U.S. patent application number 14/923343 was filed with the patent office on 2016-09-22 for cassette and bicycle wheel assembly.
This patent application is currently assigned to PRAXIS WORKS LLC. The applicant listed for this patent is Praxis Works LLC. Invention is credited to David M. Earle, Ding-Jiun Lin.
Application Number | 20160272002 14/923343 |
Document ID | / |
Family ID | 56924451 |
Filed Date | 2016-09-22 |
United States Patent
Application |
20160272002 |
Kind Code |
A1 |
Earle; David M. ; et
al. |
September 22, 2016 |
CASSETTE AND BICYCLE WHEEL ASSEMBLY
Abstract
A bicycle wheel assembly may include a cassette having a
plurality of sprocket portions, the cassette being configured such
that a cavity or recess is formed in a large end of the cassette. A
wheel hub coupled to the cassette may include a spoke connection
flange that is disposed at least partially within the cavity of the
cassette, facilitating a more acute spoke angle.
Inventors: |
Earle; David M.;
(Watsonville, CA) ; Lin; Ding-Jiun; (Taipei City,
TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Praxis Works LLC |
Aptos |
CA |
US |
|
|
Assignee: |
PRAXIS WORKS LLC
Aptos
CA
|
Family ID: |
56924451 |
Appl. No.: |
14/923343 |
Filed: |
October 26, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14660856 |
Mar 17, 2015 |
9168976 |
|
|
14923343 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 53/28 20130101;
B21D 53/86 20130101; Y10T 29/49462 20150115; B60B 27/023 20130101;
Y10T 29/49506 20150115; B23K 2101/00 20180801; B60B 31/005
20130101; B60B 1/042 20130101; Y10T 29/49465 20150115; B60B 27/0026
20130101; Y10T 29/49481 20150115; B60B 1/003 20130101; B60B 1/041
20130101; B60B 27/047 20130101; B21D 53/26 20130101; B62M 9/10
20130101 |
International
Class: |
B60B 27/04 20060101
B60B027/04; B60B 1/04 20060101 B60B001/04; B60B 27/02 20060101
B60B027/02; B60B 1/00 20060101 B60B001/00; B60B 27/00 20060101
B60B027/00 |
Claims
1. A bicycle wheel assembly comprising: a hub assembly having a
first flange, a second flange, and a freehub body adjacent to the
second flange; a rim attached by a first plurality of spokes to the
first hub flange and by a second plurality of spokes to the second
hub flange; and a cassette coupled to the freehub body, a large end
of the cassette defining an open cavity and including a first
sprocket portion; wherein the second flange and the cassette are
disposed such that the second plurality of spokes extends into the
cavity.
2. The assembly of claim 1, wherein the cassette is connected to
the freehub body by a spline joint.
3. The assembly of claim 1, wherein the first sprocket portion is
concave.
4. The assembly of claim 1, wherein the first sprocket portion is
annular.
5. The assembly of claim 1, the first sprocket portion having a
first outer diameter (OD), the cassette further including an
annular second sprocket portion having a second OD smaller than the
first OD, wherein the second sprocket portion is joined to the
first sprocket portion.
6. The assembly of claim 5, wherein the first sprocket portion and
the second sprocket portion are joined by at least one weld.
7. The assembly of claim 5, wherein the first sprocket portion and
the second sprocket portion are joined by at least one removable
fastener.
8. A bicycle component assembly comprising: a wheel hub having a
spoke connection flange; and a cassette coupled to the wheel hub,
the cassette including a plurality of stepped sprocket portions
defining a small end, a large end opposite the small end, and a
cavity having an open mouth at the large end; wherein the spoke
connection flange is located at least partially within the
cavity.
9. The assembly of claim 8, the plurality of stepped sprocket
portions including a first annular sprocket portion and a second
annular sprocket portion, the first annular sprocket portion having
a plurality of protruding connector members, each connector member
being welded to the second annular sprocket portion.
10. The assembly of claim 8, wherein the large end of the cassette
includes an annular sprocket portion, such that the cavity is at
least partially formed by an inner diameter of the annular sprocket
portion.
11. The assembly of claim 10, wherein the annular sprocket portion
is a first annular sprocket portion, the large end of the cassette
further including a second annular sprocket portion joined to the
first annular sprocket portion.
12. The assembly of claim 11, wherein the second annular sprocket
portion is welded to the first annular sprocket portion.
13. The assembly of claim 8, wherein the large end of the cassette
includes a concave sprocket portion, such that the cavity is at
least partially formed by a concave shape of the sprocket
portion.
14. The assembly of claim 13, further including a freehub body
coupled to the wheel hub, wherein the concave sprocket portion
includes a central interface forming a spline joint with the
freehub body.
15. The assembly of claim 13, the plurality of stepped sprocket
portions including a pair of annular sprocket portions, the pair of
annular sprocket portions being welded together and forming a
central opening, wherein the concave sprocket portion is adjacent
to the pair of annular sprocket portions and is disposed partially
within the central opening.
16. The assembly of claim 15, wherein the concave sprocket portion
is connected to the pair of annular sprocket portions by at least
one removable fastener.
17. A bicycle component assembly comprising: a wheel hub having a
spoke connection flange; a plurality of spokes extending between
the spoke connection flange and a wheel rim; and a cassette coupled
to the wheel hub, the cassette including a plurality of stepped
annular sprocket portions, a largest one of the sprocket portions
defining an end plane of the cassette and having an inner diameter
larger than the spoke connection flange; wherein the plurality of
spokes breaks the end plane of the cassette.
18. The assembly of claim 17, wherein the spoke connection flange
breaks the end plane of the cassette.
19. The assembly of claim 17, wherein the plurality of spokes
extend from an outboard side of the spoke connection flange.
20. The assembly of claim 17, wherein a first one of the annular
sprocket portions is welded to a second one of the annular sprocket
portions.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of U.S. Non-Provisional
Application Ser. No. 14/660,856 filed Mar. 17, 2015 which is
incorporated herein by reference in its entirety for all
purposes.
FIELD
[0002] This disclosure relates to bicycles and bicycle
manufacturing. More specifically, the disclosed embodiments relate
to systems and methods relating to sprocket clusters and associated
rear wheels for bicycles.
INTRODUCTION
[0003] A typical bicycle drive train includes two pedals attached
to respective crankarms on opposite sides of the bicycle frame. The
crankarms are typically joined together by a spindle that passes
through the frame, rigidly attaching the crankarms at positions
that are rotated by 180 degrees relative to each other. This allows
the alternating pedaling motion with which all bicycle riders are
familiar. The pedals are also rotationally coupled to a toothed
gear or set of gears, commonly referred to as the chainring or
drive wheel. The chainring, in turn, drives a sprocket on the rear
wheel of the bicycle via a continuous chain looped around the
chainring and sprocket. Typically, a rider may select from a
plurality of rear sprockets of different sizes, depending on
factors such as riding conditions, rider comfort, and desired
speed. The plurality of rear sprockets are arranged in a stepped or
stacked formation by size, coaxial with the rear wheel hub. The
sprockets are traditionally attached to the hub in a freehub or a
freewheel arrangement. In either standard arrangement, each
sprocket is connected or coupled to the hub individually, such as
by a splined connection.
