Hub system, method and apparatus with adjustable dead zone

Abstract

A flywheel hub having a non-zero dead-zone distance in order to reduce or eliminate pedal recoil. The dead zone distance can have or be adjusted to a desired length that includes a length that enables a silent idle operation in which the pawls of the flywheel body do not engage or contact the teeth of the ratchet, thereby eliminating any contact-based idle sound.

Description

[0001] Related applications

[0002] This patent application claims priority under 35 U.S.C. § 119(e) to co-pending U.S. Provisional Patent Application No. 63 / 425,251, filed on November 14, 2022, entitled “SILENT BICYCLE FREEWHEEL HUB WITH ADJUSTABLE ENGAGEMENT DEADBAND,” which is incorporated herein by reference. Technical Field

[0003] The present invention generally relates to flywheel hubs. More particularly, the present invention relates to a flywheel hub having a deadband that can be adjusted as desired. Background Art

[0004] Most bicycles today utilize a freewheel hub in the rear wheel to allow the rear wheel to "freewheel," or roll forward, without requiring the rest of the bicycle's drivetrain to continuously move. A typical freewheel hub uses one or more spring-loaded pawls mounted on the freehub body (i.e., freehub body) that move within a toothed ratchet attached to the hub shell. As the bicycle rolls forward, the pawls "ratchet" over the teeth of the toothed ratchet, disengaging the bicycle cassette, chain, sprocket, and crank from the rear wheel.

[0005] When the rider resumes pedaling forward, a certain amount of relative movement occurs between the freehub body and the hub shell before the spring-loaded pawl engages the toothed ratchet. This relative movement and / or the distance it takes is the deadband of the ratchet mechanism. Specifically, the deadband can be the mechanical distance the freehub body can move and / or rotate relative to the toothed ratchet before hub engagement occurs. In conventional freewheel hubs, this deadband distance depends on the number of teeth in the toothed ratchet. Typical toothed ratchets have 12 to 70 teeth, sometimes more. In such conventional hub designs, the deadband distance can typically be zero or near zero, depending on the number of ratchet teeth. Depending on the time and speed at which the rider begins pedaling (and thus begins rotating the freehub in the engagement direction), as well as the rider's coasting speed at that time, there will be a time delay before torque is transferred from the bicycle freewheel to the bicycle wheel (due to the engagement of the freewheel's pawl with the hub shell's ratchet). However, the effects of the freehub design on this time delay can most easily be accounted for mechanically, with the mechanical deadband being a direct input into this time delay.

[0006] A disadvantage of freewheel hubs with zero or near-zero dead zone is observed in the form of pedal kickback, particularly when a freewheel hub is used with a full-suspension bicycle. Full-suspension bicycles mount the rear wheel on a swingarm or linkage that allows the rear wheel to move up and down as the bicycle navigates bumps on or off-road. A typical full-suspension linkage involves a certain amount of chainstay length growth as the shock moves through its travel, where the chainstay length is the distance between the rear hub axle and the bicycle crankset spindle. As the shock compresses, this distance grows, and since the bicycle chain travels this distance from the crank chainrings to the bicycle freewheel, the chain will have tension applied to it as the chainstay length grows.

[0007] In some cases, when a particularly large and sudden compression is caused in the suspension, for example, if the rider is riding at high speed over a large bump or landing from a jump, and the suspension must absorb a large amount of energy quickly, the rider may slide with their weight on the bicycle pedals. In these cases, the chain tension due to the increased length of the chain stay will cause the flywheel to rotate forward rapidly with a large force and may cause the flywheel ratchet mechanism to engage. If the rear wheel contacts the ground, the chain force will counteract the suspension motion and will reduce the efficiency of the suspension system in absorbing the impact force. The chain force will also apply a counter torque to the bicycle pedal cranks, which can be felt by the rider as "pedal kickback," where pedal kickback refers to the sensation of pedal motion felt by the rider and the reduction in suspension efficiency due to the instantaneous chain load in the system.

[0008] In this case, the likelihood of pedal kickback increases with the number of ratchet teeth in the freewheel hub ratchet, as it reduces the system's deadband distance. Therefore, conventional freewheel hubs have the disadvantage that riders may experience pedal kickback, which is only exacerbated when used on a full-suspension bicycle. In fact, some hubs use a sprag clutch engagement mechanism instead of a ratchet pawl, effectively reducing the deadband distance to zero. Therefore, these hubs are more likely to experience pedal kickback under fast suspension travel. Bikes with increased suspension travel and longer chainstay lengths are also more likely to experience pedal kickback. Furthermore, the number of teeth on the toothed crank sprocket and the toothed pulley sprocket used in fast suspension travel will obviously have an impact on pedal kickback, as the chain's resting position is controlled by the relative sizes of these sprockets. Summary of the Invention

[0009] A freewheel hub having a non-zero deadband distance to reduce or eliminate pedal kickback. This allows the freewheel hub body to always move through a predetermined free motion before the hub engages, regardless of the relative position of the freewheel hub body and the hub shell, and regardless of the number of teeth in the freewheel hub ratchet mechanism. The deadband distance can be configured and / or adjusted to a desired length, including a length that enables silent freewheel operation, in which the pawls of the freewheel body do not engage or contact the teeth of the ratchet, thereby eliminating any contact-based freewheeling sound. For example, a rider can adjust the hub deadband by adding and including an adjustable deadband key to the freewheel body. This deadband key changes the deadband length and can allow the rider to reduce or eliminate pedal kickback and improve the suspension function on certain bicycles according to their preference and comfort in certain riding situations. Furthermore, if the deadband length is adjusted to a sufficiently long length, in addition to improving suspension function, the rider can also eliminate the rattling noise inherent in using spring-loaded pawls in the ratchet mechanism. Instead, when the rider pushes forward on the pedals and engages the hub, the freehub pawls simply press against the ratchet teeth. This allows the bike to coast quietly, a feeling many riders find enjoyable.

[0010] A first aspect relates to a bicycle hub system. The system comprises: a bicycle wheel including a hub shell assembly having a central aperture for receiving an axle, a ratchet hole, and a toothed ratchet positioned within the ratchet hole; and a freehub assembly including an outer hub sprocket attachment feature, a pawl support member having a plurality of pawl pivot channels, a plurality of pawls pivotably coupled within the pivot channels, and a biasing member applying a biasing force to the plurality of pawls that prevents the plurality of pawls from pivoting away from a dead zone surface of the pawl support member; wherein the pawl support member is positioned within the toothed ratchet such that when the freehub assembly is rotated relative to the hub shell assembly in a first direction, the plurality of pawls can pivot away from the pawl support member until the plurality of pawls engage teeth of the toothed ratchet, thereby causing the hub shell assembly to rotate with the freehub assembly in the first direction.

[0011] In some embodiments, the biasing member is a spring that prevents the plurality of pawls from pivoting away from the pawl support member. In some embodiments, each of the plurality of pawls includes a recess for receiving the biasing member. In some embodiments, when fully rotated toward the dead zone surface, the plurality of pawls cannot contact the teeth of the toothed ratchet. In some embodiments, the system further includes a pawl pusher having a plurality of push protrusions positioned along the dead zone surface of the pawl support member. In some embodiments, when the free hub assembly rotates relative to the hub shell assembly in a first direction, the push protrusions slide along the dead zone surface of the pawl support member and push against the tops of the plurality of pawls, thereby forcing the plurality of pawls to pivot away from the dead zone surface of the pawl support member. In some embodiments, the hub shell assembly further includes a one-way clutch operatively coupled to the pawl pusher such that the clutch prevents the push protrusions from rotating relative to the hub shell assembly in the first direction, thereby causing the push protrusions to slide along the dead zone surface when the free hub assembly rotates relative to the hub shell assembly in the first direction. In some embodiments, the deadband surface extends between each of the pivot channels and a corresponding one of the plurality of stop walls of the pawl-support member, thereby forming a plurality of deadband cavities adjacent to the deadband surface.

