Cable assembly for a motor vehicle

Abstract

A cable assembly for a motor vehicle. The invention relates to a cable assembly (300) for a motor vehicle. Accordingly, the invention discloses comprising a coaxial cable (310) having an inner cable (314) and an outer cable sleeve (312), the inner cable (314) being axially movable within the outer cable sleeve (312). The cable assembly (300) further has a rod (320) resting against one end of the outer cable sleeve (312) such that at least a portion (320b) of the rod (320) having a conical outer surface extends with a reduced diameter towards a second end (320b') of the rod (320). The cable assembly further has a tube (330) having an inlet end (330a) and an outlet end (330b) such that the tube (330) has a conical bore extending with a reduced diameter from the inlet end (330a) to the outlet end (330b).

Description

Technical Field

[0001] This invention relates to a cable assembly for motor vehicles. Background Technology

[0002] Motor vehicles use cables for braking systems, clutch systems, accelerator systems, etc. A typical cable is operatively connected at one end to an actuator and at the other end to a corresponding component. The actuator is primarily a lever, such as a brake actuator lever or a clutch actuator lever, thereby making the component a brake assembly, clutch assembly, or accelerator assembly. Therefore, operation of the actuator affects the corresponding component. Thus, when the actuator is operated, the effect in the corresponding component needs to be immediately visible. For example, when a user operates the brake lever, the user expects the vehicle to begin slowing down and eventually stop as soon as the lever is pressed.

[0003] However, slack in the cable causes many problems, resulting in delays or complete failures in the actuator's ability to function when it is operated. Figure 4 A prior art configuration of cable 200 connected to joystick 250 is shown. The cable includes an outer cable 210 and an inner cable 220 disposed within the outer cable 210. Joystick 230 is circumferentially attached to one end of the outer cable 210. Joystick 230 is generally divided into three sections: a first section 230a, which is circumferentially attached to the outer cable 210; a second section 230b, which is a loop abutting against a tube 240 disposed within a joystick holder 260; and a third section 230c, which enters into the tube 240. Thus, the outer cable 210 is held in place, and the inner cable 220 passes through the tube 240, thereby engaging the ball head 270 formed at one end of the inner cable 220 with the joystick 250. However, the outer cable 210 is generally slack and is curved. Therefore, when the lever 250 is activated, it must travel to overcome the slack in the external cable 210. Only when the external cable 210 is straightened will the lever 250 travel further to the desired distance to pull the internal cable 220 as needed. The extra distance the lever must travel due to the slack in the external cable 220 also provides the driver with an unwanted limp feeling.

[0004] Typically, the lever 250 has a free play, which forces it to travel a predetermined distance before pulling the internal cable 220 to engage the corresponding component. Therefore, as mentioned earlier, the additional distance the lever 250 needs to travel due to the slack in the external cable 220 is added to the distance traveled due to the free play. For example, if the lever 250 has a 20mm free play and the additional distance required due to slack is 3mm, then assuming a lever ratio of 5mm, the total distance the lever 250 needs to travel before pulling the internal cable 220 will be 35mm. Therefore, for a lever that can travel a maximum distance of 70mm before contacting the vehicle's handlebars, the lever has only 35mm of effective travel remaining. It should be noted that the free play increases over time due to wear and breakage of components. For example, in the case of a braking system, the free play increases with wear and breakage of the brake pads and drums. This increase in free clearance, together with the slack in the external cable 220, further affects the effective travel distance of the joystick 250.

[0005] Especially in the case of braking systems, when the brake lever has only a reduced travel distance due to free play and slack, the rider is very likely to hit the handlebars during emergency braking. This phenomenon is commonly known as bottoming out, which is unnecessary and dangerous because it can cause the vehicle to tip over and lead to an accident.

[0006] Therefore, there is a need in the art for a cable assembly that at least solves the problem of slack in external cables. Summary of the Invention

[0007] In one aspect, the present invention relates to a cable assembly for a motor vehicle. The cable assembly has a cable, a rod abutting one end of the cable, and a tube. At least a portion of the rod has a tapered outer surface extending toward a second end of the rod with a decreasing diameter. The tube has an inlet end, an outlet end, and a tapered orifice extending from the inlet end to the outlet end with a decreasing diameter.

[0008] In one embodiment of the present invention, the cable is a coaxial cable having an inner cable and an outer cable sheath, wherein the inner cable is axially movable within the outer cable sheath.