SUMMARY
[0004] The present disclosure provides a bicycle wheel assembly,
which may include a hub assembly having a first flange, a second
flange, and a freehub body adjacent to the second flange. A rim may
be attached by a first plurality of spokes to the first hub flange
and by a second plurality of spokes to the second hub flange. A
cassette may be coupled to the freehub body, and a large end of the
cassette may define an open cavity and include a first sprocket
portion. The second flange and the cassette may be disposed such
that the second plurality of spokes extends into the cavity.
[0005] In some embodiments, a bicycle component assembly may
include a wheel hub having a spoke connection flange; and a
cassette coupled to the wheel hub, the cassette including a
plurality of stepped sprocket portions defining a small end, a
large end opposite the small end, and a cavity having an open mouth
at the large end. The spoke connection flange may be located at
least partially within the cavity.
[0006] In some embodiments, a bicycle component assembly may
include a wheel hub having a spoke connection flange, and a
plurality of spokes extend between the spoke connection flange and
a wheel rim. A cassette may be coupled to the wheel hub, the
cassette including a plurality of stepped annular sprocket
portions, a largest one of the sprocket portions defining an end
plane of the cassette and having an inner diameter larger than the
spoke connection flange. In these embodiments, the plurality of
spokes breaks the end plane of the cassette.
[0007] Features, functions, and advantages may be achieved
independently in various embodiments of the present disclosure, or
may be combined in yet other embodiments, further details of which
can be seen with reference to the following description and
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a front elevation view of an illustrative bicycle
wheel assembly in accordance with aspects of the present
disclosure.
[0009] FIG. 2 is a left side isometric view of the assembly of FIG.
1.
[0010] FIG. 3 is a right side isometric view of the assembly of
FIG. 1.
[0011] FIG. 4 is a partial sectional front elevation view of the
assembly of FIG. 1.
[0012] FIG. 5 is an isometric view of an illustrative sprocket
cluster in accordance with aspects of the present disclosure.
[0013] FIG. 6 is a block diagram showing steps performed in an
illustrative method for manufacturing a sprocket cluster in
accordance with aspects of the present disclosure.
[0014] FIG. 7 is an isometric view of an illustrative intermediate
article of manufacture resulting from a step of the method shown in
FIG. 6.
[0015] FIG. 8 is an isometric view of another illustrative
intermediate article of manufacture from a step of the method shown
in FIG. 6.
[0016] FIG. 9 is an isometric view of another illustrative
intermediate article of manufacture from a step of the method shown
in FIG. 6.
[0017] FIG. 10 is an alternate isometric view of the article of
FIG. 9.
[0018] FIG. 11 is an isometric view of another illustrative
intermediate article of manufacture from a step of the method shown
in FIG. 6.
[0019] FIG. 12 is an isometric exploded view of another
illustrative sprocket cluster in accordance with aspects of the
present disclosure.
[0020] FIG. 13 is an isometric view of the assembled sprocket
cluster of FIG. 12.
[0021] FIG. 14 is a magnified partial view of a portion of the
sprocket cluster of FIG. 12, showing relationships between certain
sprocket components.
[0022] FIG. 15 is an isometric view of another illustrative
sprocket cluster in accordance with aspects of the present
disclosure.
[0023] FIG. 16 is a partial rear elevation view of an illustrative
bicycle wheel, showing relationships between a hub and spokes.
[0024] FIG. 17 shows the hub and spokes of FIG. 16, with an
illustrative concave sprocket installed thereon.
[0025] FIG. 18 is a sectional view of the assembly of FIG. 17, with
additional smaller sprockets installed.
DESCRIPTION
[0026] Overview
[0027] Various embodiments of devices and methods relating to a
bicycle wheel assembly having a unitary (or partially unitary)
cassette and improved spoke spread angle are described below and
illustrated in the associated drawings. Unless otherwise specified,
the methods, bicycle wheel assembly, and/or its various components
may, but are not required to, contain at least one of the
structure, components, functionality, and/or variations described,
illustrated, and/or incorporated herein. Furthermore, the
structures, components, functionalities, and/or variations
described, illustrated, and/or incorporated herein in connection
with the present teachings may, but are not required to, be
included in other wheel assemblies and/or methods. The following
description of various embodiments is merely exemplary in nature
and is in no way intended to limit the disclosure, its application,
or uses. Additionally, the advantages provided by the embodiments,
as described below, are illustrative in nature and not all
embodiments provide the same advantages or the same degree of
advantages.
[0028] A bicycle wheel assembly (e.g., a rear wheel assembly) may
include a rim, a central hub, several spokes connecting the rim to
the hub, and a cogset or gear cluster coupled to one end portion of
the hub (e.g., a freehub). An illustrative wheel assembly is shown
in FIGS. 1 and 2, and described in detail in the examples below.
Cogsets may be interchangeably referred to herein as cassettes,
sprocket clusters, and/or gear clusters. A cassette may include a
plurality of sprockets (also referred to as gears and/or cogs),
each of the sprockets having a different outer diameter and/or
number of teeth. The sprockets may be arranged coaxially by size,
with a largest sprocket on an inboard end of the cassette, and a
smallest sprocket on an outboard end of the cassette. One or more
of the sprockets may be rotationally coupled to the hub, such as by
a splined connection to an axial projection of the hub.
[0029] The cassette makes up a portion of a typical bicycle drive
train, and the drive chain of the bicycle drives the wheel through
a selected sprocket of the cassette. While a chain drive and
toothed sprocket cluster are described herein, it should be
understood that other drive mechanisms may be used, such as a belt
drive.
[0030] Typically, to allow each of the sprockets to transfer chain
motion into wheel revolution, each of the sprockets must be
individually splined or otherwise attached to the hub. However, the
improved wheel assembly described in detail below includes a
cassette wherein two or more of the sprockets are affixed to each
other, thereby enabling the unconnected (e.g., unsplined) sprockets
to drive the wheel via the connected (e.g., splined) sprockets. In
some examples, some or all of the sprockets are affixed to each
other, and one or two of the smaller sprockets are connected (e.g.,
splined) to the hub. In some examples, the largest sprocket is
affixed to the next largest sprocket, such that the largest
sprocket is not required to connect directly to the hub. The
sprockets may be axially spaced and affixed to each other by
welding or otherwise attaching radially distributed projections of
one sprocket to the face of a neighboring sprocket. Accordingly,
the unitary portion of the cassette may be described as a series of
coaxial sprockets affixed to each other.
[0031] This arrangement and method of manufacture facilitates use
of one or more sprockets that are not required to interface
directly with the hub. Accordingly, these unconnected (e.g.,
unsplined) sprockets can have an annular shape with an inner
diameter larger than the hub. In some examples, each successively
larger sprocket may have a successively larger inner diameter,
resulting in a roughly cone-shaped cavity in the center of the
cassette. This cavity may result in a lower weight of the cassette,
as unneeded material is no longer present in a center portion of
the cogset.