[0012] In some embodiments, when the plurality of pawls are fully rotated against the deadband surface, a different pairing of one of the plurality of pawls and one of the plurality of push fingers is at least partially positioned within each of the deadband cavities. In some embodiments, when the freehub assembly is rotated relative to the hub shell assembly in a second direction opposite to the first direction, each of the push fingers slides along the deadband surface until the push finger abuts one of the stop walls. In some embodiments, the freehub assembly further comprises a deadband adjustment key configured to selectively couple to a keyway of the pawl support member, the keyway being positioned adjacent to one of the deadband recesses. In some embodiments, when coupled within the keyway, a block of the deadband adjustment key extends into one of the deadband recesses adjacent to the stop wall, such that when the freehub assembly is rotated relative to the hub shell assembly in the second direction, each of the push fingers slides along the deadband surface until one of the push fingers abuts the block of the deadband adjustment key. In some embodiments, the outer hub sprocket attachment feature is an outer step pulley spline for coupling with one or more sprockets.

[0013] A second aspect relates to a bicycle hub assembly. The bicycle hub assembly includes a toothed ratchet having a plurality of teeth, and a freehub assembly, the freehub assembly including a pawl support member having a plurality of pawl pivot channels, a plurality of pawls pivotably coupled within the pivot channels, and a biasing member applying a biasing force to the plurality of pawls, the biasing force preventing the plurality of pawls from pivoting away from a dead zone surface of the pawl support member. The pawl support member is positioned within the toothed ratchet such that when the freehub assembly is rotated relative to the toothed ratchet in a first direction, the plurality of pawls can pivot away from the pawl support member until the plurality of pawls engage teeth of the toothed ratchet, thereby causing the toothed ratchet to rotate with the freehub assembly in the first direction.

[0014] In some embodiments, the biasing member is a spring that prevents the plurality of pawls from pivoting away from the pawl support member. In some embodiments, each of the plurality of pawls includes a recess for receiving the biasing member. In some embodiments, the plurality of pawls cannot contact the teeth of the toothed ratchet when fully rotated toward the dead zone surface. In some embodiments, the assembly further includes a pawl pusher having a plurality of push fingers positioned along the dead zone surface of the pawl support member. In some embodiments, when the free hub assembly is rotated in a first direction relative to the toothed ratchet, the push fingers slide along the dead zone surface of the pawl support member and push against the tops of the plurality of pawls, thereby forcing the plurality of pawls to pivot away from the dead zone surface of the pawl support member. In some embodiments, the hub shell assembly further includes a one-way clutch operatively coupled to the pawl pusher such that the clutch prevents the push fingers from rotating relative to the toothed ratchet in the first direction and thereby causes the push fingers to slide along the dead zone surface when the free hub assembly is rotated in the first direction relative to the toothed ratchet.

[0015] In some embodiments, the deadband surface extends between each of the pivot channels and a corresponding one of the plurality of stop walls of the pawl support member, thereby forming a plurality of deadband cavities adjacent to the deadband surface. In some embodiments, when the plurality of pawls are fully rotated against the deadband surface, a different pairing of one of the plurality of pawls and one of the plurality of push fingers is at least partially positioned within each of the deadband cavities. In some embodiments, when the freehub assembly is rotated in a second direction opposite to the first direction relative to the toothed ratchet, each of the push fingers slides along the deadband surface until the push finger abuts one of the stop walls. In some embodiments, the freehub assembly further comprises a deadband adjustment key configured to selectively couple to a keyway of the pawl support member, the keyway being positioned adjacent to one of the deadband recesses. In some embodiments, when coupled within the keyway, the block of the deadband adjustment key extends into one of the deadband recesses adjacent the stop wall such that when the freehub assembly is rotated in the second direction relative to the toothed ratchet, each of the push fingers slides along the deadband surface until one of the push fingers abuts the block of the deadband adjustment key. In some embodiments, the freehub assembly includes an outer hub sprocket attachment feature for coupling with one or more sprockets.

[0016] A third aspect relates to a method for providing a bicycle hub system. The method includes providing a hub shell assembly including a toothed ratchet positioned within a ratchet aperture, the hub shell assembly being adapted to couple to a bicycle rim via a plurality of spokes; providing a freehub assembly including an outer hub sprocket attachment feature, a pawl support member having a plurality of pawl pivot channels, a plurality of pawls pivotably coupled within the pivot channels, and a biasing member applying a biasing force to the plurality of pawls, the biasing force resisting pivoting away from a dead zone surface of the pawl support member; and coupling the freehub assembly to the hub shell assembly such that the pawl support member is positioned within the toothed ratchet and, when the freehub assembly is rotated relative to the hub shell assembly in a first direction, the plurality of pawls are capable of pivoting away from the pawl support member until the plurality of pawls engage teeth of the toothed ratchet, thereby causing the hub shell assembly and the freehub assembly to rotate in the first direction.

[0017] In some embodiments, the biasing member is a spring that prevents the plurality of pawls from pivoting away from the pawl support member. In some embodiments, each of the plurality of pawls includes a recess for receiving the biasing member. In some embodiments, when fully rotated toward the dead zone surface, the plurality of pawls cannot contact the teeth of the toothed ratchet. In some embodiments, the free hub assembly further includes a pawl pusher having a plurality of push fingers positioned along the dead zone surface of the pawl support member. In some embodiments, when the free hub assembly rotates relative to the hub shell assembly in a first direction, the push fingers slide along the dead zone surface of the pawl support member and push against tops of the plurality of pawls, thereby forcing the plurality of pawls to pivot away from the dead zone surface of the pawl support member. In some embodiments, the hub shell assembly further includes a one-way clutch operatively coupled to the pawl pusher such that the clutch prevents the push fingers from rotating relative to the hub shell assembly in the first direction, thereby causing the push fingers to slide along the dead zone surface when the free hub assembly rotates relative to the hub shell assembly in the first direction.

[0018] In some embodiments, the deadband surface extends between each of the pivot channels and a corresponding one of the plurality of stop walls of the pawl support member, thereby forming a plurality of deadband cavities adjacent to the deadband surface. In some embodiments, when the plurality of pawls are fully rotated against the deadband surface, a different pairing of one of the plurality of pawls and one of the plurality of push fingers is at least partially positioned within each of the deadband cavities. In some embodiments, when the freehub assembly is rotated in a second direction opposite to the first direction relative to the hub shell assembly, each of the push fingers slides along the deadband surface until the push finger abuts one of the stop walls. In some embodiments, the freehub assembly further comprises a deadband adjustment key configured to selectively couple to a keyway of the pawl support member, the keyway being positioned adjacent to one of the deadband recesses. In some embodiments, the method further comprises sliding the deadband adjustment key into the keyway so that a block of the deadband adjustment key extends into one of the deadband recesses adjacent the stop wall, and when the free hub assembly rotates relative to the hub shell assembly in a second direction, sliding each of the push fingers along the deadband surface until one of the push fingers abuts the block of the deadband adjustment key. In some embodiments, the outer hub sprocket attachment feature is an outer step pulley spline for coupling with one or more sprockets. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Several exemplary embodiments are described with reference to the accompanying drawings, wherein like components have like reference numerals. The exemplary embodiments are intended to illustrate, not to limit, the present invention. The drawings include the following:

[0020] Figure 1 A side view of a bicycle assembly is shown in accordance with some embodiments.

