U.S. patent application number 13/467938 was filed with the patent office on 2012-08-30 for cogset assembly for a bicycle.
This patent application is currently assigned to SPECIALIZED BICYCLE COMPONENTS, INC.. Invention is credited to Christopher P. D'Aluisio.
Application Number | 20120220402 13/467938 |
Document ID | / |
Family ID | 40794681 |
Filed Date | 2012-08-30 |
United States Patent
Application |
20120220402 |
Kind Code |
A1 |
D'Aluisio; Christopher P. |
August 30, 2012 |
COGSET ASSEMBLY FOR A BICYCLE
Abstract
A bicycle hub assembly comprises a shaft, a first load bearing
adjacent said shaft, a hub main body surrounding said shaft, and a
cogset. The cogset can define an inner surface, and the inner
surface can define a seat configured to receive the first load
bearing. Further, the inner surface can define an opening of
variable size. The cogset can also define an inner end and an outer
end, and the opening can generally increase in size from the outer
end to the inner end.
Inventors: |
D'Aluisio; Christopher P.;
(Corralitos, CA) |
Assignee: |
SPECIALIZED BICYCLE COMPONENTS,
INC.
Morgan Hill
CA
|
Family ID: |
40794681 |
Appl. No.: |
13/467938 |
Filed: |
May 9, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12019495 |
Jan 24, 2008 |
8197371 |
|
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13467938 |
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Current U.S.
Class: |
474/160 |
Current CPC
Class: |
B62M 9/12 20130101 |
Class at
Publication: |
474/160 |
International
Class: |
F16H 55/30 20060101
F16H055/30 |
Claims
1. A monoblock cogset comprising: an inner surface comprising a
plurality of ratchet teeth; a plurality of cogs; and a portion for
receiving a bearing assembly along said inner surface, wherein the
cogset is a monoblock cogset.
2. The monoblock cogset of claim 1, wherein said inner surface has
variable size along the axis of the cogset.
3. The monoblock cogset of claim 2, wherein said inner surface
generally increases in size monotonically from one end to
another.
4. The monoblock cogset of claim 3, wherein said cogset includes at
least one cog with cog size less than 11.
5. The monoblock cogset of claim 1, wherein said cogset is
configured to be combined with an additional cogset.
6. A cogset assembly comprising: a first monoblock cogset
comprising: an inner surface comprising a plurality of ratchet
teeth; and a plurality of cogs; and a second monoblock cogset
comprising a plurality of cogs and being configured to be mounted
on said first monoblock cogset.
7. The cogset assembly of claim 6, wherein said first and second
monoblock cogsets are substantially formed from at least two
distinct materials.
8. The cogset assembly of claim 7, wherein at least one of said
materials is titanium.
9. A cogset comprising: a plurality of cogs; an inner surface
comprising a spline portion, said inner surface having variable
size along the axis of the cogset; and a portion for receiving a
bearing assembly along said inner surface.
10. The cogset of claim 9, wherein said inner surface generally
increases in size monotonically from one end to another.
11. The cogset of claim 9, wherein said cogset includes at least
one cog with cog size less than 11.
12. The cogset of claim 9, wherein said cogset comprises an outer
surface, said outer surface comprising cogs substantially formed
from at least two distinct materials.
13. The cogset of claim 12, wherein at least one of said materials
is titanium.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
patent application Ser. No. 12/019,495, filed Jan. 24, 2008, and
entitled "COGSET ASSEMBLY FOR A BICYCLE", the entirety of which is
hereby expressly incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The inventions described herein generally relate to
apparatuses for driving bicycles.
[0004] 2. Description of the Related Art
[0005] The related art includes bicycle drives such as gears and
sprockets, connected by chain to pedals or some other power
source.
SUMMARY OF THE INVENTION
[0006] In accordance with some embodiments of a cogset assembly for
a bicycle, a bicycle hub assembly comprises a shaft, a first load
bearing adjacent said shaft, a hub main body surrounding said
shaft, and a cogset. The cogset can define an inner surface, and
the inner surface can define a seat configured to receive the first
load bearing. Further, the inner surface can define an opening of
variable size. The cogset can also define an inner end and an outer
end, and the opening can generally increase in size from the outer
end to the inner end.
[0007] In some embodiments the cogset can further define two
mounting portions. The first mounting portion can define a smaller
open cross-section than the second mounting portion, and can
cooperate to rotatably mount the cogset on a shaft. The second
mounting portion can cooperate to mount the cogset on a hub
assembly.
[0008] Further, in some embodiments the shaft can define an outer
surface that can define a smaller diameter portion. The smaller
diameter portion can be adjacent an outer end of the cogset. A
larger diameter portion can be adjacent an inner end of the cogset.
The shaft can also define a smaller diameter portion positioned
opposite the outer end of the cogset. The shaft can be
substantially composed of carbon fiber, aluminum, steel, similar
materials, or mixes thereof. The shaft can also have a diameter
greater than 15 mm.
[0009] Further, some embodiments can comprise a ratchet mounted on
the hub main body. Similarly, in some embodiments a ratchet portion
can be mounted on the cogset, corresponding to the ratchet mounted
on the hub. In other embodiments, a ratchet assembly can be mounted
on the cogset.
[0010] In some embodiments, a bicycle hub assembly can comprise a
hub main body. The hub main body can be surrounded by a bushing. A
cogset can be rotatably supported by the bushing. The cogset can
further define an inner surface, and the inner surface can define
an opening of variable size. Further, the opening can generally
increase in size from an outer end to an inner end, each defined by
the inner surface of the cogset. The hub assembly can further
comprise a ratchet mounted on the hub main body, and a ratchet
portion mounted on the cogset. In other embodiments, the hub
assembly can comprise a ratchet assembly mounted on the cogset.