[0032] Additionally, the largest sprocket need not be coupled
directly to the hub, so an opening or mouth of the cavity may be
present in the large end of the cassette. In some examples, a
similar cavity may be provided by a largest sprocket that is
concave rather than annular, as described further below. As this
cavity mouth is also the area of the wheel assembly where the
cassette-side spokes attach to a flange (or other suitable portion)
of the hub, the flange may be moved outward from its typical
position, toward or even into the interior of the cassette. Spokes
may pass from the rim to the cassette-side flange, breaking the
plane of the innermost, largest sprocket. As compared to a standard
cassette, or any cassette having an innermost sprocket or other
component that connects to the hub, this open-mouthed cassette may
permit a more advantageous wheel geometry. For example, the
cassette-side spokes may form a more acute angle with the hub axis.
For example, the spread between the flanges of the hub may be
widened. A wider angle of the spokes, as measured at the rim, may
improve wheel stiffness and lateral performance. In some examples,
the same spread between flanges may be maintained, but the dish of
the wheel may be lessened, such as by shifting the flanges toward
the cassette.
[0033] As described in further detail below, a method of
manufacturing the wheel assembly may include steps to manufacture
all or a portion of the cassette. For example, two sprockets
intended to be side by side in the cassette may be stamped and
shaped. At least one of the stamped sprockets may include finger
portions that extend radially inward. These finger portions may be
reshaped to protrude transverse to the plane of the sprocket (e.g.,
orthogonally). The sprockets may then be attached to each other by
welding the transverse finger portions (also referred to as "ears")
to the face of the other sprocket. Any suitable connection method
may be used instead of or in combination with welding, such as
bolting, keying, adhering, and/or the like. Additional sprockets
may be attached to the two-sprocket intermediate article of
manufacture, by repeating the steps substantially as described
above and in further detail below.
[0034] Examples, Components, and Alternatives
[0035] The following examples describe selected aspects and
components of exemplary bicycle wheel assemblies as well as related
systems and/or methods. These examples are intended for
illustration and should not be interpreted as limiting the entire
scope of the present disclosure. Each example may include one or
more distinct inventions, and/or contextual or related information,
function, and/or structure.
Illustrative Wheel Assembly:
[0036] As shown in FIGS. 1-5, this section describes an
illustrative bicycle wheel assembly having a hollow or partially
hollow cassette and a spoke arrangement that extends into the
cassette.
[0037] In this example, a bicycle wheel assembly is generally
indicated at 10. Assembly 10 includes a circular rim 12 coupled to
a central hub 14 by a plurality of spokes 16. A cassette 18 is
coupled to hub 14 on one side of the assembly. Cassette 18 is
configured to comprise a portion of the drive train of a bicycle on
which the wheel assembly is mounted. Bicycle drive trains are
typically on the right side of the bicycle. It is noted that other
configurations of the various components are possible, such as when
assembly 10 is used on certain examples of recumbent bicycles and
the like. However, it will be assumed for ease of description
herein that assembly 10 corresponds to the rear wheel in a typical
bicycle configuration. Accordingly, FIG. 1 shows a front elevation
view of assembly 10 (i.e., as seen from the front of a bicycle,
looking rearward). Similarly, FIGS. 2 and 3 are left and right
isometric views, respectively.
[0038] Rim 12 may include any suitable wheel rim configured to hold
a tire on an outer circumferential portion 20 and to function as a
connection surface for spokes 16 on an inner circumferential
portion 22. Spokes 16 may be connected to rim portion 22 using any
suitable method and/or device. For example, spokes 16 may be
attached to rim portion 22 using spoke nipples 24 commonly used in
the art. Any suitable number of spokes may be used, such as
twenty-four or thirty-six spokes. Additionally or alternatively,
rim 12 may be coupled to hub 14 by components other than spokes.
For example, wheel assembly 10 may include a disc wheel or an
aerodynamic spoked wheel (e.g., a tri-spoke). Rim 12 may be
constructed of any suitable materials. For example, rim 12 may
comprise aluminum or steel, alloys thereof, carbon fiber, and/or
the like.
[0039] Hub 14 may include any suitable structure configured to
couple a central axle to wheel assembly 10 and to provide a
connection or mounting surface for spokes 16 and cassette 18. In
the example shown in FIGS. 1-4, Hub 14 includes a body portion 26,
a left hub flange 28, a right hub flange 30, and a splined portion
32 extending from hub 14 on the cassette side of the assembly
(e.g., adjacent to the right hub flange). Right hub flange 30 may
alternatively be referred to as the cassette-side flange. Hub 14 is
shown in the drawings as a hub shell, in that the standard central
axle is not illustrated. Splined portion 32 is referred to as
"splined." However, portion 32 may include any suitable torque
transfer structure configured to rotationally couple portion 32 to
the cassette.
[0040] Hub 14 has a central axis 34 about which the hub and wheel
rotate. Hub 14 may define a flange-to-flange width 36 between
flanges 28 and 30. Hub 14 may have an overall hub width 38, defined
axially between a first (i.e., left) terminal end 40 and a second
(i.e., right) terminal end 42.
[0041] Left hub flange 28 may include spoke attachment points
distributed around the hub flange, such as spoke holes 44. Spoke
holes 44 are configured to receive a quantity of spokes 46, which
are a subset of spokes 16. Likewise, right hub flange 30 may
include spoke attachment points distributed around the hub flange,
such as spoke holes 48. Spoke holes 48 are configured to receive a
quantity of spokes 50, which are also a subset of spokes 16. Spokes
46 may be referred to interchangeably as left side spokes or left
spokes. Similarly, spokes 50 may be referred to interchangeably as
right side spokes, right spokes, or cassette-side spokes.
[0042] In the example shown, Rim 12 may be substantially centered
with respect to the overall hub width 38. This results in the wheel
being centered with respect to the bicycle frame and rear fork.
However, as best seen in the sectional view of FIG. 4, rim 12 is
not centered with respect to hub flange width 36. Flanges 28 and 30
are not symmetrical relative to the rim, and right side flange 30
is closer to an overall centerline 52 than left side flange 28.
This is required to make room for the sprocket cluster (i.e.,
cassette 18). Because left spokes 46 are attached to left flange
28, and right spokes 50 are attached to right flange 30, the spokes
on the left side of the wheel assembly form a deeper overall cone
shape than the angle of the spokes on the right side. The spokes on
the right side form a shallower or flatter cone. This aspect of the
wheel, in which the rear wheel is centered relative to the bicycle
frame, is referred to as dishing or the dish.
[0043] Given a constant rim diameter, an angle 54 of right side
spokes 50 with respect to axis 34 is limited by the location of
holes 48 in right flange 30, which is limited axially by cassette
18 and radially by the diameter of the flange or the radial
distance of the flange from axis 34. It may be desirable for angle
54 to be more acute (i.e., closer to the angle formed by the left
side spokes), because the more acute angle may improve lateral
wheel stiffness. Accordingly, flange 30 may be moved farther from
axis 34, such as by increasing the diameter of flange 30 and/or by
increasing the diameter of hub body 26 to move flange 30 closer to
the rim. Additionally or alternatively, angle 54 may be made more
acute by locating flange 30 closer to right terminal hub end 42,
i.e., toward cassette 18.
