half with a first portion of said
cooling area formed therein and a second housing half with a second
portion of said cooling area formed therein.
18. A bicycle disc brake caliper according to claim 1, wherein said
coolant member has an inlet opening with a one-way valve coupled
thereto and an outlet opening with a pressure release valve coupled
thereto.
19. A bicycle disc brake caliper according to claim 1, wherein said
coolant member being a closed system with a high specific heat gel
located in said coolant area.
20. A bicycle disc brake caliper according to claim 1, further
comprising a coolant reservoir fluidly coupled to said coolant area
of said coolant member.
21. A bicycle disc brake caliper according to claim 20, wherein
said coolant member has an inlet opening with a one-way valve
coupled thereto and an outlet opening with a pressure release valve
coupled thereto.
22. A bicycle disc brake caliper according to claim 20, further
comprising a valve disposed between said coolant reservoir and said
coolant area of said coolant member.
23. A bicycle disc brake caliper according to claim 22, wherein
said coolant member includes a coolant level gauge coupled
thereto.
24. A bicycle disc brake caliper according to claim 22, wherein
said coolant reservoir is a lightweight water bottle with a
flexible conduit extending between said water bottle and said
coolant member.
25. A bicycle disc brake caliper according to claim 22, wherein
said valve has a manually operable lever to selectively supply
coolant from said coolant reservoir to said coolant area of said
coolant member.
26. A bicycle disc brake caliper according to claim 25, wherein
said coolant member has an inlet opening with a one-way valve
coupled thereto and an outlet opening with a pressure release valve
coupled thereto.
27. A bicycle disc brake caliper according to claim 1, wherein said
coolant member includes a coolant level gauge coupled thereto.
28. A bicycle disc brake assembly, comprising: a bicycle brake
operating device with a mounting member adapted to be coupled to a
portion of a bicycle, said bicycle brake operating device having a
master piston movably located in a master cylinder; an actuation
fluid reservoir in fluid communication with said master cylinder; a
caliper housing with a frame mounting member sized to be coupled to
a portion of a bicycle frame, said caliper housing includes an
actuating passage in fluid communication with said master cylinder
via a conduit; and a piston unit movably coupled to said caliper
housing and in fluid communication with said actuating passage to
move said piston unit between a release position in which said
piston unit is spaced from a brake disc mounted to a wheel of a
bicycle and a braking position in which said piston unit engages
the brake disc of the bicycle wheel, said caliper housing includes
an actuating conduit in fluid communication with said piston unit
to move said piston unit via an actuation fluid, and a coolant
member coupled to said caliper housing, said coolant member having
a coolant area for receiving coolant to create a coolant heat sink
that transfers heat from said caliper housing.
29. A bicycle disc brake assembly according to claim 28, wherein
said brake operating device includes a movable lever operatively
coupled to said master piston.
30. A bicycle disc brake assembly according to claim 28, wherein
said coolant member includes a coolant level gauge coupled
thereto.
31. A bicycle disc brake assembly according to claim 28, wherein
said caliper housing has a disc receiving slot extending through
said piston unit to receive the brake disc therein, said slot has
an upstream end and a downstream end such that the brake disc
rotates from said upstream end to said downstream end, said coolant
member being located adjacent said downstream end of said slot.
32. A bicycle disc brake assembly according to claim 28, wherein
said coolant member has a first opening and a second opening with a
conduit path extending therebetween.
33. A bicycle disc brake assembly according to claim 32, wherein
said conduit path includes a radiator to dissipate heat from
coolant passing therethrough.
34. A bicycle disc brake assembly according to claim 32, wherein
said conduit path further includes a pump for circulating coolant
through said coolant area.
35. A bicycle disc brake assembly according to claim 32, wherein
said pump includes a switch for selectively activating and
deactivating said pump.
36. A bicycle disc brake assembly according to claim 34, wherein
said pump includes a temperature sensor mounted to said caliper
housing for at least partially controlling activation and
deactivation of said pump.
37. A bicycle disc brake assembly according to claim 34, wherein
said pump includes a three position switch for selecting an on
position, a temperature sensing position and an off position.
38. A bicycle disc brake assembly according to claim 34, wherein
said pump is driven by an electric motor.
39. A bicycle disc brake assembly according to claim 38, wherein
said electric motor is battery operated.
40. A bicycle disc brake assembly according to claim 32, further
comprising a fluid conduit extends directly between said first and
second openings with at least a portion of said conduit being
transparent.