[0021] Figure 2 A detailed view of a rear triangle of a bicycle assembly is shown, according to some embodiments.

[0022] Figure 3 A perspective view of a hub assembly is shown, according to some embodiments.

[0023] Figure 4 An exploded view of a wheel hub assembly is shown, according to some embodiments.

[0024] Figure 5 An exploded view of a hub shell assembly is shown, according to some embodiments.

[0025] Figure 6 The hub shell assembly according to some embodiments is shown along Figure 5 A cross-sectional view taken along line A is shown.

[0026] Figure 7 A perspective view of a free hub body assembly is shown, according to some embodiments.

[0027] Figure 8 Shown is a partially exploded view of a freehub body assembly according to some embodiments.

[0028] Figure 9 A perspective view of a free hub bearing assembly is shown, according to some embodiments.

[0029] Figure 10 A side view of a free hub bearing assembly is shown, according to some embodiments.

[0030] Figure 11 A perspective view of a pawl pusher is shown, according to some embodiments.

[0031] Figure 12 Shown is a right end view of a pawl pusher according to some embodiments.

[0032] Figure 13 A perspective view of a ratchet pawl is shown, according to some embodiments.

[0033] Figure 14 An end view of a ratchet pawl is shown, according to some embodiments.

[0034] Figure 15 A perspective view of a ratchet ring gear is shown, according to some embodiments.

[0035] Figure 16 A side detail view of a ratchet ring gear is shown, according to some embodiments.

[0036] Figure 17 A perspective view of a biasing element is shown, according to some embodiments.

[0037] Figure 18 A perspective view of a deadband adjustment key is shown, according to some embodiments.

[0038] Figure 19 A cross-sectional side view of a free hub bearing assembly including a coupled deadband adjustment key within a ratchet gear ring with the pawl retracted is shown, according to some embodiments.

[0039] Figure 20 A cross-sectional side view of a free hub bearing assembly without a deadband adjustment key within the ratchet gear ring is shown with the pawl retracted, according to some embodiments.

[0040] Figure 21 A cross-sectional side view of a free hub bearing assembly without a deadband adjustment key within the ratchet gear ring is shown with the pawl extended, according to some embodiments.

[0041] Figure 22 A cross-sectional side view of a free hub bearing assembly including a coupled deadband adjustment key within a ratchet gear ring with a pawl extended is shown, according to some embodiments.

[0042] Figure 23 A method of providing a hub assembly according to some embodiments is shown. DETAILED DESCRIPTION

[0043] Embodiments of the present application relate to bicycle and / or freewheel hubs having a non-zero deadband distance to reduce or eliminate pedal kickback. This allows the freewheel hub body to always move through a predetermined free motion before the hub engages, regardless of the relative positions of the freewheel hub body and the hub shell, and regardless of the number of teeth in the freewheel hub ratchet mechanism. The deadband distance can have and / or be adjusted to a desired length, including a length that enables silent freewheel operation, in which the pawls of the freewheel body do not engage or contact the teeth of the ratchet, thereby eliminating any contact-based freewheeling sounds.

[0044] Reference will now be made in detail to embodiments of bicycle and / or flywheel hubs, as illustrated in the accompanying drawings. The same reference numerals will be used throughout the drawings and the detailed description that follows to represent the same or similar parts. For the sake of clarity, not all conventional features of the embodiments described herein are shown and described. It should be understood that in the development of any such actual embodiment, many implementation-specific decisions may be made in order to achieve the developer's specific goals, such as compliance with application- and business-related constraints, and that these specific goals will vary from implementation to implementation and from developer to developer. Furthermore, it should be understood that such development efforts may be complex and time-consuming, but remain a routine engineering undertaking for those of ordinary skill in the art having the benefit of this disclosure.

[0045] Figure 1 A bicycle assembly 200 is shown according to some embodiments. Figure 1 As shown, bicycle assembly 200 includes a bicycle rear wheel 202 (including a hub assembly 1), a bicycle front triangle 204, and a bicycle rear triangle 206 coupled to the front triangle 204. The bicycle front triangle 204 and the bicycle rear triangle 206 are coupled together via a bicycle shock absorber link 216, which compresses a bicycle rear shock absorber 210 coupled between the front triangle 204 and the shock absorber link 216. Assembly 200 also includes a bicycle crank 208, which is operably coupled to a bicycle chain ring 209, which is engaged with a bicycle chain 212. A bicycle stepper pulley 214 is mounted to the bicycle rear wheel 202, which is engaged with the bicycle chain 212. A bicycle rear derailleur 215 is engaged with the chain 212 and mounted to the rear triangle 206 near the rear wheel 202. Alternatively, one or more of the aforementioned components may be omitted. Furthermore, although only the aforementioned components have been described in detail, it should be understood that the bicycle assembly 200 can include one or more other components that are well known in the art and are not described herein for the sake of brevity.

[0046] Figure 2 Detailed views of a bicycle rear triangle 206 and a bicycle rear wheel 202 are shown according to some embodiments. Figure 2 As shown, the superimposed geometry shows the rest axle position AR, the compressed axle position AC, the wheel path WP, the bicycle chain stay length L1, and the bicycle chain stay length L2. In particular, the geometry is superimposed to illustrate the changes in bicycle frame geometry under shock absorber compression. When not under significant compression, the axle is at position AR and the chain stay length is equal to L1. When in compression, the axle moves along path WP to position AC, thereby increasing the chain stay length to L2. As mentioned above, if the deadband is zero or minimal, this increase in chain stay length can cause the flywheel body to suddenly rotate relative to the flywheel housing and thereby cause pedal kickback.

[0047] Figure 3 1 shows a perspective view of a wheel hub assembly 1 according to some embodiments. Figure 3 As shown, the hub assembly 1 includes a first end 2 , a second end 4 , and a hub center axis 6 . Figure 4 1 shows a perspective exploded view of a wheel hub assembly 1 according to some embodiments. Figure 4As shown, the hub assembly includes a hub shell assembly 30, a free hub body assembly 100, a hub axle 14, and a hub axle cap 10. Both the hub shell assembly 30 and the free hub body assembly 100 can be slid onto the hub axle 14 so that they are seated on the hub axle support surface 20. The hub axle cap 10 can be threaded onto the axle 14, wherein the hub axle cap threads 12 are threaded onto the hub axle threads 16, so that the right end 18 of the hub axle is opposite the end cap 10, and the assemblies 30, 100 are located therebetween.

[0048] Figure 5 1 shows an exploded perspective view of a hub shell assembly 30 according to some embodiments. Figure 5 As shown, the hub shell assembly 30 includes a hub shell 32, a hub shell disc flange 34, a hub shell bearing 36, a hub shell ratchet hole 38, one or more hub shell ratchet spline grooves 40, a one-way clutch 42 having an outer race 44 and an inner bore 46, and a toothed ratchet 180. In some embodiments, the one-way clutch is a sprag clutch. Alternatively, the one-way clutch 42 can be other types of overrunning or one-way clutches, including but not limited to roller clutches, pawl clutches, wrap spring type clutches, face gear clutches, and / or other similar clutches. Some of these clutches will not allow for quiet hub operation, but they will allow for the same adjustable deadband operation of the hub 1.