[0009] In another embodiment of the invention, the rod abuts against one end of the outer cable sheath. Furthermore, the tapered opening of the tube is configured to receive the tapered portion of the rod through the inlet end and allow the inner cable to pass through the outlet end, thereby causing the tapered portion of the rod to frictionally engage with the tube.

[0010] In another embodiment, the tapered hole is tapered at an angle ranging from about 1° to 45° relative to the axial axis of the tube.

[0011] In yet another embodiment of the invention, the pipe is located within a component assembly of the motor vehicle. The component assembly includes a brake assembly or a clutch assembly.

[0012] In another aspect, the present invention relates to a joystick retainer for a motor vehicle. The joystick retainer is mounted on the handlebars of the motor vehicle and is coupled to a joystick movable relative to the handlebars. The joystick retainer includes a tube having an inlet end, an outlet end, and a tapered orifice extending from the inlet end to the outlet end in a decreasing diameter.

[0013] In one embodiment of the invention, the tapered hole is configured to receive a rod abutting against one end of a cable, wherein at least a portion of the rod has a tapered outer surface extending toward a second end of the rod with a reduced diameter, and the tapered portion of the rod frictionally engages with the tube. Attached Figure Description

[0014] Reference will be made to embodiments of the invention, examples of which are illustrated in the accompanying drawings. These drawings are intended to be illustrative and not restrictive. Although the invention is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these specific embodiments.

[0015] Figure 1 A left-side view of an exemplary vehicle according to one embodiment of this subject is shown.

[0016] Figure 2 A general plan view of a synchronous braking system with cable assemblies according to an embodiment of the present invention is shown.

[0017] Figure 3 A schematic diagram of a front wheel according to one embodiment of this subject is shown.

[0018] Figure 4 The configuration of a cable assembly according to the prior art is shown.

[0019] Figure 5a A cable assembly and an actuation lever are shown according to an embodiment of the present invention.

[0020] Figure 5b This is a schematic diagram of a cable with a pole according to an embodiment of the present invention.

[0021] Figure 6 A tube located in a joystick retainer according to an embodiment of the present invention is shown.

[0022] Figure 7 A tube located in a joystick retainer according to an embodiment of the present invention is shown.

[0023] Figure 8 A perspective view of a cable assembly and an actuation lever according to an embodiment of the present invention is shown.

[0024] Figure 9 A front brake panel assembly according to another embodiment of the invention is shown. Detailed Implementation

[0025] This invention relates to a cable assembly for motor vehicles.

[0026] Figure 1 A left-side view of an exemplary vehicle 10 according to one embodiment of this subject matter is illustrated. The vehicle 10 includes a frame assembly 105. The frame assembly 105 includes a head tube 105A and a main frame assembly 105B. One or more front suspensions 110 connect front wheels 115 to a handlebar assembly 190, which forms a steering assembly for the vehicle 10. The steering assembly is rotatably arranged about the head tube 105A. The main frame assembly 105B extends rearwardly and downward from the head tube 105A and includes a curved portion that subsequently extends generally in a longitudinal direction. Furthermore, the frame assembly 105 includes one or more rear tubes 105C that extend rearwardly at an angle from the rear portion of the main frame assembly 105 toward the rear portion of the vehicle 10.

[0027] Vehicle 10 includes a power unit comprising at least one of an internal combustion (IC) engine 125 and a traction motor 135. For example, the traction motor 135 may include a brushless direct current (BLDC) motor. The power unit is coupled to the rear wheel 145. In one embodiment, the IC engine 125 is pivotally connected to the frame assembly 105. In this embodiment, the IC engine 125 is mounted to a swing arm 141, and the swing arm 141 is pivotally connected to the frame assembly 105. In one embodiment, the traction motor 135 is arranged near the IC engine 125. In this embodiment, the hub of the traction motor 135 is mounted to the rear wheel 145. Furthermore, vehicle 10 includes a transmission 131 that connects the rear wheel 145 to the power unit. The transmission 131 includes a continuously variable transmission (CVT), an automatic transmission, or a fixed-ratio transmission. A seat assembly 151 is arranged above the power unit and is supported by a rear tube 105C of the frame assembly 105. The seat assembly 151 is hingedly openable. The frame assembly 105 defines a step-through portion ST in front of the seat assembly 151. A floor 155 is arranged at the step-through portion ST, allowing the cyclist to operate the vehicle 10 from a seated position by placing their feet on the floor 155. Furthermore, the floor 155 is capable of bearing loads.