[0011] In some embodiments, a bicycle hub assembly can comprise a
hub main body defining an axis. The bicycle hub assembly can
further comprise a cogset surrounding a portion of the hub main
body. Further, the cogset can extend axially from the hub main body
and be rotatable with respect thereto. The cogset can further
define an inner surface, said inner surface defining an opening of
variable size. Further, the opening can generally increase in size
from an outer end to an inner end, each defined by the inner
surface of the cogset. The hub assembly can also comprise a ratchet
mounted on the hub main body. The hub assembly can further comprise
a ratchet portion mounted on the cogset. In other embodiments, the
hub assembly can comprise a ratchet assembly mounted on the
cogset.
[0012] In some embodiments, a bicycle hub assembly can comprise a
bicycle shaft, a first load bearing adjacent the shaft, a hub main
body surrounding the bicycle shaft, and a cogset. The cogset can be
positioned substantially directly against the first load bearing.
Similarly, the cogset can be positioned within a half (1/2)
millimeter of the load bearing.
[0013] In some embodiments, a cogset can comprise an inner surface
comprising a plurality of ratchet teeth. The cogset can further
comprise a plurality of cogs and a portion for receiving a bearing
assembly along the inner surface. The inner surface can have
variable size along the axis of the cogset. Further, the inner
surface can generally increase in size monotonically from one end
of the cogset to another. The cogset can further include at least
one cog with cog size less than 11. The cogset can also comprise an
outer surface, said outer surface comprising cogs substantially
formed from at least two distinct materials. At least one of said
materials can be titanium.
[0014] In some embodiments a cogset can comprise a plurality of
cogs and an inner surface comprising a spline portion. The inner
surface can comprise variable size along the axis of the cogset and
a portion for receiving a bearing assembly. The inner surface can
generally increase in size monotonically from one end of the cogset
to another. The cogset can further include at least one cog with
cog size less than 11 teeth. The cogset can also comprise an outer
surface comprising cogs substantially formed from at least two
distinct materials. At least one of said materials can be
titanium.
[0015] For purposes of this summary, certain aspects, advantages,
and novel features of the invention are described herein. It is to
be understood that not necessarily all such advantages may be
achieved in accordance with any particular embodiment of the
invention. Thus, for example, those skilled in the art will
recognize that the invention may be embodied or carried out in a
manner that achieves one advantage or group of advantages as taught
herein without necessarily achieving other advantages as may be
taught or suggested herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 depicts a bicycle with one embodiment of a cogset and
hub assembly.
[0017] FIG. 2A depicts a perspective view of a cogset and hub
assembly.
[0018] FIG. 2B depicts an exploded view of the cross-sectioned
cogset and hub assembly of FIG. 2A.
[0019] FIG. 3A depicts a side view of the cogset and hub assembly
mounted on a bicycle.
[0020] FIG. 3B depicts a side cross-sectional view of the cogset
and hub assembly of FIG. 3A.
[0021] FIGS. 4 and 5 depict axial cross-sectional views of the
cogset and hub assembly of FIG. 3A along 4-4 and 5-5,
respectively.
[0022] FIG. 6 depicts an exploded view of a cogset assembly.
[0023] FIG. 7A depicts a perspective view of an alternative
embodiment of a cogset and hub assembly.
[0024] FIG. 7B depicts an exploded cross-sectional view of the
cogset and hub assembly of FIG. 7A.
[0025] FIG. 8A depicts a side view of a cogset and hub assembly of
FIG. 7A.
[0026] FIG. 8B depicts a side cross-sectional view of the cogset
and hub assembly of FIG. 8A.
[0027] FIG. 9 depicts an axial cross-sectional view of the cogset
and hub assembly of FIG. 8A along 9-9.
[0028] FIG. 10 depicts an exploded view of a cogset assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] A number of objectives are presented in the context of
bicycle design. It is generally desirable to provide a bicycle that
is simultaneously light, reliable, capable of both high and low
gear ratios, and comprising minimal friction or loss, as well as
other objectives. Material strength is often proportional to
material size and weight, and thus lightness and reliability often
present conflicting objectives.
[0030] The disclosure herein describes a cogset assembly for a
bicycle. The disclosure herein additionally describes a hub
assembly for a rear bicycle wheel. The disclosure herein
additionally describes combinations of cogset and hub
assemblies.
[0031] FIG. 1 depicts a bicycle 1 with a cogset and hub assembly 6.
The bicycle 1 can comprise a frame 11, pedals 3, pedal sprocket 5,
chain 4, cogset and hub assembly 6, and rear wheel 2. The frame 11
can comprise stays 12 that can connect a rear wheel 2 to the main
portion of the bicycle frame 11. The rear wheel 2 can be driven by
pedals 3 via a chain 4. The links of the chain 4 can be configured
to interact with the pedal sprocket 5, which causes the chain 4 to
rotate upon the rotation of the pedals 3. The chain 4 can further
interact with a cogset and hub assembly 6 to cause the cogset and
hub assembly 6 to rotate, thus also rotating the rear wheel 2 as
discussed below. The rear wheel 2 may further comprise a derailleur
7 capable of moving the chain 4 between a plurality of sprockets.
Additionally, the rear wheel 2 may comprise a plurality of spokes 9
for improving the structural integrity and strength of the rear
wheel.