[0049] Figure 6 1 shows a cross-sectional view of the hub shell assembly 30 taken at the section line according to some embodiments. Figure 6 As shown, the hub shell 32 includes a hub shell body 54, a hub shell disc flange 34 (e.g., for coupling with a brake rotor), a left hub shell spoke flange 50, and a right hub shell spoke flange 52 (e.g., both for coupling with one or more spokes (not shown)). Figure 6 As shown, the hub shell bearing 36 can be positioned within the bearing cavity within the flange 34 (e.g., for receiving the shaft 14), the one-way clutch 42 can be engaged within the hub shell clutch aperture 56 (e.g., for receiving the handle 142 of the pusher 140), and the ratchet 180 can be positioned within the hub shell ratchet aperture 38. In particular, when positioned within the hub shell ratchet aperture 38, the plurality of ratchet ring spline teeth 184 (see FIG. 1 ) of the ratchet ring 180 are engaged. Figure 15) each of which extends into a different one of the hub shell ratchet spline grooves 40. Thus, when the ratchet ring 180 rotates, the ratchet ring spline teeth 184 apply a force to the ratchet spline grooves 40, thereby causing the hub shell 32 to similarly rotate. Additionally, the outer surface of the shank 142 of the pusher 140 can contact the inner bore 46 of the one-way clutch 42, causing the inner bore 46 to rotate with the pusher 140 in a first rotational direction, but resisting and / or stopping rotation of the pusher 140 in the opposite direction (e.g., by friction between the outer surface of the shank 142 and the inner bore 46).

[0050] Figure 7 and Figure 8 A perspective view and a partially exploded perspective view of a free hub body assembly 100 according to some embodiments are shown, respectively. Figure 7 and 8 As shown, the free hub body assembly 100 includes a bearing assembly (or pawl support member) 102, a pawl pusher 140, a deadband adjustment key 108, one or more ratchet pawls 106a-106c, and a pawl biasing element 104. In some embodiments, the biasing element 104 is a wire spring. Alternatively, the biasing element 104 can be other types of biasing elements, including but not limited to one or more leaf springs, one or more coil springs, one or more rubber bands, one or more magnets (e.g., placed in the free hub body below the steel pawl 106), and / or any other type of spring-loaded mechanism.

[0051] Figure 9 and 10 1 and 2 show a perspective view and a side view, respectively, of a bearing assembly 102 according to some embodiments. Figure 9 and 10 As shown, the bearing assembly 102 includes a free hub end bearing 122 (e.g., for receiving the shaft 14), a free hub outer bearing 126 having an outer bearing outer race 128, a free hub inner bearing 124 having an inner bearing inner race 125 (e.g., for receiving the shaft 14), a stepper pulley spline 120, stepper pulley mounting threads 116, a stepper pulley mounting boss 118, a biasing element groove 134, one or more pawl cylindrical grooves 130a-130c, one or more dead zone surfaces 132a-132c, one or more pusher stop surfaces 136a-136c, and a dead zone adjustment keyway 138. The stepper pulley spline 120 and / or the stepper pulley mounting boss 118 are capable of receiving a splined stepper pulley (not shown) for coupling with a drive assembly of the bicycle 200 (e.g., bicycle crank 208, bicycle chain ring 209, bicycle chain 212, derailleur 215, and / or other components). A step pulley locking bolt (not shown) can be threadedly coupled to the step pulley mounting threads 116 to secure the step pulley to the splines 120. Figure 9 and10 As shown, the bearing assembly 102 includes three pawl cylindrical grooves 130a-130c, dead zone surfaces 132a-132c and pusher stop surfaces 136a-136c and a single dead zone reduction groove 138, and more or fewer pawl cylindrical grooves 130a-130c, dead zone surfaces 132a-132c, pusher stop surfaces 136a-136c and dead zone reduction grooves 138 can be envisioned.

[0052] Similarly, although Figure 7 and 8 As shown, the freehub body assembly 100 includes a pawl pusher 140 having three fingers 144, a single deadband adjustment key 108, three ratchet pawls 106a-106c, and a single pawl biasing element 104, but pawl pushers 140 having more or fewer fingers 144, more or fewer deadband adjustment keys 108, more or fewer ratchet pawls 106a-106c, and / or more or fewer pawl biasing elements 104 are contemplated. In particular, the number of deadband adjustment keys 108 can correspond to the number of deadband adjustment key slots 138, and the number of fingers 144, cylindrical slots 130a-130c, deadband surfaces 132a-132c, and stop surfaces 136a-136c can correspond to the number of pawls 106a-106c. The space defined between each pawl cylindrical groove 130a-130c, the corresponding stop surface 136a-136c and the corresponding dead zone surface 132a-132c is capable of forming a plurality of dead zone cavities that are filled by the protrusion 144 of the pusher 140, the pawl 106a-106c (at least in the fully retracted position) and the dead zone adjustment key 108 (when coupled within the dead zone adjustment key slot 138).

[0053] Figure 11 and 12 1 and 2 show a perspective view and a front view, respectively, of a pawl pusher 140 according to some embodiments. Figure 11 and 12 As shown, the pawl pusher 140 includes a central cavity 147 (for receiving the shaft 14), a handle or clutch cylinder 142, a finger flange 146 and one or more pawl fingers 144a-144c. Each finger 144 includes a finger detent surface 148, a finger outer diameter portion 154, a finger positioning cylindrical surface 150 and a pusher flywheel stop 152. In operation, the positioning cylindrical surface 150 of the pawl finger 144 is able to slide along the dead space surface 132a-132c within the dead space cavity between the pawl 106a-106c and the stop wall 136a-136c or the inserted key 108. Therefore, the pawl surface 148 is able to slide along the pawl pusher cam surface 166 (see Figure 14) to pivot the pawls 106a-106c from the retracted position to the extended position. When sliding in the opposite direction, the pusher flywheel stop 152 can contact the stop walls 136a-136c and / or the inserted key 108 (thereby defining a deadband distance).

[0054] Figure 13 and 14 A perspective view and an end view, respectively, of ratchet pawls 106a-106c are shown according to some embodiments. Figure 13 and 14 As shown, the ratchet pawls 106a-106c include a pawl cylinder 160, a pawl biasing element recess 162, a pawl spring pad 164, a pawl pusher cam surface 166, a pawl drive surface 168, and a pawl top radius 170. The pawl pusher cam surface 166 is configured to slide on the pusher finger 144 as described above. The pawl drive surface 168 is configured to engage the ratchet tooth receiving surface 186, and / or the pawl top radius 170 is configured to fit within the valley between the teeth 185 of the ratchet wheel 180 (thereby engaging the ratchet wheel 180 and causing the ratchet wheel 180 to rotate with the free hub assembly 100).

[0055] The pawl cylinder 160 of each pawl 106a-106c can be slidably mounted in one of the pawl cylinder slots 130a-130c. When positioned in one of the slots 130a-130c, the pawl 106a-106c can pivot about the central axis of the slot 130 between a retracted position adjacent to the corresponding dead zone surface 132a-132c and an extended position away from the dead zone surface 132a-132c. The biasing element 104 can be mounted in the gap 134 (see FIG. Figure 10 ), at least partially surrounding or blocking the pawls 106a-106c from pivoting away from the dead zone surfaces 132a-132c. In particular, the biasing element 104 can be positioned within the pawl biasing element recess 162 and adjacent to or surrounding the pawl spring pad 164 of each of the pawls 106a-106c to prevent pivoting away from the dead zone surfaces 132a-132c and / or bias the pawls 106a-106c in the retracted position. In effect, by providing a shortened pad 164, the pawls 106a-106c enable the biasing element 104 to have a smaller diameter and / or size and be closer to the dead zone surfaces 132a-132c.