41. A bicycle disc brake assembly according to claim 28, wherein
said piston unit includes at least first and second pistons.
42. A bicycle disc brake assembly according to claim 41, wherein
said caliper housing includes a first housing half with a first
portion of said cooling area formed therein and a second housing
half with a second portion of said cooling area formed therein.
43. A bicycle disc brake assembly according to claim 28, wherein
said coolant member has an inlet opening with a one-way valve
coupled thereto and an outlet opening with a pressure release valve
coupled thereto.
44. A bicycle disc brake assembly according to claim 28, wherein
said coolant member being a closed system with a high specific heat
gel located in said coolant area.
45. A bicycle disc brake assembly according to claim 28, further
comprising a coolant reservoir fluidly coupled to said coolant area
of said coolant member.
46. A bicycle disc brake assembly according to claim 45, further
comprising said coolant member has an inlet opening fluidly coupled
to said coolant reservoir and an outlet opening with a pressure
relieve valve coupled to said outlet opening.
47. A bicycle disc brake assembly according to claim 45, further
comprising a valve disposed between said coolant reservoir and said
coolant area of said coolant member.
48. A bicycle disc brake assembly according to claim 47, further
comprising said coolant reservoir is a lightweight water bottle
with a flexible conduit extending between said water bottle and
said coolant member.
49. A bicycle disc brake assembly according to claim 47, further
comprising said valve has a manually operable lever to selectively
supply coolant from said coolant reservoir to said coolant area of
said coolant member.
50. A bicycle disc brake assembly according to claim 49, further
comprising said coolant member has an inlet opening with a one-way
valve coupled thereto and an outlet opening with a pressure release
valve coupled thereto.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to disc brakes for stopping
rotation of a wheel of a bicycle. More specifically, the present
invention relates to a fluid cooling system for cooling a bicycle
disc brake.
[0003] 2. Background Information
[0004] Bicycling is becoming an increasingly popular form of
recreation as well as a means of transportation. Moreover,
bicycling has become a very popular competitive sport. Whether the
bicycle is used for recreation, transportation or competition, the
bicycle industry is constantly improving their components. One
particular component of the bicycle which has been extensively
redesigned over the past years is the braking systems of
bicycles.
[0005] There are several types of bicycle brake devices, which are
currently available on the market. Examples of some types of common
bicycle brake devices include rim brakes, caliper brakes and disc
brakes. If a rider wants a very high performance brake system, then
the rider typically wants a disc brake system. Disc brake systems
provide a substantial braking power in relationship to the amount
of braking force applied to the brake lever. Moreover, disc brake
systems typically provide a high level of consistency in all types
of weather and riding conditions. However, one problem with disc
brakes is that the hydraulic or actuating fluid can become
overheated such that vapor-lock occurs. In other words, the heat
generated by braking results in the hydraulic fluid increasing in
volume so as to cause the brake pads to engage the brake disc even
when the brake lever is in the release position. When vapor-lock
occurs, the bicycle wheels can lock up and throw the rider off of
the bicycle.
[0006] In the prior art disc brake systems, several methods have
been utilized to avoid vapor-lock. For example, the caliper housing
can be made larger to absorb more heat. Another method has been to
make a larger brake disc with a wider surface area. Also,
vapor-lock can be suppressed by utilizing high quality hydraulic
fluid. Yet another method to avoid vapor-lock has been to use brake
or friction pads which do not transfer the heat to the brake
housing as readily as conventional friction pads. These prior art
methods of avoiding vapor-lock have many problems. One particular
problem, is that these solutions often are expensive to
manufacture. Also, some of these prior art solutions are not
completely effective.
[0007] In view of the above, there exists a need for a fluid cooled
disc brake for a bicycle which overcomes the above-mentioned
problems in the prior art. This invention addresses these needs in
the prior art as well as other needs, which will become apparent to
those skilled in the art from this disclosure.
SUMMARY OF THE INVENTION
[0008] One object of the present invention is to provide a bicycle
disc brake with a fluid cooling system.
[0009] Another object of the present invention is to provide an
improved bicycle disc brake, which is reliable and durable.
[0010] The foregoing objects of the present invention can be
attained by providing a bicycle disc brake caliper with a cooling
member that transfers heat away from the actuating fluid.