[0044] With continuing reference to FIGS. 1-4, and specifically to
the more detailed view of FIG. 5, cassette 18 may include any
suitable number of sprocket portions 56 arranged coaxially and in
an ascending order by size (e.g., diameter). This arrangement may
also be referred to as a "stepped" arrangement of the sprocket
portions. At least a portion of cassette 18 may be unitary, such
that some or all of sprocket portions 56 form a single, undivided
piece. In this regard, cassette 18 (or the unitary portion of
cassette 18) may also be referred to as an inseparable unit, in the
sense that separation of the sprocket portions can only be achieved
through destructive methods such as cutting or breaking. For
example, each sprocket portion may be permanently affixed to a
neighboring sprocket portion. Permanently affixing or joining the
sprocket portions may be achieved by fusing the sprocket portions
to each other. For example, two sprocket portions may be fused by
causing the portions, at least in part, to coalesce (e.g., by
welding).
[0045] Each sprocket portion may include any suitable structure
configured to provide a drive train interface (e.g., sprocket teeth
configured to interface with a bicycle chain) and a
sprocket-to-sprocket interface configured to provide an attachment
and spacing mechanism between sprocket portions (e.g., protrusions
fused to a neighboring sprocket portion).
[0046] This unitary set of sprocket portions facilitates the
inclusion of an opening or cavity 58 in a large end 60 of cassette
18. Instead of individual sprockets, each of which must interface
with splined portion 32 of the hub, only one (or a subset) of the
sprocket portions of cassette 18 needs to interface with the hub to
transmit force between the cassette and the hub. Sprocket portions
that connect to the hub may be described as having a central
aperture that is configured to mate with portion 32 (e.g., a
splined freehub). This frees one or more of the larger sprocket
portions to be formed as annular disks having an inner radius
continuously larger than the hub. In some examples, only the
largest sprocket portion is formed in this manner. Cavity 58
extends into the large end of the cassette until reaching the first
sprocket portion that connects to the hub. Accordingly, in examples
where only the largest sprocket portion is annular, cavity 58 may
be described as having a depth of one sprocket. In other examples,
a plurality of the largest sprocket portions are formed as annular
disks. Moreover, the larger the sprocket portion outer radius, the
larger the inner radius may be. The axially-growing inner radii of
the sprocket portions may thereby form a roughly conical cavity 58
within cassette 18.
[0047] In some examples, cassette 18 may be unitary, and additional
sprocket portions may be coupled to the same splined portion 32.
For example, one or more smaller standard sprockets may be splined
to the hub adjacent to cassette 18. Cassette 18 and/or additional
sprockets may be held axially to the hub by a threaded keeper or
any suitable structure or device configured to prevent cassette 18
from axially detaching from the hub.
[0048] As mentioned above, angle 54 may be made more acute by
locating flange 30 farther outboard, i.e., closer to right terminal
hub end 42. Cavity 58 facilitates relocation of right flange 30
beyond what is possible with standard cassettes, and beyond what is
possible with any sprocket cluster that interfaces with hub 14 at
the largest/inboard end of the cluster. In other words, hub flange
30 and/or a portion of right spokes 50 may be located at least
partially inside cavity 58, i.e., outboard of a plane 62 defined by
the inboard face of the large end of cassette 18. Outboard is
defined herein as a direction away from lateral centerline 52 of
the wheel assembly, whereas inboard is defined as a direction
toward lateral centerline 52.
Illustrative Manufacturing Method and Intermediate Articles of
Manufacture:
[0049] This section describes a method 100 for manufacturing a
cassette suitable for use with a wheel assembly such as wheel
assembly 10. This section also describes various intermediate
articles of manufacture associated with method 100 and cassette 18;
see FIGS. 5-11.
[0050] In general, this section describes a method for making a
cassette (or portion of a cassette) for a bicycle. The method
includes joining a first generally planar sprocket portion to a
second generally planar sprocket portion. The first sprocket
portion has a plurality of connector portions each unitary with the
first sprocket portion and extending transverse to the plane of the
first sprocket portion. The two sprocket portions are joined by
fusing at least one of the connector portions to the second
sprocket portion. The first sprocket portion is generally annular
and has a first inner diameter (ID) and the second sprocket portion
is generally annular and has a second ID sized differently from the
first ID.
[0051] In some embodiments, the method includes producing a
substantially planar first sprocket portion having a generally
annular shape, a first plurality of teeth extending radially
outward around a first outer diameter (i.e., outer circumference),
and a first plurality of finger portions extending radially inward
around an inner diameter (i.e., inner circumference). The method
may further include producing a substantially planar second
sprocket portion having a second plurality of teeth extending
radially outward around a second outer diameter. The first
plurality of finger portions may be shaped to produce a plurality
of connector portions protruding transverse to the plane of the
first sprocket portion. The first sprocket portion may be joined to
the second sprocket portion by fusing the plurality of connector
portions to the second sprocket portion. The first sprocket portion
and the second sprocket portion may be coaxial, and the first
sprocket portion may be spaced from the second sprocket by the
plurality of connector portions.
[0052] In some embodiments, the method may include selecting a
substantially planar and annular first sprocket portion having a
first outer diameter, and a plurality of connection members
protruding transverse to the plane of the sprocket portion. A
substantially planar second sprocket portion having a second outer
diameter different from the first outer diameter may also be
selected. The first and second sprocket portions may be aligned
coaxially. The first and second sprocket portions may be joined,
such as by fusing (e.g., coalescing or welding) the connection
members of the first sprocket portion to the second sprocket
portion.
[0053] FIG. 5 is an example of a unitary, hollow cassette 18, as
described above. FIG. 6 is a flowchart illustrating steps performed
in an illustrative method for manufacturing a cassette (e.g.,
cassette 18), and may not recite the complete process or all steps
of the process. Although various steps of method 100 are described
below and depicted in FIG. 6, the steps need not necessarily all be
performed, and in some cases may be performed in a different order
than the order shown. FIGS. 7 through 11 depict intermediate
articles of manufacture associated with method 100 and/or cassette
18, all as further described below.
[0054] At step 102, an individual sprocket portion 200
(corresponding to one sprocket portion of sprocket portions 56) is
created, e.g., by cutting and/or stamping the sprocket portion from
a flat plate or sheet of steel or other suitable metal. Step 102
may be repeated any number of times. For example, multiple copies
of substantially identical sprocket portions may be created. For
example, multiple different sprocket portions may be created, such
as sprocket portions having different sizes and/or tooth counts.
For simplicity, only one sprocket portion 200 is described with
respect to step 102. At this step, sprocket portion 200 may be
substantially planar, and may be referred to as a "blank" 202.
[0055] As shown in FIG. 7, sprocket portion 200 in the form of
blank 202 includes a generally annular plate having an inner
diameter (ID) 204, an outer diameter (OD) 206, and a generally
constant thickness. In this context, and as commonly used in the
art, the terms ID and OD each describe both a respective diameter
and a respective perimeter (e.g., circumference) of the object. For
example, OD may refer interchangeably to both the diametrical size
and the circumferential edge portion of the outer circle defined by
blank 202.