[0056] When in the extended position (see Figure 21 and 22), the pawls 106a-106c pivot away from the dead zone surfaces 132a-132c so that they can engage the teeth 185 of the ratchet 180 (e.g., contact the ratchet tooth receiving surface 186 and / or the bottom of the valley between the teeth 185). In some embodiments, when in the retracted position, the pawls 106a-106c can contact the dead zone surfaces 132a-132c and / or be fully positioned within the corresponding dead zone cavity (e.g., when the corresponding pusher protrusion 144 can slide adjacent to the stop wall 136a-136c or can slide adjacent to the inserted key 108), but still do not hinder or block the pivoting of the corresponding pawl 106a-106c (see Figure 19 and 20 Alternatively, when in the retracted position, the pawls 106a-106c can be at least partially blocked from contacting the deadband surfaces 132a-132c and / or fully positioned within the corresponding deadband cavity (e.g., when fully slid against the inserted key 108, the corresponding pusher finger 144 hinders or blocks the corresponding pawl 106a-106c from pivoting toward the deadband surface 132a-132c). In particular, by inserting and / or selecting the size of the key 108, the user can adjust the retracted position by adjusting the proximity of the finger 144 to the pawl 106a-106c and / or the extent to which the finger 144 blocks the pawl 106a-106c from pivoting inwardly.

[0057] Figure 15 and 16 A perspective view and a detail view, respectively, of a toothed ratchet 180 according to some embodiments are shown. Figure 15 As shown, the toothed ratchet 180 includes an annular body having an outer surface 182, one or more external splines 184 protruding from the outer surface 182 of the body, and a plurality of internal teeth 185 protruding from the inner surface of the body. Each of the internal teeth 185 has a ratchet tooth receiving surface 186 and a ratchet tooth sliding surface 188, wherein a valley is formed where the sliding surface 188 of each tooth meets the receiving surface 186 of the adjacent tooth 185. The ratchet tooth pitch angle P is represented as the angle between two adjacent teeth 185. The sliding surface 188 can be longer than the receiving surface 186 and / or form a smaller angle relative to the adjacent inner surface of the body. Additionally, the shape, profile, and / or size of the pawl drive surface 168 and the pawl top radius 170 of each pawl 106a-106c can complement the shape and / or curvature of the valley of the sliding surface 188.

[0058] Thus, when the pawls 106a-106c extend so that they contact the teeth 185 and move / rotate in one direction from the valleys between the teeth 185 along the adjacent sliding surface 188, the smaller angle allows the pawls 106a-106c to slide over the teeth 185 without engaging the teeth 185. Conversely, when moving / rotating in the opposite direction from the valleys between the teeth 185 along the adjacent receiving surface 186, the larger / steeper angle causes the pawl drive surface 168 and / or pawl top radius 170 to abut against the receiving surface 186 and / or within the valleys, thereby engaging the teeth 185 and forcing the ring to rotate in the same direction as the pawls 106a-106c. Alternatively, the sliding surface 186 and the receiving surface 188 can have the same length and / or angle.

[0059] Figure 17 1 shows a perspective view of the biasing element 104 according to some embodiments. Figure 17 As shown, the biasing element 19 includes an elongated body shaped to surround each of the pawls 106a-106c, the body having a gap 194 that allows the body to bend to fit around the pawls 106a-106c before springing back to its original shape, and a tang 192 that captures one or more of the pawls 106a-106c and thereby prevents the biasing element 104 from rotating relative to the pawls 106a-106c. The biasing element 104 can comprise a flexible material or a combination of materials including, but not limited to, rubber, metal, plastic, or other flexible materials known in the art. As described above, the biasing element 104 can fit within the gap 134 (see FIG. Figure 10 ), at least partially surrounding or blocking the pawls 106a-106c from pivoting away from the dead zone surfaces 132a-132c. In particular, the biasing element 104 can be positioned within the pawl biasing element recess 162 and adjacent to or surrounding the pawl spring pad 164 of each pawl 106a-106c to resist pivoting away from the dead zone surfaces 132a-132c and / or bias the pawls 106a-106c in the retracted position. In effect, by providing a shortened pad 164, the pawls 106a-106c enable the biasing element 104 to have a smaller diameter and / or size and be closer to the dead zone surfaces 132a-132c. Additionally, the pad 164 provides a surface for the tang 192 to grip / clamp, thereby preventing the biasing element 104 from rotating relative to the pawls 106a-106c.

[0060] Figure 18 FIG. 1 shows a perspective view of the deadband adjustment key 108 according to some embodiments. Figure 18As shown, the deadband adjustment key 108 includes an adjustment block 232 and a coupling member 234. The coupling member 234 can have a stem configured to fit within the deadband adjustment key slot 138 and a retaining sheet extending below the inside of the slot, thereby preventing the stem / key from falling out of the slot 138. The adjustment block 232 can extend from the slot 138 into the adjacent deadband recess, close to the stop wall 136 of the recess (see FIG. Figure 19 and 22 ). Thus, when inserted into slot 138, adjustment block 232 reduces the size of the deadband recess by reducing the maximum distance that push finger 144 of that recess (and all other push fingers 144, as they are coupled together) can slide away from the detents 106a-106c of that recess. In fact, although Figure 18 A first width (eg Figure 19 The bearing assembly 102 includes an adjustment block 232 having a width R shown, but it should be understood that the adjustment block 232 can have a larger or smaller width, and / or the system can include multiple keys 108 having blocks 232 of different widths, allowing the user to select a key 108 having a desired width as a means of adjusting the deadband distance of the system. Alternatively, the bearing assembly 102 can include multiple slots 138 along one of the deadband recesses, allowing the deadband distance to be adjusted by inserting the key 108 into one of the slots 138 having a desired distance from the stop wall 136 and / or the detents 106a-106c of the recess.

[0061] Figure 19 FIG is a cross-sectional view of a hub assembly 1 according to some embodiments, wherein the free hub body assembly 100 is inserted (eg, concentrically nested) within the toothed ratchet 180. Figure 19 As shown, the pawls 106a-106c are in a retracted position (e.g., due to the force applied by the biasing element 104), wherein the inserted block 232 of the deadband adjustment key 108 reduces the distance between the pawls 106a-106c and the protruding fingers 144a-144c. As a result, the hub assembly 1 is in a freewheeling configuration wherein the hub shell assembly 30 (e.g., the ratchet 180) is able to rotate clockwise relative to the freehub body assembly 100 (e.g., the pawls 106a-106c). In effect, because the pawls 106a-106c are able to retract such that they do not contact the ratchet 180, the hub assembly 1 is in a silent freewheeling configuration wherein the hub assembly 1 does not produce the rattling sound that would be produced in conventional assemblies due to the contact of the pawls 106a-106c with the ratchet 180. Figure 19 As shown, in this configuration, the pawl 106a is positioned so that the pawl pusher cam surface 166 contacts the deadband surface 132a and / or is located within the deadband cavity. In addition, the pusher flywheel stop 152 contacts the block 232, thereby forming a deadband reduction angle R between the pusher flywheel stop 152 and the stop surface 136.

[0062] Figure 20 is another cross-sectional view of the hub assembly 1 according to some embodiments, wherein the free hub body assembly 100 is inserted (eg, concentrically nested) within the toothed ratchet 180. However, unlike Figure 19 Different, in Figure 20 138, key 108 is not inserted into slot 138, so that the deadband distance is maintained at its maximum value. In particular, pawls 106a-106c are in a retracted position (e.g., due to the force applied by biasing element 104), wherein fingers 144a-144c slide away from pawls 106a-106c against stop wall 136. Thus, hub assembly 1 is again in a silent idle configuration, wherein hub shell assembly 30 (e.g., ratchet 180) is able to rotate clockwise relative to free hub body assembly 100 (e.g., pawls 106a-106c). However, unlike Figure 19 The configuration is different in Figure 20 A longer deadband distance in will increase the time required for the fingers 144a-144c to push the pawls 106a-106c to the extended position and therefore increase the time required for the pawls 106a-106c to engage the ratchet 180, thereby reducing the possibility of pedal kickback.