Basically, the bicycle disc brake caliper has a housing, a piston
unit and a coolant member. The housing has a frame mounting member
sized to be coupled to a portion of a bicycle frame. The piston
unit is movably coupled to the housing between a release position,
in which the piston unit is spaced from a brake disc mounted to a
wheel of a bicycle, and a braking position, in which the piston
unit engages the brake disc of the bicycle wheel. The coolant
member is coupled to the housing. The coolant member has a coolant
area for receiving coolant to create a coolant heat sink that
transfers heat from the housing. The housing has an actuating
passage in fluid communication with the piston unit to move the
piston unit via an actuating fluid.
[0011] The foregoing objects of the present invention can be
attained by providing a bicycle disc brake assembly with a cooling
member that transfers heat away from the actuating fluid.
Basically, the bicycle disc brake assembly has a bicycle brake
operating device, an actuation fluid reservoir, a caliper housing
and a piston unit. The bicycle brake operating device is provided
with a mounting member adapted to be coupled to a portion of a
bicycle. The bicycle brake operating device has a master piston
movably located in a master cylinder. The actuation fluid reservoir
is in fluid communication with the master cylinder. The caliper
housing is provided with a frame mounting member, which sized to be
coupled to a portion of a bicycle frame. The caliper housing has an
actuating passage in fluid communication with the master cylinder
via a conduit. The piston unit is movably coupled to the caliper
housing. The piston unit is in fluid communication with the
actuating passage to move the piston unit between a release
position, in which the piston unit is spaced from a brake disc
mounted to a wheel of a bicycle, and a braking position, in which
the piston unit engages the brake disc of the bicycle wheel. The
caliper housing has an actuating conduit in fluid communication
with the piston unit to move the piston unit via an actuation
fluid. The coolant member is coupled to the caliper housing. The
coolant member has a coolant area for receiving coolant to create a
coolant heat sink that transfers heat from the caliper housing.
[0012] Other objects, advantages and salient features of the
present invention will become apparent to those skilled in the art
from the following detailed description, which, taken in
conjunction with the annexed drawings discloses preferred
embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Referring now to the attached drawings which form a part of
this original disclosure:
[0014] FIG. 1 is a side elevational view of a portion of a bicycle
with a fluid cooled bicycle disc brake assembly coupled thereto in
accordance with one embodiment of the present invention;
[0015] FIG. 2 is a partial side elevational view of a portion of
the front fork of the bicycle with the radiator, motor and pump of
the cooling system coupled thereto in accordance with the
embodiment of the present invention illustrated in FIG. 1;
[0016] FIG. 3 is a partial front elevational view of a portion of
the front fork of the bicycle with the radiator, motor and pump of
the cooling system coupled thereto in accordance with the
embodiment of the present invention illustrated in FIG. 1;
[0017] FIG. 4 is a partial cross-sectional view of the radiator,
motor and pump of the cooling system coupled to a portion of the
front fork of the bicycle in accordance with the embodiment of the
present invention illustrated in FIG. 1;
[0018] FIG. 5 is a partial side elevational view of a portion of
the fluid cooled bicycle disc brake assembly coupled to the front
fork of the bicycle in accordance with the embodiment of the
present invention illustrated in FIG. 1;
[0019] FIG. 6 is a side elevational view of a bicycle disc brake
caliper of the fluid cooled bicycle disc brake assembly in
accordance with the embodiment of the present invention illustrated
in FIG. 1;
[0020] FIG. 7 is an exploded front elevational view of the bicycle
disc brake caliper of the fluid cooled bicycle disc brake assembly
in accordance with the embodiment of the present invention
illustrated in FIG. 1;
[0021] FIG. 8 is an inside elevational view of a first housing half
of the bicycle disc brake caliper of the fluid cooled bicycle disc
brake assembly in accordance with the embodiment of the present
invention illustrated in FIG. 1;
[0022] FIG. 9 is an inside elevational view of a second housing
half of the bicycle disc brake caliper of the fluid cooled bicycle
disc brake assembly in accordance with the embodiment of the
present invention illustrated in FIG. 1;
[0023] FIG. 10 is a top plan view of a bicycle brake operating
device for the fluid cooled bicycle disc brake assembly in
accordance with the embodiment of the present invention illustrated
in FIG. 1;
[0024] FIG. 11 is a schematic diagram of the fluid cooled bicycle