[0028] The vehicle 10 includes an onboard battery (not shown) that drives the traction motor 135. In addition, the frame assembly 105 is covered by a plurality of main panels, including a front panel 160A, leg guards 160B, seat covers 160C, and left and right side panels 160D, which are mounted on the frame assembly 105 and cover the frame assembly 105 and the components mounted therein.

[0029] Furthermore, the front fender 165 covers at least a portion of the front wheel 115. In this embodiment, the front fender 165 is integrated with the front panel 160A. A common box is arranged below the seat assembly 151 and is supported by the frame assembly 105. A fuel tank (not shown) is arranged near the common box. The rear fender 175 covers at least a portion of the rear wheel 145 and is positioned below the fuel tank and above the rear wheel 145. One or more suspensions 195 are provided at the rear of the vehicle 10 to connect the control arm 141 and the rear wheel 145 to the frame assembly 105 to dampen forces from the wheel 145 and the power unit to prevent them from reaching the frame assembly 105.

[0030] In addition, vehicle 10 comprises multiple electrical and electronic components, including headlights 185A, taillights 185B, a transistor controlled ignition (TCI) unit (not shown), an alternator (not shown), and a starter motor (not shown). Furthermore, vehicle 10 includes an anti-lock braking system (ABS), a synchronized braking system (SBS), or a vehicle control system (VCS).

[0031] Figure 2 A general plan view of a synchronous braking system 100 with cable assemblies according to an embodiment of the present invention is shown. As shown, brake cable 110 is connected at one end to brake lever 140 and at the other end to rear brake assembly 170. Brake cable 110, connected at one end to brake lever 140, and brake cable 130, connected at one end to brake lever 150, are connected at the other end to front brake assembly 180. Brake levers 140 and 150 are mounted on handle 190. Therefore, activation of brake lever 140 will cause the rear brake assembly 170 and the front brake assembly 180 to operate synchronously. Activation of lever 150 will only cause the front brake assembly 180 to operate.

[0032] Figure 3A schematic diagram of a front wheel according to one embodiment of this subject matter is shown. The front wheel 115 includes a rim 117 that supports a tire. In the illustrated embodiment, the front wheel 115 is an alloy wheel having an arm portion and a hub portion integrated with the rim 117. In the illustrated embodiment, the front wheel brake 180 is a drum brake mounted to the hub portion of the front wheel 115. For example, in one embodiment, the cable assembly includes a synchronized front brake cable 110, and a separate front brake cable 130 can be connected to the front wheel brake 180.

[0033] The front wheel brake 180 includes a cam lever 119, and each of the synchronized front brake cable 110 and the independent front brake cable 130 is functionally connected to the cam lever 119. The cam lever 119 is rotatably supported on a plate member 121 of the front wheel brake. The plate member 121 is provided with at least a cable base 123, on which one end of the outer sheath of the two brake cables 110, 130 is supported, and the inner cables of the brake cables slidably pass through the outer sheath and the cable base 123. The front brake lever 150 (e.g.) Figure 2 (As shown) is connected to the cam lever 119 of the front wheel brake 180 via an independent front brake lever 130, and the synchronous brake lever 140 (as shown) Figure 2 (As shown) is connected to the cam lever 119 of the front wheel 115 via the synchronized front brake cable 110.

[0034] Figure 5a and Figure 8 The cable assembly 300 of the present invention is depicted at the end of the actuator. The cable assembly 300 has, as shown in the figure... Figure 3 The coaxial cable 310 is further described in section b. The coaxial cable 310 has an outer cable sheath 312 and an inner cable 314. The outer cable sheath 312 extends from a first end 312a to a second end 312b (not shown). The first end 312a is adjacent to the lever 350, while the second end 312b is adjacent to a component (not shown).

[0035] The internal cable 314 is axially movable within the external cable sleeve 312, thereby extending the internal cable 314 between the lever end 314a and the component end 314b (not shown). Therefore, the lever end 314a of the internal cable 314 extends beyond the first end 312a of the external cable sleeve 312, and the component end 314b of the internal cable 314 extends beyond the second end 312b of the external cable sleeve 312.

[0036] Both the lever end 314a and the component end 314b of the internal cable 314 have bullet heads 316 formed at their respective ends. These bullet heads are used to connect the internal cable 314 to the corresponding unit. Therefore, as... Figure 5a, Figure 5b and Figure 8 As shown, the bullet head 316 formed at the lever end 314a of the internal cable 314 is used to connect the lever end 314a of the internal cable 314 to the lever 350. In this regard, a device for engaging the bullet head 316 is provided in the lever 350.