[0063] Figure 21 FIG is another cross-sectional view of the hub assembly 1 according to some embodiments, wherein the free hub body assembly 100 is inserted (eg, concentrically nested) within the toothed ratchet 180. Figure 21As shown, the pawls 106a-106c are in the extended position because the extension force exerted by the fingers 144a-144c on the pawls 106a-106c overcomes the biasing force exerted by the biasing element 104. Specifically, when the freehub body assembly 100 begins to rotate clockwise (e.g., due to pedaling), the one-way clutch 42 provides a dragging or stopping force to the handle 142 of the pusher 140, causing the fingers 144a-144c to move counterclockwise relative to the pawls 106a-106c (and the rest of the assembly 100). As a result, the fingers 144a-144c slide along the deadband surfaces 132a-132c toward the pawls 106a-106c and eventually contact the pawls 106a-106c, sliding under the tops 168 and surface 166, thereby pivoting the pawls 106a-106c away from the deadband surfaces 132a-132c toward the teeth 185 of the ratchet 180 and into the extended position. When in the extended position, the pawls 106a-106c contact / engage the teeth 185 of the ratchet 180, such that pedaling torque applied to the freehub body assembly 100 is transferred to the hub shell assembly 30 via the pawls 106a-106c pressing against the teeth 185 of the ratchet 180 (which press against the hub shell assembly 30). In this extended position, the ratchet pawls 106a-106c are positioned so that the pawl drive surfaces 168 press against the ratchet tooth receiving surfaces 186. The engagement deadband angle / length A represents the free movement of the fingers 144a-144c of the pawl pusher 140 before the ratchet pawl 106a fully contacts the ratchet wheel 180. In practice, because the key 108 is not inserted into the keyway 138, the pawl pusher 140 must move the maximum deadband distance to fully extend the pawls 106a-106c and / or engage the ratchet wheel 180.

[0064] As described above, when transitioning from the extended position to the retracted position, as the pawls 106a-106c move counterclockwise relative to the ratchet 180, the pawls 106a-106c slide against the sliding surfaces 188 of the teeth 185 without engaging with the teeth 185, thereby enabling the ratchet 180 to rotate clockwise independently of the free hub body assembly 100. Conversely, when transitioning from the retracted position to the extended position, as the pawls 106a-106c move clockwise relative to the ratchet 180, once the pawls 106a-106c pivot so as to contact the ratchet 180, the pawls 106a-106c catch / engage one of the receiving surfaces 186 of the teeth 186, thereby causing the ratchet 180 to rotate clockwise due to the clockwise rotational force of the free hub body assembly 100.

[0065] Figure 22 is another cross-sectional view of the hub assembly 1 according to some embodiments, wherein the free hub body assembly 100 is inserted (e.g., concentrically nested) within the toothed ratchet 180. In particular, Figure 22Basically similar to Figure 21 , except that the deadband adjustment key 108 is inserted into the keyway 138, thereby reducing the deadband distance. Therefore, as shown by the reduced length B, instead of Figure 21 106a-106c to fully extend and / or engage the ratchet 180. Thus, the hub assembly 1 provides the advantage of enabling the deadband distance to be adjusted and / or configured to enable silent freewheeling. In particular, the combination of the biasing element 104 that causes the pawls 106a-106c to automatically retract to the retracted position when the assembly 100 is rotated in a drive direction (e.g., clockwise) and the one-way ratchet 42 and / or pusher 140 that causes the pawls 106a-106c to extend enables the assembly to be customized to reduce pedal kickback and / or achieve a rider's desired level of responsiveness.

[0066] In operation, as described above, the hub 1 can operate in two modes. In the first mode, "freewheel," the hub 1 freewheels when the bicycle 200 rolls forward and the pedal cranks 208 remain stationary. The cranks 208, chain 212, freewheel pulley 214, and freehub body assembly 100 remain stationary relative to the bicycle frames 204 and 206, while the rear wheel rotates forward. In the second mode, the hub 1 drives the bicycle 200 forward when the cyclist pedals the pedal cranks 208 forward. The chainring 209 rotates and applies tension to the bicycle chain 212, causing the bicycle freewheel pulley 214 and freehub body assembly 100 to rotate. The freehub body assembly 100 applies torque to the hub shell assembly 30, causing the wheel to rotate and drive the bicycle 200 forward. In this way, the rider propels the bicycle 200 forward by rotating the pedals.

[0067] In more detail, as described above, when the ratchet pawls 106a-106c are in the retracted position toward the bearing assembly 102, the hub assembly 1 idles, as shown in FIG. Figure 19 As shown. In the freewheeling condition, the hub shell assembly 30 rotates clockwise relative to the hub central axis 6 while the freehub body assembly 100 remains stationary. Therefore, the one-way clutch 42 also rotates clockwise relative to the pusher handle 142. The one-way clutch 42 can be designed and installed so that it allows the pusher handle 142 to rotate freely in drive (e.g., pedaling forward or clockwise), but locks and prevents or stops rotation in the opposite direction (e.g., counterclockwise). Therefore, when the hub shell assembly 30 is freewheeling, because the physical properties of any free-running clutch cannot be zero, the residual drag in the clutch 42 can cause the pawl pusher 140 to continue to rotate clockwise relative to the pawl pusher central axis 147, which is nominally the same as the hub central axis 6.

[0068] During freewheeling, the biasing element 104 contacts the pawl pad 164 and presses the pawls 106a-106c inwardly toward the center of the hub 100, thereby allowing the ratchet 180 to rotate freely about the ratchet pawls 106a-106c without contact and, therefore, without sound. In particular, as described above, the biasing element 104 can be sized so that it provides a constant inward force on the pawl spring pad 164 toward the hub center axis 6 throughout the free range of the pawls 106a-106c within the assembly 1. This force can be controlled by sizing the static diameter of the shape of the elongated body of the biasing element 104, by selecting the strength / flexibility of the material of the biasing element 104, and / or by the diameter of the body of the biasing element 104.

[0069] Depending on how the hub deadband distance is designed, the pusher stop wall 152 can press against the free hub stop surface 136 or the deadband adjustment key block 232 (if the deadband adjustment key 108 is installed on the hub 100). If the deadband adjustment key 108 is not installed, the components of the hub will be in Figure 20 If the deadband adjustment key 108 is installed, the component will be in Figure 19 In the configuration shown.

[0070] When the rider transitions from coasting to moving the pedal cranks 208 and actively pedaling the bicycle 200 forward, a dead zone is created in the hub 1. As the pedal cranks 208 begin to move, the freehub bearing assembly 102 begins to rotate clockwise relative to the hub central axis 6 until the speed of the freehub bearing assembly 102 matches the rolling speed of the hub shell assembly 30. Once these rotational speeds match, the pusher stem 142 is stationary relative to the one-way clutch 42, and thus, when the one-way clutch 42 begins to generate torque on the pusher stem 142, and therefore, the pawl pusher 140 begins to rotate in the opposite direction (e.g., counterclockwise) relative to the freehub bearing assembly 102. As this rotation occurs, the pusher cam surfaces 166 of the pawls 106a-106c move toward and contact the pawl surfaces 148 of the pusher fingers 144a-144c. Once this occurs, the ratchet pawls 106a-106c begin to pivot about the pawl cylinder 160, causing the pawl top radius 170 to move outward toward the ratchet wheel 180. Since the ratchet wheel 180 can still rotate relative to the free hub bearing assembly 102, the pawl top radius 170 contacts the ratchet wheel 180 at a random location based on when the pedal stroke begins, wheel speed, and other factors. Once this contact occurs, the pawl top radius 170 slides on the ratchet tooth sliding surface 188 until the pawl drive surface 168 contacts the ratchet tooth receiving surface 186. Once this contact occurs, torque is transferred from the free hub bearing assembly 102 to the hub shell assembly 30 via the ratchet pawls 106a-106c, which press against the teeth 185.