disc brake assembly in accordance with the embodiment of the
present invention illustrated in FIG. 1;
[0025] FIG. 12 is an inside elevational view of a modified first
housing half of the bicycle disc brake caliper of the fluid cooled
bicycle disc brake assembly in accordance with another embodiment
of the present invention;
[0026] FIG. 13 is an inside elevational view of a modified second
housing half of the bicycle disc brake caliper of the fluid cooled
bicycle disc brake assembly in accordance with the embodiment of
the present invention illustrated in FIG. 12;
[0027] FIG. 14 is a side elevational view of selected parts of a
fluid cooled bicycle disc brake assembly in accordance with another
embodiment of the present invention illustrated;
[0028] FIG. 15 is a side elevational view of a bicycle disc brake
caliper with a closed coolant chamber or member in accordance with
another embodiment of the present invention illustrated; and
[0029] FIG. 16 is a side elevational view of a bicycle disc brake
caliper with a refillable coolant chamber or member in accordance
with another embodiment of the present invention illustrated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Referring initially to FIG. 1, a front portion of a bicycle
10 is illustrated with a fluid cooled disc brake assembly 12
coupled thereto in accordance with one embodiment of the present
invention. Bicycles such as bicycle 10 are well known in the art,
and thus, bicycle 10 and its various components will not be
discussed or illustrated in detail herein. It will be apparent to
those skilled in the art that bicycle 10 can be any type of
bicycle, e.g., mountain bike, a hybrid bike or a road bike. Bicycle
10 is a conventional bicycle, which basically includes a bicycle
frame 14 with a handle bar 15, front and rear forks 16 (only front
fork shown), front and rear wheels 17 (only front wheel shown) and
a drive train (not shown).
[0031] While only the front portion of bicycle 10 is illustrated as
having a fluid cooled disc brake assembly 12, it will be apparent
to those skilled in the art from this disclosure that a second
fluid cooled disc brake assembly 12 can be utilized for stopping
the rear wheel of bicycle 10. Moreover, it will also be apparent to
those skilled in the art from this disclosure that various changes
and modifications can be made from the embodiments disclosed herein
without departing from the scope of the invention as defined in the
appended claims.
[0032] Fluid cooled disc brake assembly 12 basically includes a
cooling system 20, a disc brake caliper 21, a disc brake 22 and a
brake operating mechanism 23. Cooling system 20 is basically
mounted on the front fork 16 of bicycle 12. Likewise, disc brake
caliper 21 is also mounted on front fork 16 of bicycle 12 adjacent
brake disc 22. Brake disc 22 is fixedly coupled to front wheel 17
for rotation therewith. Brake operating mechanism 23 is preferably
fixedly mounted on handle bar 15 adjacent the hand portion of
handle bar 15. Accordingly, brake operating mechanism 23 is
operated such that disc brake caliper 21 moves from a release
position in which bicycle wheel 17 and brake disc 22 are free to
rotate, and a braking position in which disc brake caliper 21
applies a braking force against brake disc 22 to stop rotation of
bicycle wheel 17 and brake disc 22. Cooling system 20 is preferably
designed to prevent vapor lock from occurring within disc brake
caliper 21. Specifically, cooling system 20 is preferably designed
to act as a coolant heat sink that transfers heat from disc brake
caliper 21.
[0033] Turning now to FIGS. 3-6, a portion of cooling system 20 is
illustrated in more detail. Cooling system 20 basically includes a
coolant member 24 (FIG. 6), pump 25 and radiator 26. In this
embodiment, coolant member 24 is integrally formed with a portion
of disc brake caliper 21 as explained below in more detail. Of
course, it will be apparent to those skilled in the art from this
disclosure that coolant member 24 can be a separable member which
is fixedly coupled to disc brake caliper 21 to create a coolant
heat sink which transfers heat away from disc brake caliper 21.
Coolant member 24 will be discussed in more detail below together
with the description of disc brake caliper 21.
[0034] Preferably, pump 25 and radiator 26 are mounted to front
fork 16 of bicycle 10 by a mounting bracket assembly. The mounting
bracket assembly includes a cross-strap 28a and a pair of
intermediate straps 28b and 28c. Accordingly, pump 25 and radiator
26 are mounted as a compact unit on fork 16.
[0035] Pump 25 is preferably a rotary pump which moves coolant
through coolant member 24 and radiator 26. In particular, as seen
in FIGS. 3-6, a first flexible conduit 30a extends from coolant
member 24 to an inlet opening 32a of radiator 26, a second flexible
conduit 30b extends from an outlet opening 32b of radiator 26 to an
inlet opening 34a of pump 25, and a third flexible tubing 30c
extends from an outlet 34b of pump 25 to coolant member 24.