[0056] A plurality of teeth 208 are spaced or disposed around OD
206. Teeth 208 may include any suitable structure configured to
interface with a bicycle drive train (e.g., a bicycle chain),
thereby enabling sprocket portion 200 to function as a drive gear
for the rear wheel. For example, as shown in FIG. 7, teeth 208 may
be generally triangular and spaced to correspond with standard
bicycle chain links. Different sizes of sprocket portion 200 may
include different numbers of teeth 208, to accommodate desired
gearing for the wheel assembly. At step 102, teeth 208 may be in an
unfinished state.
[0057] A plurality of finger portions 210 are spaced or disposed
around ID 204. Finger portions 210 on blank 202 may include any
suitable structure capable of being stamped or cut from a flat
plate and then shaped into a connection member for attaching
sprocket portion 200 to another sprocket portion. For example, as
shown in FIG. 7, finger portions 210 may include a plurality of
elongate members projecting radially inward, i.e., toward the
center of blank 202. A radius 212 may be formed at the proximal
ends (i.e., bases) of the members, such that the finger portions
are defined and separated by U-shaped gaps 214.
[0058] Step 102 may be summarized as stamping or cutting to create
a blank having a perimeter or profile that includes inner shapes
and outer teeth. After step 102, the gear or sprocket portion is a
flat plate having an inner and outer shape. Step 102 may be
summarized as producing a substantially planar first sprocket
portion having a generally annular shape, a first plurality of
teeth extending radially outward around a first outer diameter, and
a first plurality of finger portions extending radially inward
around an inner diameter.
[0059] At step 104, teeth 208 may be modified to change the
sectional profile of one or more of the teeth. In general, the
profile(s) may be modified to facilitate better chain engagement,
better chain disengagement, and/or other shifting
characteristics.
[0060] Modification of the tooth profile(s) may be accomplished by
forging, cutting, chamfering, beveling, smoothing, filing,
grinding, any combination of these, and/or the like. Following
completion of step 104, teeth 208 of sprocket portion 200 may be
partially tapered or chamfered as shown in FIG. 8. Step 104 may be
described as creating shifting profiles on teeth 208, such as by
making small cuts and chamfers on the individual teeth to
facilitate smooth shifting.
[0061] Depending on the method used to create the profiles, step
104 may include trimming of excess material and/or cleaning or
refining of the profile. For example, chamfering the teeth using a
forging method may result in some unnecessary material being
squeezed out. This excess material may be trimmed off and cleaned
up. In some examples, this trimming operation may be performed in
parallel with other operations, such as those described below.
[0062] In some embodiments, step 104 may be summarized as forming
or creating a profile on each of a plurality of teeth, which may
include forging and/or trimming each tooth.
[0063] At step 106, finger portions 210 may be modified to form
connector portions 216 that extend transverse to the plane of
sprocket portion 200. Connector portions 216 may include any
suitable structure that is unitary with sprocket portion 200 and
protrudes transverse (e.g., orthogonal) to the plane of the
sprocket portion. For example, finger portions 210 may be modified
by bending, forming, shaping, forging, pressing, any combination of
these, and/or the like. Modification results in at least a distal
end of each finger being reoriented to extend transverse to the
plane of sprocket portion 200. In some examples, such as the one
shown in FIGS. 9 and 10, each of the finger portions may be
modified in a substantially identical fashion, such that all of the
transverse connector portions 216 extend in the same direction.
[0064] Sprocket portion 200 may have a first major face 220 and a
second major face 222 opposite and spaced from first major face
220. Connector portions 216 may be sized to correspond with a
desired spacing between sprocket portions. For example, connector
portions 216 may protrude from major face 220 of sprocket portion
200 by a distance corresponding to the desired lateral spacing
between sprocket portions. A terminal end 218 of each connector
portion 216 may be shaped to interface with a neighboring sprocket
portion. For example, the face of terminal end 218 may be flat to
interface with a neighboring sprocket portion that is expected to
be planar.
[0065] In some embodiments, step 106 may be summarized as shaping a
plurality of finger portions to produce a plurality of connector
portions protruding transverse to the plane of the sprocket
portion. The connector portions may be disposed around the ID of
the sprocket portion. In some embodiments, step 106 may include
modifying a corresponding plurality of elongate members of the
sprocket portion to form the plurality of connector portions.
[0066] At step 108, sprocket portion 200 is affixed to another
sprocket portion 224 to form a unitary structure 226, as shown in
FIG. 11. Sprocket portions 200 and 224 may be referred to as the
first sprocket portion and the second sprocket portion,
respectively. In the example shown in the drawings, sprocket
portion 224 may include any suitable sprocket portion substantially
similar to sprocket portion 200 (described above). In other
examples, sprocket portion 224 may include a standard sprocket or a
sprocket portion otherwise configured to couple directly to the
hub, or may comprise a cassette or portion of a cassette. As
compared to sprocket portion 200, second sprocket portion 224 may
have different dimensions or alternative characteristics. For
example, second sprocket portion 224 may have a larger or smaller
OD (a smaller OD is shown in FIG. 11). For example, second sprocket
portion 224 may have a different number of teeth on the OD. For
example, the first sprocket portion may include a greater tooth
count than the second sprocket portion. For example, second
sprocket portion 224 may have a different thickness, a different
number of fingers or connector portions, and/or a differently-sized
ID.
[0067] Sprocket portions 200 and 224 may be permanently connected
or joined, such as by fusing connector portions 216 of first
sprocket portion 200 to a major face 228 of second sprocket portion
224. Any suitable fusing method may be used. For example, step 108
may include welding (e.g., laser beam welding). After step 108, the
first and second sprocket portions will be permanently attached,
forming a single unitary structure 226. In some examples, such as
the one depicted in FIG. 11, the two sprocket portions may be
coaxial. In some examples, connector portions may extend in an
opposite direction, and connector portions 230 of second sprocket
224 may be joined to face 220 of the first sprocket portion. In
some examples, connector portions of a given sprocket portion may
extend in more than one direction (i.e., some in one direction and
some in an opposite direction). In those examples, the connector
portions of the same sprocket portion can be fused (e.g., welded)
or otherwise joined to two neighboring sprocket portions.
[0068] Depending on the number and location of the connector
portions, it may be possible to connect the first and second
sprocket portions to each other in one of a plurality of possible
mutual orientations. For example, connector portions of sprocket
portion 200 may be attached to sprocket portion 224 near the bases
of connector portions or fingers on the second sprocket
portion.
[0069] Second sprocket portion 224 may be manufactured by following
one or more of the preceding steps described above. In some
embodiments, as indicated by step 110, the first and/or second
sprocket portion may be selected from one or more sprocket portions
already manufactured or otherwise provided. Second sprocket portion
224 may be in the same state of manufacture as is the first
sprocket portion at this step, meaning second sprocket portion may
have profiled teeth and shaped connector portions. In some
examples, one or more steps may be performed with respect to the
second sprocket portion after the two sprocket portions are
connected. For example, profiling and/or trimming of the teeth of
sprocket portion 224 may be performed after welding.