[0032] FIGS. 2A, 3A depict a perspective view and a side view of
one embodiment of the cogset and hub assembly 6. The cogset and hub
assembly 6 may comprise a shaft 36, a hub main body 40, and a
cogset 20. The cogset 20 may comprise a plurality of cogs 21 shaped
to engage the chain 4. Through the cogs 21, the rotation of the
chain 4 can cause the rotation of the cogset 20. The rotation of
the cogset 20, through means discussed below, can in turn cause the
rotation of the hub 40. The rotation of the hub 40, through the
flanges 45 and spokes 9, can cause the rotation of the rear wheel
2. End caps 60, 61 can further rotate with the cogset 20 and hub
40. In other embodiments the end caps 60, 61 can rotate
independently of the cogset 20 and/or hub 40, or they can remain
stationary.
[0033] Referring to FIGS. 2B, 3A, and 3B, the cogset 20 can be
located near a driven end 100 of the cogset and hub assembly 6 and
the large end cap 61 can be located near a free end 101 of the
cogset and hub assembly 6. The cogset 20 can be connected to a hub
40 at a hub facing end or inner end 23 of the cogset 20 and a
sprocket facing end or first end 41 of the hub 40. The hub 40
further comprises a free end or second end 42 opposite the first
end 41. At the free end 42 the hub 40 can connect to a large end
cap 61 that can in turn connect to a connection means 70 for
attaching the cogset and hub assembly 6 to the frame 11 via the
stays 12 (not pictured in FIG. 3B). Alternatively, the hub 40 can
connect directly to a connection means 70 (not pictured in FIG.
3B). As shown, the hub 40 further comprises two radially extending
flanges 45, which can connect to a plurality of spokes 9 (shown in
FIG. 1). The flanges 45 can be provided a set distance apart. For
purposes of this application, "free end" is a broad term used
broadly to distinguish the driven end 100, 41 and is not intended
to mean that there are no items attached to or covering the free
end 101, 42.
[0034] The cogs 21 are provided radially and can be grouped into
circular sprockets. The cogs 21 on a sprocket can describe a radius
or cog size which, in conjunction with the analogous radius or cog
size of the pedal sprocket 5, determines a gear ratio.
[0035] The cogset 20 and hub 40 can be mounted on a shaft 36. The
shaft 36 may comprise a shaft main body 30, a driven end cap 60,
and a free end cap 61. In some embodiments, use of the end caps 60,
61 can be advantageous to provide a means of sealing the driven end
22 of the cogset 20 and the ends of the shaft main body 30.
Further, in some embodiments, the use of end caps 60, 61 may
provide for greater ease of manufacture and/or weight reduction
advantages. Alternatively, in some embodiments, the shaft can
comprise a single piece and/or one or both of the end caps 60, 61
can be eliminated.
[0036] The shaft 36 can be mounted by way of connection means 70 to
stays 12. The distance between the stays 12 can define an assembly
length L.sub.A along the axis of the cogset and hub assembly 6. As
best shown in FIG. 3A, the length of the shaft 36 may span the
entire assembly length L.sub.A. In addition, the shaft 36,
including the end caps 60, 61, along with the hub 40 and the cogset
20 may span the entire assembly length L.sub.A.
[0037] As shown, the rear wheel cogset 20 can comprise a plurality
of sprockets with different radii or cog sizes. Similarly, the
pedal sprocket 5 can also comprise a plurality of sprockets with
different radii or cog sizes. A greater number of sprockets can
comprise a greater portion of the assembly length L.sub.A. Further,
the cogs on the sprockets can be a set distance apart, both on a
given sprocket and between sprockets. The cogs on adjacent
sprockets can be at least a set distance apart so as to allow space
for the chain 4 to surround each cog without causing interference
with the cogs of an adjacent sprocket. Further, the cogs on a
single sprocket can be a set radial distance apart on each sprocket
so as to accommodate a single chain 4 designed to interact with all
the sprockets of the cogset 20.
[0038] As depicted in 3A, the cogset and hub assembly 6 may be
connected to two stays 12. The stays 12 may comprise generally
forked shapes such that the cogset and hub assembly 6 can slide
into position. The shaft 36 can then be rigidly held between the
stays 12 by a connection means 70 so that the cogset and hub
assembly 6 is secured to the bicycle 1. Said connection means 70
can comprise nuts and bolts, a quick-release, or any other means
for creating a substantial force between the cogset and hub
assembly 6 and the stays 12, such that frictional forces hold the
assembly in place. The stays 12 can also comprise hooks,
enclosures, or any other means to hold the cogset and hub assembly
6 in place.
[0039] Referring to FIGS. 2B, 3A and 3B, the hub 40 comprises an
inner surface 48 defining an interior hub opening 81 configured to
receive a shaft 36 and allow rotation of the hub relative to the
shaft. Friction between the shaft 36 and hub 40 can be reduced with
hub bearings 31, 32. Alternatively, bushings, lubricants,
low-friction surfaces, rollers, or the like can also be used.
[0040] Referring to FIG. 2B, the cog-facing end 41 of the hub 40
can comprise a splined portion 49 configured to interact with the
spline of a first axial ratchet portion 50 such that the rotation
of the first axial ratchet portion causes an equivalent rotation of
the hub and vice versa. The cogset 20 may define a splined portion
24 configured to interact with a second axial ratchet portion 51.