Accordingly, conduits 30a, 30b and 30c form a continuous loop or
conduit path between coolant member 24, pump 25 and radiator 26.
Coolant is forced through the conduit path by pump 25 for removing
heat from coolant member 24 and disc brake caliper 21.
[0036] As best shown in FIG. 4, pump 25 is preferably operated by a
motor 36 which rotates an impeller 38 to force fluid for coolant
through pump 25. Motor 36 in the preferred embodiment is an
electric motor that is battery operated. More specifically, two
conventional batteries 40 are utilized to power motor 36. A
three-positioned switch 42 is provided for controlling the
operation of motor 36. Specifically, switch 42 has a central off
position, an on position and a sensor position. In the off
position, motor 36 is idle, and thus, pump 25 is not operated. In
the on position, motor 36 turns impeller 38 of pump 25 to force
fluid or coolant through the conduit path of cooling system 20. The
sensor position operates motor 36 based on the temperature of the
coolant or disc brake caliper 21. In particular, as seen in FIG. 6,
a sensor 44 is mounted to disc brake caliper 21 to determine the
temperature of either the coolant or the housing of disc brake
caliper 21. Accordingly, switch 42 and motor 36 are electrically
coupled to sensor 44 such that motor 36 only operates when the
temperature of the coolant and/or housing of disc brake caliper 21
reaches a predetermined temperature level, e.g., greater than
80.degree. C. Once the coolant or disc brake caliper 21 reaches
this predetermined temperature level, motor 36 will operate to turn
impeller 38 for pumping coolant or fluid through coolant member 24
and radiator 26 to reduce the temperature of caliper 21.
[0037] It will be apparent to those skilled in the art that other
types of pumping systems, motors and temperature sensors can be
utilized in the cooling system 20 of the present invention. For
example, a pump can be used in which the pump is operated by
rotating parts of the bicycle 10. Moreover, pumps, motors and
sensors such as pump 25, motor 36 and sensor 44 are well known in
the prior art. Thus, these parts will not be described or
illustrated in detail.
[0038] Radiator 26 is preferably a conventional type of radiator,
which includes a conduit path with a large surface area so as to be
air-cooled. Since radiator 26 is relatively conventional in
construction, radiator 26 will not be described or illustrated in
detail herein.
[0039] It will be apparent to those skilled in the art that pump 25
and/or radiator 26 can be eliminated. For example, the conduit path
can be set up as a "coffee percolator" such that the coolant is
self-circulating through coolant member 24.
[0040] Turning now to FIGS. 5-9, disc brake caliper 21 will now be
described in more detail. Disc brake caliper 21 is fixedly coupled
to fork 16 adjacent to brake disc 22 for applying a clamping force
to stop the rotation of bicycle wheel 17 and brake disc 22. Disc
brake caliper 21 basically includes a housing 50, a piston unit 51
and coolant member 24 integrally formed with housing 20. Disc brake
caliper 21 is basically a conventional disc brake caliper except
that cooling system 20 has been coupled to it for removing heat
therefrom. More specifically, except for the addition of coolant
member 24 to disc brake caliper 21, the structure and function of
disc brake caliper 21 is relatively conventional. Therefore, disc
brake caliper 21 will not be discussed or illustrated in detail
herein.
[0041] As seen in FIGS. 7-9, housing 50 is preferably constructed
of a heat conductive material, which can readily transfer the heat
to the coolant. For example, housing 50 can be constructed of
aluminum. Housing 50 includes a first housing half 52a and a second
housing half 52b which are bolted together in a conventional
manner. For all practical purposes, first and second housing halves
52a and 52b are substantially identical in construction, except
that housing half 52a has coolant system attached thereto, and
second housing half 52b has brake operating mechanism 23 attached
thereto for supplying an actuating fluid to first and second
housing halves 52a and 52b. Also, second housing half 52b has a
pair of outwardly extending flanges that form a mounting member 54
for bolting disc brake caliper 21 to fork 16 of bicycle 10. When
housing halves 52a and 52b are bolted together, a disc brake slot
is formed therebetween for receiving brake disc 21
therebetween.
[0042] As seen in FIGS. 8 and 9, first housing half 52a has a
coolant cavity or area 56a, a pair of circular piston recesses 57a
and an internal fluid actuating passage 58a. Likewise, second
housing half 52b has a coolant cavity or area 56a, a pair of piston
receiving recesses 57b and an internal fluid actuating passage 58b.
Cavities or areas 56a and 56b form a large coolant chamber.