[0070] In some embodiments, step 108 may be summarized as joining a
first sprocket portion to a second sprocket portion by fusing a
plurality of connector portions to the second sprocket portion. The
first sprocket portion and the second sprocket portion are
concentric, and the first sprocket portion is spaced from the
second sprocket by the plurality of connector portions. In some
embodiments, step 108 may be summarized as joining a first
generally planar sprocket portion having a plurality of connector
portions each unitary with the first sprocket portion and extending
transverse to the plane of the first sprocket portion, to a second
generally planar sprocket portion by fusing at least one of the
connector portions to the second sprocket portion. The first
sprocket portion is generally annular and has a first inner
diameter (ID) and the second sprocket portion is generally annular
and has a second ID sized differently from the first ID.
[0071] At step 112, one or more additional sprocket portions may be
connected to unitary structure 226 to form a larger unitary
structure. Additional sprocket portions may be obtained through
step 110 and/or through one or more of steps 102-106, as described
above regarding second sprocket portion 224. Additional sprocket
portions may be substantially similar to portions 200 and 224, and
may be of a different size and/or tooth count. For example, a third
sprocket portion may be attached to face 222 of sprocket portion
200. For example, a smaller sprocket portion may be attached to the
connector portions of sprocket portion 224. Accordingly, a series
of sprocket portions may be so connected to form a single unitary
structure 226', such as cassette 18 shown in FIG. 5. Because the
cassette is unitary in nature, only a subset of the sprocket
portions of the cassette need to be coupled to hub 14. For example,
only a smallest sprocket portion or the two smallest sprocket
portions may have a splined or keyed interface with splined portion
32 of hub 14. In some examples, a sprocket portion other than the
smallest may be used. For example, one or more sprocket portions of
intermediate size in cassette 18 may be coupled to the hub. In some
examples, as described above, additional sprocket portions other
than those of cassette 18 may be coupled to the same splined
portion 32. Cassette 18 and/or additional sprockets may be held
axially to the hub by a threaded keeper or any suitable structure
or device configured to prevent cassette 18 from axially detaching
from the hub.
Additional Illustrative Wheel Assemblies:
[0072] This section describes additional illustrative wheel
assemblies similar to bicycle wheel assembly 10; see FIGS.
12-18.
[0073] FIGS. 12-18 show various aspects and examples of wheel
assemblies having hollow or partially hollow cassettes with stepped
sprocket portions, and spoke arrangements that extend into the
cassettes. As described above, a cassette having an open cavity at
a large end may facilitate more acute spoke angles (see, e.g.,
spoke angle 54 of FIG. 4). For example, the cassette may allow the
spoke connection flange of a hub to be disposed such that the
cassette-side spokes extend at least partially into the mouth of
the cavity. Accordingly, wheel assemblies having hubs and cassettes
constructed in accordance with aspects of the present disclosure
may include spokes having a wider lateral spread than standard
wheels. This section describes two additional examples of such
wheel assemblies. As mentioned above, the structures, components,
functionalities, and/or variations described with respect to each
of these examples may be interchangeable with or included in other
wheel assemblies or cassettes described herein. Additionally,
certain aspects of these examples may be utilized in or produced by
a related manufacturing method, e.g., method 100.
[0074] FIG. 12 is an exploded view of a cassette 300 and related
components suitable for use in a wheel assembly similar to assembly
10 described above and/or assembly 400 described below. FIG. 13 is
an assembled view of cassette 300. As with cassette 18, a plurality
of annular sprocket portions is used to form an open-mouthed cavity
in the large end of the cassette. Here, a large end 302 of cassette
300 includes an annular first sprocket portion 304, an annular
second sprocket portion 306, and a third sprocket portion 308
having a central spline feature 310.
[0075] A subassembly (also referred to as a cluster or subcluster)
312 of the cassette includes a fourth sprocket portion 314, a fifth
sprocket portion 316, a sixth sprocket portion 318, and a seventh
sprocket portion 320. Sprocket portions 314, 316, and 318 each have
a plurality of connector members 322 for attaching the respective
sprocket portion to the next smaller (adjacent) sprocket portion.
For example, sprocket portions 314 through 320 (or a subset
thereof) may be fused, e.g., welded, together using connector
members 322 according to method 100. FIG. 14 is a magnified view of
subassembly 312, showing how, in this example, connector members
322 of sprocket portions 314 through 318 are insertable into
corresponding apertures 324 of sprocket portions 316 through 320,
respectively. After inserting members 322 into apertures 324, the
members may be welded in place. This plug-and-socket topology may
enable added security over welding such members to a face of the
adjacent sprocket portion.
[0076] Additionally, one or more connector members 322 and
apertures 324 may be keyed or differently sized, to visually
indicate and/or physically necessitate a proper alignment between
the sprocket portions. For example, as shown in FIG. 14, one
connector member 322A may be larger than the rest, and may have a
correspondingly sized aperture 324A, such that sprocket portions
314 and 316 are rotationally aligned only when member 322A is
inserted in aperture 324A.
[0077] Returning to FIGS. 12 and 13, a subcluster 326 including
sprocket portions 304, 306, and 308 may be pinned or otherwise held
together, such as by one or more removable fasteners 328 (see FIG.
13). Subcluster 326 may be attachable to a cassette driver 330 of a
hub, e.g., using a lockring 332. Subcluster 312 may be attached to
subcluster 326 using one or more removable fasteners 334. For
example, sprocket portion 314 of subcluster 312 may be bolted to
sprocket portion 308 of subcluster 326, through threaded apertures
in one or both of the sprocket portions.
[0078] At the small, or outboard, end of cassette 300, a third
subcluster 336 of smaller sprocket portions may be assembled onto a
splined sleeve 338 and/or spacer 340. For example, an eighth
sprocket portion 342, a ninth sprocket portion 344, a tenth
sprocket portion 346, and an eleventh sprocket portion 348 may be
keyed or otherwise coupled to sleeve 338, which is in turn
connectable to the hub.
[0079] As best viewed in FIG. 13, subcluster 326 forms an
open-mouthed cavity or recess 350 in large end 302 of cassette 300.
Sprocket portions 304 and 306 are each annular, having an inner
diameter larger than the diameter of the hub. Accordingly, a first
plane defined by the inboard face of sprocket portion 304 will be
spaced from a second plane defined by sprocket 308. The depth of
this space (i.e., cavity or recess 350) will correspond to the
thickness of the two inboard sprockets. As shown in FIG. 4 (and
later in FIG. 18), this cavity can receive the cassette-side
spokes, and in some examples the spoke connection flange of a hub
assembly, thereby facilitating more acute spread angles for the
spokes of a wheel. In other words, the spokes can break the first
plane and be disposed at least partially within cavity 350.
[0080] Although eleven sprocket portions grouped into three
subcluster types are described in this example, any suitable number
of sprockets may be utilized and combined in any suitable number of
subclusters. In some examples, more or fewer sprockets may be
present, as well as more or fewer subcluster types. In some
examples, one or more of the subcluster types may be absent, or
arranged in a different order.
[0081] FIGS. 15-18 depict various aspects of another illustrative
cassette and wheel assembly 400. Wheel assembly 400 includes a
cassette 402, a hub 404, and a wheel (partially shown) having a
plurality of spokes 406.