The first axial ratchet portion 50 and the second axial ratchet
portion 51 may each have teeth 56, 57, respectively. The teeth 56
of the first axial ratchet portion 50 may be axially facing and
configured to interact with the desirably axially facing teeth 57
of a second axial ratchet portion 51. These axial ratchet portions
50, 51 can be biased together by a pair of springs 52 between which
the axial ratchets are provided. When the axial ratchet portions
50, 51 are biased together their teeth 56, 57 interact such that
the axial ratchets can rotate relative to one another in only one
direction. Rotation of one axial ratchet in the opposite direction,
while compelled against the other axial ratchet, will cause said
other axial ratchet to also rotate in said opposite direction. By
way of the splines, the ratchets 50, 51 can thus force similar
rotational properties between the hub 40 and the cogset 20. The
axial ratchets 50, 51 may rotate around the shaft 36 directly, or
be spaced somewhat from the shaft 36 as shown here via a bushing
53. It will be clear from the description herein that other methods
can be used to reduce friction between the axial ratchets 50, 51
and the shaft 36.
[0041] The cogset 20 can be configured and/or equipped to rotate
about and mount onto the hub 40 and/or the shaft 36. The cogset 20
may mount onto the hub 40 at the cogset inner end 23 or, as shown,
spaced somewhat outward from its inner end. In various embodiments,
the cogset may be mounted onto the hub spaced at least 1/4 inch,
1/2 inch, 3/4 inch, 1 inch, 11/4 inch, and 11/2 inch from the inner
end 23 of the cogset 20. The cogset 20 may be mounted on the hub
spaced no more than 1/4 inch, 1/2 inch, 3/4 inch, 1 inch, 11/4
inch, 11/2 inch, 13/4 inch and 2 inches from the inner end 23 of
the cogset 20. Typically, the inner end of the cogset 20 will be
defined by the innermost cog of the cogset. Typically, this
innermost cog will be the largest diameter cog of the cogset 20,
but alternative configurations are possible, such as providing the
largest diameter to the outermost cog. In various embodiments the
sprocket facing end 41 of the hub 40 will extend into the cogset 20
at least 1/4 inch, 1/2 inch, 3/4 inch, 1 inch, 11/2 inch, 13/4
inch, 2 inches, 21/4 inches, 21/2 inches, 23/4 inches or 3 inches.
A bushing 43 can be provided between the hub 40 and the cogset 20
to facilitate rotation and reduce friction between them. Other
friction-reducing elements can be used. Similarly, the cogset 20
can mount on the shaft 36 at the outer end 22, as depicted here by
way of cogset bearing 35. The cogset 20 can thus act as part of the
hub 40.
[0042] As discussed above, at the ends 100, 101 of the cogset and
hub assembly 6 can be provided end caps 60, 61. A short end cap 60
can be provided near the cogset 20 and a long end cap 61 can be
provided near the hub 40. Thus, the spokes 9 connecting the hub 40
and the wheel 2 can be positioned near the center of the space
between the stays 12. In some embodiments, the cogset 20 and the
long end cap 61 may be shorter, allowing for a longer hub 40 or
shorter assembly length L.sub.A. Providing a longer hub 40 may be
undesirable due to increased weight. Similarly, providing a shorter
assembly length L.sub.A may be desirable by providing a shorter
moment arm on the shaft 36. It will be clear from the description
herein that other factors may be considered in choosing the
assembly length L.sub.A and the size of the hub 40.
[0043] In other embodiments the spokes 9 may be positioned
substantially toward the free end 101 or to the driven end 100 of
the assembly length L.sub.A. When the spokes 9 are positioned
substantially toward the free end 101, more space can be available
for the sprocket 20 and hub 40. The end caps 60, 61 can comprise,
either integrally or in a separate part(s), connecting means 70
such as a nut and bolt to rigidly attach the cogset and hub
assembly 6 to the stays 12.
[0044] Referring to FIG. 3B, the cogset 20 may mount directly, or
substantially directly, onto the hub 40 and the shaft 36 by way of
a bushing 43 and cogset bearing 35 respectively. Thus, in some
embodiments, a separate sprocket carrier or other intermediary
element is not necessary. Additionally, the cogset 20 can interact
directly, or substantially directly, with the second axial ratchet
portion 51 and the hub 40 without an intermediary element. As
further shown, the end caps 60, 61 can provide a substantially
complete seal, preventing the contamination of the bearings 31, 35,
shaft 36, hub 40, cogset 20, or other elements of the cogset and
hub assembly 6. As further shown, in some embodiments no lock ring
is necessary to secure a free wheel body separate of the cog
set.
[0045] Referring to FIGS. 2B and 3B, the cogset 20 may comprise an
inner surface 80 of variable size. Said inner surface 80 may define
a cross-sectional opening which increases in size from the outer
end 22 to the inner end 23 generally monotonically, substantially
monotonically, or in some other way. The profile of the diameter of
the inner surface 80 of the cogset 20 may generally match the
profile of the diameter of the cogs of the cogset 20.
[0046] Extending inward from the inner surface 80 may be a mounting
portion or post 28. As shown, the mounting post 28 can provide the
interface between the cogset 20 and the hub 40, via the bushing 43.
The mounting post 28 may extend angularly completely around the
bushing 43, comprising a shape similar to a disc. Alternatively,
the mounting post 28 may comprise a plurality of posts comprising
spoke-like structures. Further, the position of the mounting post
28 along the axis of the cogset and hub assembly 6 may vary. As
shown in FIG. 3B the mounting post 28 is positioned within the
interior of the cogset 20. In other embodiments the mounting post
28 can sit further toward the hub facing end 23 of the cogset 20 or
further toward the outer end 22, near the ratchets 50, 51. As to be
discussed further below, varying the position of the mounting post
28 can allow greater flexibility in the design of the cogset and
hub assembly 6, such as allowing for larger ratchets 50, 51.