Preferably, coolant member 24 can hold at least approximately ten
cubic centimeters to approximately twenty cubic centimeters.
[0043] Coolant cavity or area 56a is a large chamber having an
inlet opening 60 and an outlet opening 62. Inlet opening 60 is
preferably a threaded hole, which receives a connector 64 to
connect conduit 30c thereto. Outlet opening 62 is also preferably a
threaded bore having an outlet connector 66 coupled thereto to
connect conduit 30a thereto. Connectors 64 and 66 are preferably
provided with one-way valves or check valves that allow the fluid
or coolant to pass into coolant cavities 56a and 56b through inlet
opening 60 and out of coolant cavities 56a and 56b via outlet
opening 62.
[0044] Internal fluid actuating passage 58a extends between
circular piston recesses 57a and internal fluid actuating passage
58b of second housing half 52b. In other words, the actuating fluid
from brake operating mechanism 23 flows into second housing half
52b and then into internal fluid actuating passages 58a and 58b to
operate piston unit 51.
[0045] Second housing half 52b has a first threaded opening 68,
which is in fluid communication with internal fluid actuating
passage 58b. Opening 68 is designed for attaching a hydraulic or
actuating fluid conduit thereto. A second opening 70 is also
provided for threadedly receiving a bleed nipple 72. Opening 70 is
in fluid communication with internal fluid actuating passage 58b
such that excess air can be removed from the actuating system.
Internal fluid actuating passage 58b interconnects piston recesses
57b together for receiving actuating fluid or hydraulic fluid to
activate piston unit 51.
[0046] As seen in FIG. 7, piston unit 51 preferably includes four
pistons 74 and a pair of friction pads 76. Pistons 74 are slidably
received in piston recesses 57a and 57b for movement between a
release position and a braking position. Friction pads 76 are
located on the free ends of pistons 74 for movement therewith. In
other words, as pistons 74 move from a release position to a
braking position, friction pads 76 also move from a release
position to a braking position. In the braking position, friction
pads 76 frictionally engage brake disc 22 to stop the rotation of
brake disc 22 and wheel 17. In the release position, friction pads
76 are spaced from brake disc 22 to allow brake disc 22 and wheel
17 to freely rotate therebetween. Pistons 74 and friction pads 76
are moved from their release positions to their braking positions
by actuating or hydraulic fluid applying a force to pistons 74.
More specifically, as brake operating mechanism 23 is actuated,
actuating fluid is pressurized so as to force pistons 74 and
friction pads 76 toward brake disc 22.
[0047] When brake caliper 21 is coupled to front fork 16, coolant
member 24 is positioned on the downstream end of the disc brake
caliper 21. In other words, as seen in FIG. 1, brake disc 22
rotates in a counterclockwise direction such that the coolant
member 24 is positioned downstream on disc brake caliper 21 in
relationship to the rotational direction of brake disc 22. This
allows the heat to be removed from the downstream end of brake
caliper 21 more quickly since this is the area in which the
actuating fluid is being supplied and the area of increased
heat.
[0048] Referring now to FIGS. 10 and 11, brake operating mechanism
23 will now be described in more detail. Basically, brake operating
mechanism 23 is designed to actuate the disc brake caliper 21 to
apply a forcible gripping action on brake disc 22 to stop rotation
of front wheel 17. Brake operating mechanism 23 basically includes
a brake lever 80, a hydraulic or master cylinder 81, a hydraulic or
master piston 82, and an actuation fluid reservoir 83.
[0049] Preferably, brake operating mechanism 23 is a single unit
which is mounted on handlebar 15. In particular, brake lever 80
includes a mounting portion 84 and a lever portion 85. Mounting
portion 84 is designed to be clamped onto handle bar 15 in a
conventional manner. Mounting portion 84 is integrally formed with
master cylinder 81 such that master cylinder 81, master piston 82
and actuation fluid reservoir 83 are all supported on mounting
portion 84 of brake lever 80. Lever portion 85 is pivotally coupled
to mounting portion 84 for movement between a release position and
a braking position. Normally, lever portion 84 is maintained in a
release position in a conventional manner.