[0071] Once in motion, the rider can stop pedaling to resume freewheeling. When torque is no longer applied to the freehub bearing assembly 102, the ratchet 180 resumes (e.g., clockwise) rotation relative to the freehub bearing assembly 102, and the ratchet pawl 106 is forced away from the ratchet ring 180 as the pawl top radius 170 slides back down along the ratchet tooth sliding surface 188 (and / or due to the inward biasing force applied by the biasing element 104). Simultaneously, the pawl pusher 140 freely rotates with the hub shell assembly 30 (e.g., clockwise), facilitated by sliding contact between the pawl surface 148 of the pusher 140 and the pusher cam surfaces 166 of the pawls 106a-106c. Once the ratchet pawls 106a-106c have moved to the retracted position, the pawl pusher 140 continues to rotate clockwise relative to the freehub bearing assembly 102 due to parasitic free motion drag between the pusher handle 142 and the one-way clutch 42.

[0072] Figure 23 A method of providing a wheel hub assembly 1 according to some embodiments is shown. Figure 23As shown, at step 2302, the toothed ratchet 180 is positioned within the ratchet aperture 38 of the hub shell assembly 30. The ratchet 180 can be aligned within the aperture 38 so that the splines 184 slide into the corresponding hub shell spline channels 40, thereby preventing the ratchet 180 from rotating within the aperture 38 relative to the hub shell assembly 30. At step 2304, a free hub assembly 100 is provided. At step 2306, the free hub assembly 100 is coupled to the hub shell assembly 30. In some embodiments, the coupling can include positioning the inside of the pawl support member 102 such that the toothed ratchet 180 is positioned such that when the freehub assembly 100 is rotated relative to the hub shell assembly 30 in a first direction, the plurality of pawls 106 can pivot away from the pawl support member 102 (e.g., away from the deadband surface and / or the deadband recess 132) until the plurality of pawls 106 engage the teeth 185 of the toothed ratchet 180, causing the hub shell assembly 30 to rotate in the first direction with the freehub assembly 100. In some embodiments, the method further includes selectively inserting or removing the deadband adjustment key 108 within the deadband adjustment key slot 138, and / or selecting a deadband adjustment key 108 having a desired size of block 232. Specifically, the method can include sliding the stem 234 of the deadband adjustment key 108 into the key slot 138 such that the block 232 of the deadband adjustment key 108 extends into one of the deadband recesses 132 adjacent to one of the stop walls 136. Thus, when the free hub assembly 100 is rotated in the second direction relative to the hub shell assembly 30, each of the push fingers 144 slides along the dead zone surface until one of the push fingers 144 abuts the block 232 of the dead zone adjustment key 108 (thereby reducing the size of the dead zone within the hub assembly 1).

[0073] Thus, the method provides the advantage of providing a hub assembly having a pawl 106 that is biased away from the ratchet wheel 180, thereby ensuring a non-zero deadband length (regardless of the relative positions of the pawl 106 and the teeth 185) and / or a silent hub assembly. Furthermore, the method provides the advantage of being able to adjust the deadband length / amount of the hub assembly (to reduce or adjust the backlash and / or sound generated by the hub) via a deadband adjustment key, as desired by the user.

[0074] The systems, methods, and apparatus described herein have numerous advantages. Specifically, the systems, methods, and apparatus provide the advantage of providing a hub assembly having a pawl that is biased away from the ratchet wheel, thereby ensuring a non-zero deadband length (regardless of the relative positions of the pawl and teeth). Furthermore, the systems, methods, and apparatus provide the advantage of being able to adjust the deadband length / amount of the hub assembly (to reduce or adjust the backlash and / or sound generated by the hub) according to user desires via a deadband adjustment key. Furthermore, the systems, methods, and apparatus provide the advantage of enabling the deadband distance to be adjustable and / or designed for silent idling.

[0075] The present invention has been described in terms of specific embodiments incorporating details to facilitate an understanding of the principles of construction and operation of the invention. Such reference herein to specific embodiments and details thereof is not intended to limit the scope of the appended claims. It will be apparent to those skilled in the art that modifications may be made to the embodiments chosen for illustration without departing from the spirit and scope of the invention. For example, while the hub assembly 1 is described herein with respect to a bicycle wheel, it should be understood that the assembly 1, the hub shell assembly 30, and / or the free hub assembly 100 can operate in the same manner and be incorporated into other vehicles or devices to provide a ratcheting mechanism / functionality. Furthermore, while the assembly 1 is described herein with respect to a rear wheel, it should be understood that the assembly 1, the hub shell assembly 30, and / or the free hub assembly 100 can operate in the same manner and be incorporated into other wheels and / or non-wheels using an axle / rotation based mechanism requiring a ratcheting function.

Claims

1. A bicycle hub system, comprising: a bicycle wheel comprising a hub shell assembly having a central aperture for receiving an axle, a ratchet hole, and a toothed ratchet positioned within the ratchet hole; as well as a freehub assembly comprising an outer hub sprocket attachment feature, a pawl support member having a plurality of pawl pivot channels, a plurality of pawls pivotably coupled within the pivot channels, and a biasing member applying a biasing force to the plurality of pawls, the biasing force resisting the plurality of pawls from pivoting away from a deadband surface of the pawl support member; wherein the pawl support member is positioned within the toothed ratchet such that when the free hub assembly rotates in a first direction relative to the hub shell assembly, the plurality of pawls are able to pivot away from the pawl support member until the plurality of pawls engage the teeth of the toothed ratchet, causing the hub shell assembly to rotate together with the free hub assembly in the first direction.

2. The system according to claim 1, wherein: The biasing member is a spring that prevents the plurality of pawls from pivoting away from the pawl support member.

3. The system according to claim 2, wherein: Each of the plurality of pawls includes a notch for receiving the biasing member.

4. The system according to claim 1, wherein: When fully rotated toward the dead zone surface, the plurality of pawls cannot contact the teeth of the toothed ratchet.

5. The system according to claim 1, wherein: Also included is a pawl pusher having a plurality of push fingers positioned along the deadband surface of the pawl support member.

6. The system according to claim 5, wherein: When the free hub assembly rotates in the first direction relative to the hub shell assembly, the push fingers slide along the dead zone surface of the pawl support member and push against the tops of the plurality of pawls, thereby forcing the plurality of pawls to pivot away from the dead zone surface of the pawl support member.

7. The system according to claim 6, wherein: The hub shell assembly also includes a one-way clutch, which is operatively connected to the pawl pusher, so that the clutch prevents the push protrusion from rotating in the first direction relative to the hub shell assembly, and thereby causes the push protrusion to slide along the dead zone surface when the free hub assembly rotates in the first direction relative to the hub shell assembly.

8. The system according to claim 5, wherein: The deadband surface extends between each of the pivot channels and a corresponding one of a plurality of stop walls of the pawl-support member, thereby forming a plurality of deadband cavities adjacent the deadband surface.

9. The system according to claim 8, wherein: When the plurality of pawls are fully rotated against the deadband surface, a different pairing of one of the plurality of pawls and one of the plurality of push fingers is at least partially positioned within each of the deadband cavities.