[0047] With respect to FIG. 3B, the cogset 20 and hub 40 can
further comprise seats 29, 46, 47 for the bearings 31, 32, 35. The
cogset 20 can comprise a seat 29 along its interior to receive a
cogset bearing 35 that can allow rotation about the shaft 36.
Similarly, the hub 40 can comprise hub bearing seats 46, 47 to
receive hub bearings 31, 32 that can allow rotation about the shaft
36. In one embodiment, the cogset 20 may define an outermost drive
end cogset bearing seat 29 which receives cogset bearing 35. In
some embodiments, the hub 40 can comprise a free end bearing seat
46 for receiving a free-end bearing 31. In some embodiments, the
hub 40 can define a driven end hub bearing seat 47 for receiving a
driven end hub bearing 32. In some embodiments, as illustrated, the
driven end hub bearing 32 may be spaced outward from the driven end
hub flange 45 of the hub 40 and may be spaced outward from the
inner end 23 of the cogset 20. In particular, the driven end
bearing seat 47 and driven end hub bearing 32 may be positioned at
least 1/4 inch, 1/2 inch, 3/4 inch, 1 inch, 11/4 inch, 11/2 inch,
13/4 inch and 2 inches from the inner end 23 of the cogset 20. In
various embodiments, the driven end hub bearing seat 47 and driven
end hub bearing 32 may be mounted on the hub spaced no more than
1/4 inch, 1/2 inch, 3/4 inch, 1 inch, 11/4 inch, 11/2 inch, 13/4
inch and 2 inches from the inner end 23 of the cogset 20. In
various embodiments the sprocket facing end 41 of the hub 40 will
not extend beyond the driven end hub bearing 32 or will extend
beyond the driven end hub bearing 32 at least 1/4 inches, 1/2 inch,
3/4 inch, 1 inch, 11/2 inch, 13/4 inch, 2 inches, 21/4 inches, 21/2
inches, 23/4 inches or 3 inches. The driven end hub bearing 32 and
driven end hub bearing seat 47 may be of variable size, material,
and fit depending on the loads that must be born while supporting
the weight of the bicycle 1 and its cargo, and during rotation.
[0048] The free end hub bearing seat 46 and the free end hub
bearing 31 may comprise similar positions relative to the free end
42 of the hub 40. For example, the free end hub bearing seat 46 and
free end hub bearing 31 may be positioned at least 1/4 inch, 1/2
inch, 3/4 inch, 1 inch, 11/4 inch, 11/2 inch, 13/4 inch, 2 inches,
21/4 inches, 21/2 inches, 23/4 inches, and 3 inches from the free
end 42 of the hub 40. In various embodiments, the free end hub
bearing seat 46 and free end hub bearing 31 may be mounted on the
hub spaced no more than 1/4 inch, 1/2 inch, 3/4 inch, 1 inch, 11/4
inch, 11/2 inch, 13/4 inch, 2 inches, 21/4 inches, 21/2 inches,
23/4 inches, and 3 inches from the free end 42 of the hub 40.
Further, the free end hub bearing seat 46 and the free end hub
bearing 31 may similarly comprise size, material, and fit depending
on the loads that must be born while supporting the weight of the
bicycle 1 and its cargo, and during rotation.
[0049] The cogset bearing seat 29 and cogset bearing 35 may
comprise similar positions relative to the driven end 23 of the
cogset 20 and the stay 12 on the driven end 100 of the cogset and
hub assembly 6. For example, the cogset bearing seat 29 and cogset
bearing 35 may be positioned no more than 1/4 inch, 1/2 inch, 3/4
inch, 1 inch, 11/4 inch, 11/2 inch, 13/4 inch and 2 inches from the
driven end 23 of the cogset 20. In various embodiments, the cogset
bearing seat 29 and cogset bearing 35 may be mounted on the cogset
spaced no more than 1/4 inch, 1/2 inch, 3/4 inch, 1 inch, 11/4
inch, 11/2 inch, 13/4 inch and 2 inches from the driven end 100 of
the cogset and hub assembly 6. Further, the cogset bearing seat 29
and the cogset bearing 35 may similarly comprise size, material,
and fit depending on the loads that must be born while supporting
the weight of the bicycle 1 and its cargo, and during rotation.
[0050] The bearing seats 29, 46, 47 and the bearings 31, 32, 35 can
have a wide stance. For example, the cogset and driven end hub
bearing seats 29, 47 and/or the cogset and driven end hub bearings
32, 35 can be positioned at least outside of the hub flange 45
and/or inside the cogset 20. The cogset and free end hub bearing
seats 29, 46 and/or the cogset and free end hub bearings 31, 35 can
be spaced apart at least two-thirds the combined length of the
cogset 20 and hub main body 40. The driven end and free end hub
bearing seats 45, 46 and/or the driven end and free end hub
bearings 31, 32 can be spaced apart at least 1/2 the combined
length of the cogset 20 and hub main body 40.
[0051] In some embodiments the cogset and hub assemblies 6
described herein may comprise a wide variety of materials, sizes,
shapes, and or configurations. Because in some embodiments the
cogset 20 can mount directly or substantially directly onto the hub
40 and/or shaft 36 without an intermediary element such as a
sprocket carrier, the cogset's inner diameter can be approximately
equal to the outer diameter of the hub 40 and/or the shaft 36.