[0050] Master piston 82 is movably mounted within master cylinder
81 in a conventional manner. More specifically, actuation fluid
reservoir 83 is mounted on master cylinder 82 and in fluid
communication with the interior bore of master cylinder 81 for
supplying actuation fluid thereto. Master piston 82 is connected at
one end to lever portion 85 for axially moving master piston 82
within master cylinder 81. Accordingly, actuation of lever portion
85 causes master piston 82 to move axially within master cylinder
81. This movement of master piston 82 within master cylinder 81
directs fluid pressure through a hydraulic line 86 which is coupled
to disc brake caliper 21. Thus, the pressurized actuation fluid
causes the pistons 74 and friction pads 76 to move so as to engage
brake disc 22 to stop rotation of wheel 17.
SECOND EMBODIMENT
[0051] Referring now to FIGS. 12 and 13, a modified disc brake
caliper 121 is illustrated in accordance with the present
invention. Disc brake caliper 121 is designed to be utilized in
fluid cooled disc brake assembly 12, discussed above. In fact, disc
brake caliper 121 is substantially identical to disc brake caliper
21 except that disc brake caliper 121 has its cooling cavities or
areas 156a and 156b provided with an internal conduit path. More
specifically, baffles 156c and 156d are formed within coolant
cavities or areas 156a and 156b, respectively. In view of the
similarities between disc brake caliper 21 and 121, disc brake
caliper 121 and its connection to cooling system 20 will not be
discussed or illustrated in detail herein.
[0052] Housing 150 is preferably constructed of a heat conductive
material, which can readily transfer the heat to the coolant. For
example, housing 150 can be constructed of aluminum. Housing 150
includes a first housing half 152a and a second housing half 152b
which are bolted together in a conventional manner. For all
practical purposes, first and second housing halves 152a and 152b
are substantially identical in construction, except that housing
half 152a has coolant system 20 attached thereto, and second
housing half 152b has brake operating mechanism 23 attached thereto
for supplying an actuating fluid to first and second housing halves
152a and 152b. Also, second housing half 152b has a pair of
outwardly extending flanges that form a mounting member 154 for
bolting disc brake caliper 121 to fork 16 of bicycle 10. When
housing halves 152a and 152b are bolted together, a disc brake slot
is formed therebetween for receiving brake disc 121
therebetween.
[0053] First housing half 152a has a coolant cavity or area 156a, a
pair of circular piston recesses 157a and an internal fluid
actuating passage 158a. Likewise, second housing half 152b has a
coolant cavity or area-156a, a pair of piston receiving recesses
157b and an internal fluid actuating passage 158b. Cavities or
areas 156a and 156b form a large coolant chamber. Preferably,
coolant member 124 can hold at least approximately ten cubic
centimeters to approximately twenty cubic centimeters.
[0054] Coolant cavity or area 156a is a large chamber having an
inlet opening 160 and an outlet opening 162. Inlet opening 160 is
preferably a threaded hole, which receives a connector 164 to
connect conduit 30c thereto. Outlet opening 162 is also preferably
a threaded bore having an outlet connector 166 coupled thereto to
connect conduit 30a thereto. Connectors 164 and 166 are preferably
provided with one-way valves or check valves that allow the fluid
or coolant to pass into coolant cavities 156a and 156b through
inlet opening 160 and out of coolant cavities 156a and 156b via
outlet opening 162.
[0055] Internal fluid actuating passage 158a extends between
circular piston recesses 157a and internal fluid actuating passage
158b of second housing half 152b. In other words, the actuating
fluid from brake operating mechanism 23 flows into second housing
half 152b and then into internal fluid actuating passages 58a and
158b to operate the piston unit.
[0056] Second housing half 152b has a first threaded opening 168,
which is in fluid communication with internal fluid actuating
passage 158b. Opening 168 is designed for attaching a hydraulic or
actuating fluid conduit thereto. A second opening 170 is also
provided for threadedly receiving a bleed nipple 172. Opening 170
is in fluid communication with internal fluid actuating passage
158b such that excess air can be removed from the actuating system.
Internal fluid actuating passage 158b interconnects piston recesses
157b together for receiving actuating fluid or hydraulic fluid to
activate the piston unit.
THIRD EMBODIMENT
[0057] Referring now to FIG. 14, a simplified cooling system 220.
Basically, cooling system 220 includes coolant member 224, coolant
bottle or tank 226, an on/off valve 227 and a pressure release
valve 228. Disc brake caliper 221 is substantially identical to
disc brake caliper 21 discussed above, except that a coolant gauge
229 has been added to the integral coolant member 224 to visually
inspect the amount of coolant or water contained within coolant
member 224.
[0058] In view of the similarities between disc brake caliper 221
and disc brake caliper 21 of the first embodiment, brake disc
caliper 221 will not be discussed or illustrated in detail herein.