10. The system according to claim 9, wherein: When the free hub assembly rotates relative to the hub shell assembly in a second direction opposite the first direction, each of the push fingers slides along the dead zone surface until the push finger abuts one of the stop walls.

11. The system according to claim 10, wherein: The free hub assembly also includes a deadband adjustment key configured to be selectively coupled to a keyway of the pawl support member, the keyway positioned adjacent one of the deadband recesses.

12. The system according to claim 11, wherein When the dead zone adjustment key is connected in the keyway, the block of the dead zone adjustment key extends into one of the dead zone recesses adjacent to the stop wall, so that when the free hub assembly rotates in the second direction relative to the hub shell assembly, each of the push protrusions slides along the dead zone surface until one of the push protrusions abuts the block of the dead zone adjustment key.

13. The system of claim 1, wherein: The outer hub sprocket attachment features are outer step pulley splines for coupling with one or more sprockets.

14. A bicycle hub assembly, comprising: a toothed ratchet having a plurality of teeth; as well as A free hub assembly comprising: a pawl support member having a plurality of pawl pivot channels; a plurality of pawls pivotably coupled within the pivot channels; and a biasing member applying a biasing force to the plurality of pawls, the biasing force preventing the plurality of pawls from pivoting away from a dead zone surface of the pawl support member; wherein the pawl support member is positioned within the toothed ratchet such that when the free hub assembly rotates in a first direction relative to the toothed ratchet, the plurality of pawls are able to pivot away from the pawl support member until the plurality of pawls engage the teeth of the toothed ratchet, thereby causing the toothed ratchet to rotate together with the free hub assembly in the first direction.

15. The assembly of claim 14, wherein: The biasing member is a spring that prevents the plurality of pawls from pivoting away from the pawl support member.

16. The assembly of claim 15, wherein: Each of the plurality of pawls includes a notch for receiving the biasing member.

17. The assembly of claim 14, wherein: When fully rotated toward the dead zone surface, the plurality of pawls cannot contact the teeth of the toothed ratchet.

18. The assembly of claim 14, wherein: Also included is a pawl pusher having a plurality of push fingers positioned along the deadband surface of the pawl support member.

19. The assembly of claim 18, wherein When the free hub assembly rotates in the first direction relative to the toothed ratchet, the push fingers slide along the dead zone surface of the pawl support member and push against the tops of the plurality of pawls, thereby forcing the plurality of pawls to pivot away from the dead zone surface of the pawl support member.

20. The assembly of claim 19, wherein Also included is a one-way clutch operatively coupled to the pawl pusher such that the clutch prevents the push finger from rotating in the first direction relative to the toothed ratchet and thereby causes the push finger to slide along the dead zone surface when the free hub assembly rotates in the first direction relative to the toothed ratchet.

21. The assembly of claim 18, wherein The deadband surface extends between each of the pivot channels and a corresponding one of a plurality of stop walls of the pawl-support member, thereby forming a plurality of deadband cavities adjacent the deadband surface.

22. The assembly of claim 21, wherein When the plurality of pawls are fully rotated against the deadband surface, a different pairing of one of the plurality of pawls and one of the plurality of push fingers is at least partially positioned within each of the deadband cavities.

23. The assembly of claim 22, wherein: When the free hub assembly is rotated relative to the toothed ratchet in a second direction opposite the first direction, each of the push fingers slides along the dead zone surface until the push finger abuts one of the stop walls.

24. The assembly of claim 23, wherein The free hub assembly also includes a deadband adjustment key configured to be selectively coupled to a keyway of the pawl support member, the keyway positioned adjacent one of the deadband recesses.

25. The assembly of claim 24, wherein When the dead zone adjustment key is connected in the keyway, the block of the dead zone adjustment key extends into one of the dead zone recesses adjacent to the stop wall, so that when the free hub assembly rotates in the second direction relative to the toothed ratchet, each of the push protrusions slides along the dead zone surface until one of the push protrusions abuts the block of the dead zone adjustment key.

26. The assembly of claim 14, wherein: The free hub assembly includes an outer hub sprocket attachment feature for coupling with one or more sprockets.

27. A method of providing a bicycle hub system, the method comprising: providing a hub shell assembly including a toothed ratchet positioned within a ratchet aperture, the hub shell assembly being adapted to couple with a bicycle rim via a plurality of spokes; as well as providing a freehub assembly including an outer hub sprocket attachment feature, a pawl support member having a plurality of pawl pivot channels, a plurality of pawls pivotably coupled within the pivot channels, and a biasing member applying a biasing force to the plurality of pawls, the biasing force resisting the plurality of pawls from pivoting away from a dead zone surface of the pawl support member; as well as The free-wheel hub assembly is coupled to the hub shell assembly such that the pawl support member is positioned within the toothed ratchet, and when the free-wheel hub assembly is rotated in a first direction relative to the hub shell assembly, the plurality of pawls are capable of pivoting away from the pawl support member until the plurality of pawls engage the teeth of the toothed ratchet, thereby causing the hub shell assembly and the free-wheel hub assembly to rotate in the first direction.

28. The method according to claim 27, wherein The biasing member is a spring that prevents the plurality of pawls from pivoting away from the pawl support member.

29. The method according to claim 28, wherein Each of the plurality of pawls includes a notch for receiving the biasing member.

30. The method of claim 27, wherein: When fully rotated toward the dead zone surface, the plurality of pawls cannot contact the teeth of the toothed ratchet.

31. The method of claim 27, wherein: The free hub assembly also includes a pawl pusher having a plurality of push fingers positioned along the deadband surface of the pawl support member.

32. The method according to claim 31, wherein When the free hub assembly rotates in the first direction relative to the hub shell assembly, the push fingers slide along the dead zone surface of the pawl support member and push against the tops of the plurality of pawls, thereby forcing the plurality of pawls to pivot away from the dead zone surface of the pawl support member.

33. The method according to claim 32, wherein The hub shell assembly also includes a one-way clutch, which is operatively connected to the pawl pusher, so that the clutch prevents the push protrusion from rotating in the first direction relative to the hub shell assembly, and thereby causes the push protrusion to slide along the dead zone surface when the free hub assembly rotates in the first direction relative to the hub shell assembly.

34. The method according to claim 31, wherein The deadband surface extends between each of the pivot channels and a corresponding one of a plurality of stop walls of the pawl-support member, thereby forming a plurality of deadband cavities adjacent the deadband surface.

35. The method according to claim 34, wherein When the plurality of pawls are fully rotated against the deadband surface, a different pairing of one of the plurality of pawls and one of the plurality of push fingers is at least partially positioned within each of the deadband cavities.

36. The method according to claim 35, wherein When the free hub assembly rotates relative to the hub shell assembly in a second direction opposite the first direction, each of the push fingers slides along the dead zone surface until the push finger abuts one of the stop walls.

37. The method according to claim 36, wherein The free hub assembly also includes a deadband adjustment key configured to be selectively coupled to a keyway of the pawl support member, the keyway positioned adjacent one of the deadband recesses.

38. The method according to claim 37, wherein The method also includes sliding the dead zone adjustment key into the keyway so that the block of the dead zone adjustment key extends into one of the dead zone recesses adjacent to the stop wall, and when the free hub assembly rotates in the second direction relative to the hub shell assembly, each of the push protrusions slides along the dead zone surface until one of the push protrusions abuts the block of the dead zone adjustment key.

39. The method of claim 27, wherein: The outer hub sprocket attachment features are outer step pulley splines for coupling with one or more sprockets.

Images