Thus, in some embodiments the cog size may be substantially smaller
while mounted on a shaft 36 compared to prior art cogset and hub
assemblies. For example, a cogset and hub assembly 6 mounted on a
shaft 36 may comprise at least one sprocket comprising an inner
diameter less than 1%, 2%, 3%, 5%, 7%, 10%, or 15% greater than the
diameter of the shaft 36 upon which the cogset and hub assembly 6
is mounted. Further, the shaft 36 may comprise a diameter not less
than 1 inch, 11/2 inch, 13/4 inch, 2 inches, 21/4 inches, 21/2
inches, 23/4 inches, 3 inches, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm,
or 2 cm. Alternatively, the shaft may have an external diameter
less than 1 inch, 7/8 inch, 3/4 inch, 5/8 inch, or 1/2 inch. The
shaft 36 may further comprise a lighter material such as carbon
fiber, steel, aluminum, plastics, titanium, and the like. The
cogset 20 may further be mounted directly or substantially directly
onto load bearings which similarly mount onto the hub 40 and/or
shaft 36.
[0052] Further, the size of the load bearings 31, 32, 35 may be
altered. As shown in FIG. 3B, the bearings 31, 32, 35 can be
positioned relatively wide along the axis of the cogset and hub
assembly 6. The load bearings 31, 32, 35 can comprise a bearing
diameter of approximately 9/16 inch. Alternatively, the load
bearings can comprise a bearing diameter greater than 9/16 inch.
Further, the balls in the load bearings 31, 32, 35 may comprise a
ball bearing diameter less than 1/32 inch, 1/64 inch, 1/128 inch,
3/128 inch, 0.8 mm, 0.6 mm, 0.4 mm, or 0.2 mm. Further, the load
bearings 31, 32, 35 and their respective balls may comprise
different sizes.
[0053] Further, the bearings 31, 32, 35 and bearing seats 29, 46,
47 can be positioned at varying points along the axis of the cogset
and hub assembly 6. For example, the cogset bearings 35 can be
positioned within 1%, 2%, 3%, 5%, 7%, or 10% of the assembly length
L.sub.A from the driven end 100 of the cogset and hub assembly 6.
Similarly, the hub bearings 31, 32 may be positioned within 1%, 2%,
3%, 5%, 7%, or 10% of the assembly length L.sub.A from the
corresponding ends of the hub 40.
[0054] Further, the ratchet portions 50, 51 used may comprise a
larger size. For example, the axial ratchet portions 50, 51
depicted in FIG. 3B may comprise a larger size, in this instance by
providing them further toward the inner end 23 of the cogset 20 and
similarly providing the mounting post 28 further toward the inner
end 23 of the cogset 20. The ratchet portions 50, 51 may comprise
18 teeth 56, 57 with a ratchet surface area of 0.22 square inches.
As can be seen from FIG. 3B, ample space can be provided within the
cogset and hub assembly 6 depicted for much larger axial ratchet
portions 50, 51. For example, the ratchet portions 50, 51 may
comprise more than 18 teeth 56, 57 and/or have a ratchet surface
area of greater than 0.22 square inches. Further, the axial ratchet
portions 50, 51 can, comprise lighter materials, a greater number
of teeth per degree of rotation, and further design changes.
[0055] Further, the assembly length L.sub.A can be distributed
varyingly between the parts of the cogset and hub assembly 6. For
example, the hub 40 can be made shorter or be more substantially
overlapped by the cogset 20. Further, the cogset 20 may be within
1/4 inch, 1/2 inch, 3/4 inch, 1 inch, 11/2 inch, 13/4 inch, 2
inches, 21/4 inches, 21/2 inches, 23/4 inches or 3 inches of the
spokes 9. Further, the axis length L.sub.A may be divided, for
example, such that the large end cap generally comprises 10%, 20%,
30%, or 40% of the axis length, the distance between the flanges 45
connecting to the spokes generally comprise 10%, 20%, 30%, 40%,
50%, 60%, or 70%, and/or the cogset generally comprises 10%, 20%,
30%, or 40% of L.sub.A.
[0056] Further flexibility can be provided by varying the distance
between cogs on adjacent sprockets of the cogset 20. For example,
increasing the distance between cogs on adjacent sprockets can
allow lighter materials to be used. Alternatively, decreasing the
distance between cogs on adjacent sprockets can allow a greater
number of sprockets on the cogset 20. In some embodiments the
cogset 20 may comprise greater than 9, 10, 11, 12, 13, 14, or 15
sprockets.
[0057] As shown in FIG. 4, the cogset 20 can mount almost directly
onto the hub 40, with only a bushing 43 in between to reduce
friction. The hub 40 can in turn mount onto the shaft 36 with a set
of hub bearings 31, 32 to reduce friction. As shown in FIG. 5, the
cogset 20 can mount almost directly onto the shaft 36, with only
cogset bearings 35 in between to reduce friction. In other
embodiments it may be desirable to distance the cogset 20 from the
cogset bearings 35. This distance may be approximately 1/32 inch,
1/64 inch, 1/128 inch, or 1/256 inch. Similarly, the distance may
be no more than 1/2 mm.
[0058] Referring to FIG. 6, one embodiment of the cogset 20 can
comprise two pieces 25, 26 attached by cogset spline portions 18 to
cause co-rotation. The pieces can be further connected by screws,
welds, adhesives, or any other connecting means known in the art or
combination thereof. The first cogset 25 can comprise a distinct
material from the second cogset 26. For example, the first cogset
25 can comprise aluminum, titanium, steel, and/or carbon fiber. The
second cogset 26 can comprise steel and/or titanium. Generally, the
second cogset 26 can comprise a heavier and/or stronger material
than the first cogset 25. Further, the second cogset 26 may connect
with the cogset and hub assembly 6 via the first cogset 25. The
second cogset 26 may comprise cog sizes from 11 to 14. The first
cogset 25 may comprise cog sizes from 15 to 20. In other
embodiments, the first cogset may comprise cog sizes lower than 11
while the second cogset may comprise cog sizes greater than 26. As
shown, the first cogset 25 may further comprise a spline portion 24
within its interior.