Moreover, it will be apparent to those skilled in the art from this
disclosure that brake disc caliper 221 can be utilized on bicycle
10 of the first embodiment so as to be operated by brake operating
mechanism 23 of the first embodiment to engage brake disc 22.
[0059] In this embodiment, cooling system 220 is designed such that
the rider can manually add water or coolant periodically to coolant
member 224. More specifically, the water or coolant within coolant
member 224 will be heated when the friction pads engage brake disc
22. The heated water or coolant will turn into steam or coolant
vapor if the brake disc caliper 221 gets too hot. This steam will
open pressure release valve 228 such that the water or coolant
vapor is released. Thus, the amount of coolant within coolant
member 224 will gradually be reduced. The rider then can look at
coolant gauge 229 to determine when coolant needs to be added. The
rider will then open the on/off valve 227 to allow additional water
of coolant from coolant bottle 226 to flow through conduit 230 into
coolant member 224.
[0060] Water or coolant bottle 226 can be attached to any portion
of the frame as needed and/or desired. For example, water bottle
226 can be attached to the front fork 16 of bicycle 10 in the same
location as radiator 26 of the first embodiment of FIG. 1.
Preferably, the location of water bottle 226 is such that the rider
can operate on/off valve 227 without stopping. Moreover, water
bottle 226, valve 227 and conduit 230 are preferably easily
detachable from coolant member 224 such that they can be replaced
if damaged. A one-way valve 264 preferably connects conduit 230 to
the inlet opening of coolant member 224.
FOURTH EMBODIMENT
[0061] As seen in FIG. 15, a modified disc brake caliper 321 is
illustrated. Disc brake caliper 321 is substantially identical to
disc brake caliper 21 of the first embodiment except that the
internal coolant member 324 is a closed unit, which has a high
specific heat gel located therein. Thus, this system is a
simplified version of the first embodiment. The high specific heat
gel located in coolant member 324 can be any high specific heat
gel, which can operate under the normal operating conditions of a
bicycle disc brake.
[0062] In view of the similarities between disc brake caliper 321
and disc brake caliper 21 of the first embodiment, brake disc
caliper 321 will not be discussed or illustrated in detail herein.
Moreover, it will be apparent to those skilled in the art from this
disclosure that brake disc caliper 321 can be utilized on bicycle
10 of the first embodiment so as to be operated by brake operating
mechanism 23 of the first embodiment to engage brake disc 22.
FIFTH EMBODIMENT
[0063] Referring now to FIG. 16, a modified disc brake caliper 421
is illustrated in accordance with the present invention. In this
embodiment, the coolant inlet opening 460 and coolant outlet
opening 462 are interconnected together via a transparent conduit
430. This transparent conduit 430 allows the rider to inspect the
coolant level within the coolant member 424. Also, a pressure
release valve/refill valve 428 has been added such that additional
coolant or fluid can be added as needed and/or steam or coolant
vapor be released from the coolant member 424.
[0064] Disc brake caliper 421 is substantially identical to disc
brake caliper 21 except that disc brake caliper 421 has transparent
conduit 430 extending between its inlet opening 460 and coolant
outlet opening 462 and pressure release valve/refill valve 428 has
been added. In view of the similarities between disc brake caliper
421 and disc brake caliper 21 of the first embodiment, brake disc
caliper 421 will not be discussed or illustrated in detail
herein.
[0065] In this embodiment, cooling system 420 is designed such that
the rider can manually add water or coolant periodically to coolant
member 424 via pressure release valve/refill valve 428. More
specifically, the water or coolant within coolant member 424 will
be heated when the friction pads engage brake disc 22. The heated
water or coolant will turn into steam or coolant vapor if the brake
disc caliper 421 gets too hot. This steam will open pressure
release valve/refill valve 428 such that the water or coolant vapor
is released. Thus, the amount of coolant within coolant member 424
will gradually be reduced. The rider then can look at transparent
conduit 430 to determine when coolant needs to be added. The rider
will then add additional water of coolant to coolant member 424 via
pressure release valve/refill valve 428.
[0066] While several embodiments have been chosen to illustrate the
present invention, it will be apparent to those skilled in the art
from this disclosure that various changes and modifications can be
made herein without departing from the scope of the invention as
defined in the appended claims. Furthermore, the foregoing
description of the preferred embodiments of the present invention
is provided for illustration only, and not for the purpose of
limiting the invention as defined by the appended claims and their
equivalents.
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