[0082] FIG. 15 is an isometric view of a cassette 402 of wheel
assembly 400. FIG. 16 is a rear elevation view of hub 404 and
spokes 406. FIG. 17 is a rear elevation view similar to FIG. 16,
but with a single sprocket portion of cassette 402 installed. FIG.
18 is a sectional rear elevation view taken at line 18-18, with all
sprockets of cassette 402 installed.
[0083] As with cassettes 18 and 300, cassette 402 defines an open
cavity 408 into which spokes 406 may extend. Rather than including
a number of annular sprocket portions having stepped inner
diameters (IDs), as shown in the examples of cassettes 18 and 300,
cassette 402 includes a first sprocket portion 410 that is concave.
In other words, sprocket portion 410 curves inward, being sunken or
depressed with respect to an end plane 411 defined by a periphery
412 of the sprocket (see FIG. 17). A plurality of radial arms 414
connect periphery 412 to a central spline feature 416 configured to
form a keyed or splined joint with hub 404. As with cassettes
described above, this arrangement allows connection between the hub
and the cassette, while permitting a spoke connection flange to be
located such that associated spokes are disposed at least partially
within cavity 408. In some examples, the spoke connection flange
may be itself partially or completely within cavity 408. In other
examples, the spoke connection flange may merely be positioned such
that the spokes break end plane 411 of the cassette.
[0084] Additional sprocket portions 420 may be included in cassette
402. Sprocket portions 420 may be connected to concave sprocket
portion 410 by any suitable method, including those described above
with respect to cassette 300. For example, a pair of annular
sprocket portions 422 may be welded together, forming a central
opening 424. Concave sprocket portion 410 may be adjacent to the
pair of annular sprocket portions 422, such that the concave
sprocket portion is disposed partially within the central opening.
Additional sprocket portions may be welded or otherwise affixed to
the pair just described. Concave sprocket portion 410 may be bolted
or otherwise fastened to pair 422 or any other adjacent sprocket
portion(s).
[0085] As depicted in FIG. 16, hub 404 includes a central body 426
(also referred to as a shell), a first or left spoke connection
flange 428, a second or right or cassette-side spoke connection
flange 430 spaced from the first flange, and a freehub body 432
coupled to the hub adjacent to second flange 430. As best viewed in
FIG. 18, hub 404 also includes or is associated with a wheel axle
434 and a pair of opposing end caps 436 and 438.
[0086] As depicted in FIGS. 16-18, cassette-side spokes 406 are
installed through corresponding apertures in flange 430, and extend
from an outboard (e.g., right) face or side of the flange to a rim
of the wheel (not shown, see rim of FIGS. 1-4). Spokes 406 are
substantially similar to spokes 50, described above. A second set
of spokes (not shown here) connects the rim to first flange 428
(see FIGS. 1-4).
[0087] As depicted in FIGS. 17 and 18, concave sprocket portion 410
is installed on hub 404. More specifically, central splined feature
416 of sprocket portion 410 is keyed or mated to a corresponding
outer surface of freehub body 432. Concave sprocket portion 410 and
hub 404 are configured such that spokes 406 nest within cavity 408
formed by the concave shape of the sprocket portion. In other
words, sprocket portion 410 covers or overlaps a portion of the
spoke connection flange and spokes, when viewed from the front or
rear of the wheel assembly. Specifically, cassette 402 and flange
430 are disposed such that spokes 406 break the end plane (411) of
the cassette. This is evident, for example, in FIG. 17, where an
outboard portion of spokes 406 (and flange 404) are covered by
sprocket portion 410. This is also evident in FIG. 18, where the
spatial relationship between spokes 406, flange 404, and sprocket
portion 410 is illustrated directly.
Selected Examples and Embodiments:
[0088] This section describes additional aspects and features of a
bicycle wheel assembly and related components and methods,
presented without limitation as a series of paragraphs, some or all
of which may be alphanumerically designated for clarity and
efficiency. Each of these paragraphs can be combined with one or
more other paragraphs, and/or with disclosure from elsewhere in
this application, in any suitable manner. Some of the paragraphs
below expressly refer to and further limit other paragraphs,
providing without limitation examples of some of the suitable
combinations.
[0089] A0. A method for making a cassette for a bicycle, the method
comprising: joining a first generally planar sprocket portion
having a plurality of connector portions each unitary with the
first sprocket portion and extending transverse to the plane of the
first sprocket portion, to a second generally planar sprocket
portion by fusing at least one of the connector portions to the
second sprocket portion;
[0090] wherein the first sprocket portion is generally annular and
has a first inner diameter (ID) and the second sprocket portion is
generally annular and has a second ID sized differently from the
first ID.
[0091] A1. The method of A0, wherein the plurality of connector
portions are disposed around the ID of the first sprocket
portion.
[0092] A2. The method of A0, wherein fusing the at least one
connector portion to the second sprocket portion includes
coalescing.
[0093] A3. The method of A2, wherein fusing the at least one
connector portion to the second sprocket portion includes
welding.
[0094] A4. The method of A0, wherein the first sprocket portion has
a first plurality of teeth spaced about a first outer diameter
(OD), and the second sprocket portion has a second plurality of
teeth spaced about a second OD, the second OD being sized
differently from the first OD and each tooth in the first and
second pluralities of teeth being substantially identical.
[0095] A5. The method of A0, further comprising modifying a
corresponding plurality of elongate members of the first sprocket
portion to form the plurality of connector portions.
[0096] B0. A method for making a cassette for a bicycle, the method
comprising:
[0097] producing a substantially planar first sprocket portion
having a generally annular shape, a first plurality of teeth
extending radially outward around a first outer diameter, and a
first plurality of finger portions extending radially inward around
an inner diameter;
[0098] producing a substantially planar second sprocket portion
having a second plurality of teeth extending radially outward
around a second outer diameter;
[0099] shaping the first plurality of finger portions to produce a
plurality of connector portions protruding transverse to the plane
of the first sprocket portion; and
[0100] joining the first sprocket portion to the second sprocket
portion by fusing the plurality of connector portions to the second
sprocket portion;
[0101] wherein the first sprocket portion and the second sprocket
portion are concentric, and the first sprocket portion is spaced
from the second sprocket by the plurality of connector
portions.
[0102] B1. The method of B0, wherein fusing the plurality of
connector portions to the second sprocket portion includes welding
at least one of the first plurality of connector portions to the
second sprocket portion.
[0103] B2. The method of B0, further including creating a profile
on each of the first plurality of teeth.
[0104] B3. The method of B2, wherein creating the profile on each
of the first plurality of teeth includes forging each tooth of the
first plurality of teeth.
[0105] B4. The method of B0, wherein producing the first sprocket
portion includes stamping a blank of the first sprocket portion
from a metal plate.
[0106] B5. The method of B0, wherein shaping the first plurality of
finger portions to produce the plurality of connector portions
includes bending each of the finger portions.
[0107] B6. The method of B0, wherein the first outer diameter is
sized differently from the second outer diameter.
[0108] B7. The method of B0, wherein the second sprocket portion
includes a central aperture configured to couple the second
sprocket portion to a bicycle wheel hub, and wherein the inner
diameter of the first sprocket portion is generally larger than a
diameter of the central aperture.
[0109] B8. The method of B7, wherein the central aperture is
configured to mate with a splined freehub.