[0059] FIGS. 7A and 8A depict a perspective view and a side view of
an alternative embodiment of a cogset and hub assembly 6'. As shown
in FIG. 7A, the assembly 6' can comprise a first ratchet portion
such as a plurality of radially extending pawls 54 configured to
interact with a second ratchet portion, such as a radially facing
ratchet portion of a cogset 20'. Referring to FIG. 7B, the shaft
main body 30' may comprise larger and smaller diameter portions 33,
34. The larger diameter portion 34 of the shaft main body 30' may
be associated with a larger diameter portion of the hub 40'.
Similarly, the driven end hub bearing 32' corresponding to said
larger diameter portion 34 may also be larger. The shaft main body
30' may further comprise smaller diameter portions 33 on either end
of the larger diameter portion 34, which can interface with the
outer end 22 of the cogset 20' and/or the second end 42 of the hub
40'.
[0060] As shown in FIG. 7B, the hub 40' may further comprise a pawl
receiving portion 44. The pawl receiving portion 44 may be
configured to accommodate at least one pawl 54 and a pawl spring
55. The pawls 54 may rotate about a connection with the hub 40 and
can be compelled to rotate outward by the pawl spring 55.
Alternatively, multiple springs may be used. The pawls 54 and the
pawl spring 55 can be configured to interact with a ratchet portion
27 of the cogset 20' such that the cogset 20' may rotate in only
one direction relative the pawls 54. Upon rotation of the cogset
20' in the other direction, the interaction between the pawls 54
and the ratchet portion 27 can cause the hub 40' to also rotate in
said opposite direction.
[0061] Referring to FIG. 8B, the shaft 36' can comprise a larger
diameter portion 34 near the pawls 54 of the hub 40'. As further
shown, the larger diameter portion 34 may be accommodated by larger
diameter portions of the hub 40' and cogset 20'. If desirable, the
shaft size may comprise a different diameter profile, such as a
larger diameter along the full length of the hub 40'.
[0062] In this embodiment, the mounting post 28' can be
substantially shorter to accommodate the reduced clearance between
the general profile of the inner surface 80 of the cogset 20' and
the shaft 36'. The mounting post 28' may comprise different shapes
and positions as discussed above with mounting post 28. For
example, in this embodiment the mounting post 28' may alternatively
be positioned further toward the outer end 22 of the cogset 20' or
further toward the hub-facing end 23. In either case the mounting
post 28' may further comprise a greater length.
[0063] FIG. 9 depicts a cross-sectional view of a cogset and hub
assembly 6'. As shown, the cogset 20' can comprise one or more
ratchet teeth. The ratchet teeth can engage with one or more pawls
54 mounted on the hub 40' such that rotation between the hub 40'
and cogset 20' may be achieved in only one direction. The hub 40'
can be mounted on the shaft 36' by way of hub bearings 31, 32'. As
shown, the shaft diameter can decrease in stages. The shaft 36' can
terminate at an end cap 60, 61.
[0064] FIG. 10 depicts an exploded view of a cogset 20'. As shown,
the cogset 20' can comprise two pieces 25', 26 attached by cogset
spline portions 18 to cause co-rotation, as in FIG. 6.
[0065] In some embodiments the cogset and hub assemblies 6'
described herein may comprise a wide variety of materials, sizes,
shapes, and or configurations. Because in some embodiments the
cogset 20' can mount directly or substantially directly onto the
hub 40' and/or shaft 36' without an intermediary element such as a
sprocket carrier, the cogset's inner diameter can be approximately
equal to the outer diameter of the hub 40' and/or the shaft 36'.
Thus, in some embodiments the cog size may be substantially smaller
while mounted on a shaft 36' compared to prior art cogset and hub
assemblies. For example, a cogset and hub assembly 6' mounted on a
shaft 36' may comprise at least one sprocket comprising an inner
diameter less than 1%, 2%, 3%, 5%, 7%, 10%, or 15% greater than the
diameter of the shaft 36' upon which the cogset and hub assembly 6'
is mounted. The cogset 20' may further be mounted directly or
substantially directly onto load bearings 35 which similarly mount
onto the hub 40' and/or shaft 36'.
[0066] Further, the shaft 36' may comprise a portion with a
relatively large diameter. For example, a cogset and hub assembly
6' mounted on a shaft 36' may comprise at least one sprocket
comprising an inner diameter less than 1%, 2%, 3%, 5%, 7%, 10%, or
15% greater than the diameter of the shaft 36' corresponding to
said sprocket. More generally, the shaft 36' may comprise an
average external diameter greater than 1 inch, 11/2 inch, 13/4
inch, 2 inches, 21/4 inches, 21/2 inches, 23/4 inches, 3 inches, 15
mm, 16 mm, 17 mm, 18 mm, 19 mm, or 2 cm. Alternatively, the shaft
may comprise an external diameter less than 1 inch, 7/8 inch, 3/4
inch, 5/8 inch, or 1/2 inch. Further, the shaft may comprise a
larger diameter portion 34 with diameter greater than 125%, 150%,
175%, 200%, 225%, 250%, 275%, or 300% wider than a smaller diameter
portion 33 of the shaft 36' and/or the shaft main body 30'.