[0037] In addition, such as Figure 5a , Figure 5b and Figure 8 As shown, the cable assembly 300 has a rod 320 abutting against one end of an outer cable sleeve 312. The rod 320 is a metal tube configured to receive the outer cable sleeve 312 for securing it to an actuator or component. In this respect, at least a portion of the rod 320 has a tapered outer surface extending toward one end of the rod 320 with a reduced diameter.

[0038] like Figure 5b As shown, in one embodiment of the invention, a rod 320 extends from a first end 320a' to a second end 320b' and has a first portion 320a and a second portion 320b. The inner wall of the first portion 320a of the rod 320 has an annular profile and is configured to circumferentially abut against the first end 312a of the outer cable sheath 312. The second portion 320b of the rod 320 has a tapered outer surface. The diameter of this tapered outer surface decreases toward the second end 320b' of the rod 320, such that the rod 320 has a minimum outer diameter at the second end 320b'. Therefore, the second portion 320b of the rod 320 forms a circumferential periphery around an inner cable 314 extending beyond the outer cable sheath 312. In this respect, the inner diameter of the second portion 320b of the rod is larger than the outer diameter of the inner cable 314, such that the inner cable 314 is axially movable within the second portion 320b of the rod 320.

[0039] In one embodiment of the invention, and as described above, the lever 320 is present on the first end 312a of the outer cable sleeve 312 adjacent to the operating lever 250. In another embodiment, the lever 320 is present on the second end 312b of the outer cable sleeve 312 adjacent to the component. In yet another embodiment, the lever is present on both the first end 312a and the second end 312b of the outer cable sleeve 312.

[0040] In addition, such as Figure 5a , Figure 6 and Figure 7As shown, the cable assembly 300 has a tube 330. In one embodiment of the invention, the tube 330 is located in a lever holder 340 connected to a lever 350. Therefore, operation of the lever 350 causes axial movement of the internal cable 314. The tube 330 extends from an inlet end 330a to an outlet end 330b and has a tapered orifice 360 ​​formed therethrough. The tapered orifice 360 ​​extends from the inlet end 330a to the outlet end 330b such that the diameter of the orifice 360 ​​decreases from the inlet end 330a toward the outlet end 330b. In this respect, the tapered orifice 360 ​​is defined by an inner wall 370 of the tube 330, wherein the inner wall 370 is inclined toward the outlet end 330b. In one embodiment of the invention, as Figure 7 As shown, the hole is tapered at an angle α relative to the axial axis 332 of the tube 330. The angle α ranges from 1° to 45°.

[0041] The orifice of tube 330 is configured to receive the tapered second portion 320b of the rod from the inlet end 330a of tube 330 and allow the internal cable 314 to pass through the outlet end 330b of tube 330. Therefore, the tapered second portion 320b of the rod 320 frictionally engages with tube 330. In one embodiment of the invention, the slope of the second portion 320b of the rod 320 corresponds to the slope of the inner wall 370 of tube 330, such that the entire second portion 320b of the rod frictionally engages with the inner wall of tube 330. Therefore, the tapered second portion 320b of the rod 320 abuts tightly against the inner wall 370 of tube 330. Furthermore, the internal cable 314 and the bullet head 316 are pulled outward together, forcing the internal cable through the slit of tube 330 to be located within tube 330, and forcing the bullet head to abut against the outer wall of the outlet end 330b of tube 330. The inner diameter of the outlet end 330b of the tube 330 is larger than the outer diameter of the internal cable 314 but smaller than the outer diameter of the bullet head 316. Therefore, once the internal cable 330 passes through the hole, it will not slip out due to the presence of the bullet head 316. This configuration only results in axial movement of the internal cable 314.

[0042] In one embodiment of the present invention, and as described above, and as... Figure 5a , Figure 6 , Figure 7 and Figure 8As shown, the tube 330 is present in the actuator end, i.e., in the lever retainer 340, and thus engages with the lever 320 of the present invention located in the lever retainer 340. In another embodiment, the tube 330 is present in a component assembly of the vehicle, and thus engages with the lever 320 present at the second end 312b of the outer cable sleeve 312. The component assembly may be a brake assembly or a gear assembly. In yet another embodiment, the tube 330 is present in both the actuator end and the component assembly, and engages with the lever 320 located at the first end 312a of the outer cable sleeve 312 and the lever 320 located at the second end 312b of the outer cable sleeve 312.