[0110] C0. A method for making a cassette for a bicycle, the method
comprising:
[0111] selecting a substantially planar and annular first sprocket
portion having a first outer diameter, and a plurality of
connection members protruding transverse to the plane of the
sprocket portion;
[0112] selecting a substantially planar second sprocket portion
having a second outer diameter different from the first outer
diameter;
[0113] aligning the first and second sprocket portions coaxially;
and
[0114] joining the first and second sprocket portions by welding
the connection members of the first sprocket portion to the second
sprocket portion.
[0115] C1. The method of C0, the first sprocket portion further
including a plurality of teeth spaced around the first outer
diameter.
[0116] C2. The method of C1, wherein selecting the first sprocket
portion includes selecting based on a desired number of teeth.
[0117] C3. The method of C0, further comprising selecting a
substantially planar and annular third sprocket portion having a
third outer diameter different from the first and second outer
diameters, and a plurality of connection members protruding
transverse to the plane of the third sprocket portion; and
[0118] joining the first and third sprocket portions by welding the
connection members of the third sprocket portion to the first
sprocket portion.
[0119] C4. The method of C3, wherein an inner diameter of the third
sprocket portion is larger than an inner diameter of the first
sprocket portion.
[0120] D0. An intermediate article of manufacture, comprising:
[0121] no more than two sprocket portions:
[0122] a substantially planar first sprocket portion having a
generally annular shape, an outer circumference including a first
plurality of teeth, and an inner circumference including a
plurality of fingers, each of the fingers including a connection
portion extending transverse to the plane of the first sprocket
portion;
[0123] a substantially planar second sprocket portion having a
generally annular shape, the second sprocket portion fused to the
plurality of connection portions of the first sprocket portion and
having a second plurality of teeth extending radially around an
outer circumference of the second sprocket portion;
[0124] wherein the first and second sprocket portions are coaxial
and form an inseparable unit.
[0125] D1. The article of D0, wherein the second sprocket portion
is welded to the plurality of connection portions.
[0126] D2. The article of D0, wherein the first plurality of teeth
has a greater tooth count than the second plurality of teeth.
[0127] E0. A bicycle wheel assembly comprising:
[0128] a hub assembly having a first flange, a second flange, and a
freehub body adjacent to the second flange;
[0129] a rim attached by a first plurality of spokes to the first
hub flange and by a second plurality of spokes to the second hub
flange; and
[0130] a cassette coupled to the freehub body, a large end of the
cassette defining an open cavity and including a first sprocket
portion;
[0131] wherein the second flange and the cassette are disposed such
that the second plurality of spokes extends into the cavity.
[0132] E1. The assembly of E0, wherein the cassette is splined to
the freehub body, i.e., connected to the freehub body by a spline
joint.
[0133] E2. The assembly of any of paragraphs E0 through E1, wherein
the first sprocket portion is concave.
[0134] E3. The assembly of any of paragraphs E0 through E1, wherein
the first sprocket portion is annular.
[0135] E4. The assembly of any of paragraphs E0 through E3, the
first sprocket portion having a first outer diameter (OD), the
cassette further including an annular second sprocket portion
having a second OD smaller than the first OD, wherein the second
sprocket portion is joined to the first sprocket portion.
[0136] E5. The assembly of paragraph E4, wherein the first sprocket
portion and the second sprocket portion are joined by at least one
weld.
[0137] E6. The assembly of any of paragraph E4, wherein the first
sprocket portion and the second sprocket portion are joined by at
least one removable fastener.
[0138] F0. A bicycle component assembly comprising:
[0139] a wheel hub having a spoke connection flange; and
[0140] a cassette coupled to the wheel hub, the cassette including
a plurality of stepped sprocket portions defining a small end, a
large end opposite the small end, and a cavity having an open mouth
at the large end;
[0141] wherein the spoke connection flange is located at least
partially within the cavity.
[0142] F1. The assembly of F0, the plurality of stepped sprocket
portions including a first annular sprocket portion and a second
annular sprocket portion, the first annular sprocket portion having
a plurality of protruding connector members, each connector member
being welded to the second annular sprocket portion.
[0143] F1. The assembly of F0, wherein the large end of the
cassette includes an annular sprocket portion, such that the cavity
is at least partially formed by an inner diameter of the annular
sprocket portion.
[0144] F2. The assembly of paragraph F1, wherein the annular
sprocket portion is a first annular sprocket portion, the large end
of the cassette further including a second annular sprocket portion
joined to the first annular sprocket portion.
[0145] F3. The assembly of paragraph F2, wherein the second annular
sprocket portion is welded to the first annular sprocket
portion.
[0146] F4. The assembly of any of paragraphs F0 through F3, wherein
the large end of the cassette includes a concave sprocket portion,
such that the cavity is at least partially formed by a concave
shape of the sprocket portion.
[0147] F5. The assembly of paragraph F4, further including a
freehub body coupled to the wheel hub, wherein the concave sprocket
portion includes a central interface forming a spline joint with
the freehub body.
[0148] F6. The assembly of paragraph F4, the plurality of stepped
sprocket portions including a pair of annular sprocket portions,
the pair of annular sprocket portions being welded together and
forming a central opening, wherein the concave sprocket portion is
adjacent to the pair of annular sprocket portions and is disposed
partially within the central opening.
[0149] F7. The assembly of paragraph F6, wherein the concave
sprocket portion is connected to the pair of annular sprocket
portions by at least one removable fastener.
[0150] G0. A bicycle component assembly comprising:
[0151] a wheel hub having a spoke connection flange;
[0152] a plurality of spokes extending between the spoke connection
flange and a wheel rim; and
[0153] a cassette coupled to the wheel hub, the cassette including
a plurality of stepped annular sprocket portions, a largest one of
the sprocket portions defining an end plane of the cassette and
having an inner diameter larger than the spoke connection
flange;
[0154] wherein the plurality of spokes breaks the end plane of the
cassette.
[0155] G1. The assembly of G0, wherein the spoke connection flange
breaks the end plane of the cassette.
[0156] G2. The assembly of paragraph G0, wherein the plurality of
spokes extend from an outboard side of the spoke connection
flange.
[0157] G3. The assembly of any of paragraphs G0 through G2, wherein
a first one of the annular sprocket portions is welded to a second
one of the annular sprocket portions.
CONCLUSION
[0158] The disclosure set forth above may encompass multiple
distinct examples with independent utility. Although each of these
has been disclosed in its preferred form(s), the specific
embodiments thereof as disclosed and illustrated herein are not to
be considered in a limiting sense, because numerous variations are
possible. To the extent that section headings are used within this
disclosure, such headings are for organizational purposes only. The
subject matter of the invention(s) includes all novel and
nonobvious combinations and subcombinations of the various
elements, features, functions, and/or properties disclosed herein.
The following claims particularly point out certain combinations
and subcombinations regarded as novel and nonobvious. Other
combinations and subcombinations of features, functions, elements,
and/or properties may be claimed in applications claiming priority
from this or a related application. Such claims, whether broader,
narrower, equal, or different in scope to the original claims, also
are regarded as included within the subject matter of the present
disclosure.
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