Alternatively, the shaft may comprise a maximum external diameter
greater than 1 inch, 11/2 inch, 13/4 inch, 2 inches, 21/4 inches,
21/2 inches, 23/4 inches, or 3 inches. Further, the shaft may
comprise a minimum external diameter less than 1 inch, 7/8 inch,
3/4 inch, 5/8 inch, 1/2 inch, 3/8 inch, or 1/4 inch. The shaft 36'
may further comprise a lighter material such as carbon fiber,
aluminum, titanium, plastics, and the like.
[0067] Further, the size of the load bearings 31, 32', 35 may be
altered. As shown in FIG. 8B, the bearings 31, 32', 35 can be
positioned relatively wide along the axis of the cogset and hub
assembly 6'. The load bearings 31, 32', 35 can comprise a bearing
diameter of approximately 9/16 inch. Alternatively, the load
bearings can comprise a bearing diameter greater than 9/16 inch.
Further, the balls in the load bearings 31, 32', 35 may comprise a
bearing diameter less than 1/32 inch, 1/64 inch, 1/128 inch, 3/128
inch, 0.8 mm, 0.6 mm, 0.4 mm, or 0.2 mm. Further, the load bearings
31, 32', 35 may comprise different sizes. For example, the driven
end hub bearing 32' can comprise a larger bearing diameter than the
other bearings 31, 35. Similarly, the driven end hub bearing 32'
can hold balls with diameter smaller than the other bearings 31,
35.
[0068] Further, the bearings 31, 32', 35 and bearing seats 29, 46,
47' can be positioned at varying points along the axis of the
cogset and hub assembly 6'. For example, the cogset bearings 35 can
be positioned within 1%, 2%, 3%, 5%, 7%, or 10% of the assembly
length L.sub.A from the driven end 100 of the cogset and hub
assembly 6. Similarly, the hub bearings 31, 32' may be positioned
within 1%, 2%, 3%, 5%, 7%, or 10% of the assembly length L.sub.A
from the ends 41, 42 of the hub 40'.
[0069] Further, the ratchets 54, 55, 27 used may comprise a larger
size. For example, in FIG. 8B the shaft size may be reduced to
allow for a larger ratchet. The pawls 54 may be made as large as at
least 1/4 inches, 1/2 inch, 3/4 inch, or 1 inch. The pawls 54 may
comprise a lighter material such as carbon fiber, aluminum,
titanium, or the like and still be capable of bearing the same load
due to their increased size. The ratchet may additionally comprise
a greater number of ratchet teeth per degree of rotation. Further,
the ratchets can, as in preceding discussions, comprise lighter
materials, a greater number of teeth per degree of rotation, and
further design changes.
[0070] Further, the assembly length L.sub.A can be distributed
varyingly between the parts of the cogset and hub assembly 6'. For
example, the hub 40' can be made shorter or be more substantially
overlapped by the cogset 20'. Further, the cogset 20' may be within
1/4 inch, 1/2 inch, 3/4 inch, 1 inch, 11/2 inch, 13/4 inch, 2
inches, 21/4 inches, 21/2 inches, 23/4 inches or 3 inches of the
spokes 9. Further, the axis length L.sub.A may be divided, for
example, such that the large end cap generally comprises 10%, 20%,
30%, or 40% of the axis length, the distance between the flanges 45
connecting to the spokes generally comprise 10%, 20%, 30%, 40%,
50%, 60%, or 70%, and/or the cogset generally comprises 10%, 20%,
30%, or 40%.
[0071] Further flexibility can be provided by varying the distance
between cogs on adjacent sprockets of the cogset 20'. For example,
increasing the distance between cogs on adjacent sprockets can
allow a larger chain 4, which may further comprise lighter
materials. Alternatively, decreasing the distance between cogs on
adjacent sprockets can allow a greater number of sprockets on the
cogset 20'. In some embodiments the cogset 20' may comprise greater
than 9, 10, 11, 12, 13, 14, or 15 sprockets.
[0072] As shown, the alternative embodiments depicted herein may
comprise distinct, equivalent, and altered parts. It will be clear
from the disclosure herein that parts that have only slight
differences between embodiments may still perform the same
function. For example, shafts 36, 36' comprise different shapes but
can still perform at least one shared function, namely providing
rotational support to the other parts of the cogset and hub
assemblies 6, 6'. Further, parts with distinct morphologies may
still perform substantially equivalent functions. For example, the
ratchet elements of FIGS. 2B, 3B and the ratchet elements of FIGS.
7B, 8B comprise very distinct parts, but are both capable of
controlling the relative rotational properties of the hubs 40, 40'
and cogsets 20, 20'. It will further be clear from the disclosure
herein that the specific dimensions, cog sizes, and materials
attributed to one embodiment may further be attributable to another
embodiment. For example, although the shaft 30 in FIG. 2B is
different from the shaft 30' in FIG. 7B, it will be clear that the
cogset and hub assembly 6 of FIG. 2B could be modified to
accommodate the shaft 30', while still maintaining other
differences between the cogset and hub assemblies 6, 6'.
[0073] Although the foregoing systems and methods have been
described in terms of certain preferred embodiments, other
embodiments will be apparent to those of ordinary skill in the art
from the disclosure herein. Additionally, other combinations,
omissions, substitutions and modifications will be apparent to the
skilled artisan in view of the disclosure herein. While certain
embodiments of the inventions have been described, these
embodiments have been presented by way of example only, and are not
intended to limit the scope of the inventions. Indeed, the novel
methods and systems described herein may be embodied in a variety
of other forms without departing from the spirit thereof.
Accordingly, other combinations, omissions, substitutions and
modifications will be apparent to the skilled artisan in view of
the disclosure herein.
* * * * *