[0043] Figure 9 A front brake panel assembly 180 according to another embodiment of the present invention is shown. In this embodiment, the front brake panel 180 includes a front brake panel cable base structure 182 integrated to the outer surface of the brake panel 180. In one embodiment, the front brake panel cable base 182 is provided with one or more tapered holes 182a, 182b to receive a brake cable (not shown). The brake cable is also provided with a corresponding tapered rod portion to fit snugly within the tapered holes 182a, 182b of the cable base structure 182 of the front brake panel 180.

[0044] Advantageously, the cable assembly of the present invention solves the problem of slack in the outer cable sleeve. Due to the rod and tube configuration as described above, the outer cable sleeve is tightly secured to the tube. Therefore, the outer cable sleeve remains intact during operation of the inner cable by the lever. Furthermore, since the orifice of the tube is tapered, the inner cable moves only axially and thus does not slack within the tube. Therefore, any limp feeling caused by slack in the outer and inner cables is eliminated. In addition, since the present invention eliminates slack in the outer cable, the free play alone will result in a reduction in the effective travel distance of the lever. Therefore, the chance of bottoming out is greatly reduced.

[0045] While the invention has been described with respect to certain embodiments, those skilled in the art will recognize that various changes and modifications can be made without departing from the scope of the invention as defined in the following claims.

Claims

1. A cable assembly (300) for a motor vehicle (10), the cable assembly (300) comprising: A cable (310) having an outer cable sheath (312) and an inner cable (314) axially movable within the outer cable sheath (312); and The cable assembly (300) is characterized in that it includes... A rod (320) abutting against one end of the outer cable sheath (312), the rod (320) having a first portion (320a) and a second portion (320b), wherein the first portion (320a) is configured to abut against the outer cable sheath (312), and the second portion (320b) of the rod (320) has a tapered outer surface extending toward a second end (320b') of the rod (320) with a decreasing diameter; and A tube (330) having an inlet end (330a) and an outlet end (330b), the tube (330) having a tapered hole (360) extending from the inlet end (330a) to the outlet end (330b) with a decreasing diameter, wherein the tapered hole (360) is configured to receive the second portion (320b) of the rod (320) from the inlet end (330a) of the tube (330) and allow an internal cable (314) to pass through the outlet end (330b) of the tube (330), and wherein the tapered hole (360) is configured to receive the tapered portion of the rod (320) through the inlet end (330a) and allow the internal cable (314) to pass through the outlet end (330b), thereby causing the tapered portion of the rod (320) to frictionally engage with the tube (330).

2. The cable assembly (300) according to claim 1, wherein, The cable (310) includes: a coaxial cable having the inner cable (314); and an outer cable sheath (312) in which the inner cable (314) is axially movable.

3. The cable assembly (300) according to claim 2, wherein, The rod (320) abuts against one end of the outer cable sheath (312).

4. The cable assembly (300) according to claim 1, wherein, The tapered hole (360) is tapered at an angle ranging from 1° to 45° relative to the axial axis (332) of the tube (330).

5. The cable assembly (300) according to claim 1, wherein, The pipe (330) is located in a component assembly of the motor vehicle (10).

6. The cable assembly (300) according to claim 5, wherein, The component assembly includes a brake assembly (170, 180) or a clutch assembly.

7. A lever retainer (340) for a motor vehicle (10), the lever retainer (340) being mounted on a handle (190) of the motor vehicle (10) and connected to a lever (350) movable relative to the handle (190), the lever retainer (340) comprising the tube (330) of the cable assembly (300) according to any one of claims 1 to 6.

8. The joystick retainer (340) according to claim 7, wherein, The tapered hole (360) is configured to receive a rod (320) abutting against one end of an outer cable sheath (312), wherein at least a portion (320b) of the rod (320) has a tapered outer surface extending toward a second end (320b') of the rod (320) with a reduced diameter, and the tapered second portion (320b) of the rod (320) is frictionally engaged with the tube (330).

9. The joystick retainer (340) according to claim 8, wherein, The cable (310) includes: a coaxial cable having an inner cable (314); and an outer cable sheath (312) in which the inner cable (314) is axially movable within the outer cable sheath (312) and passes through the outlet end (330b) of the tube (330).

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