Torque element for a motorized bicycle

Abstract

bicycle (10) comprising the following: a wheel with an axle (105) with a first end (195) and a second end (200); a motor (255) coupled to the axle (105); a frame (25) supported by the wheel and a first dropout (90) defining a recess (115); and a torque element (230) which is attached to the first end (195) of the axle (105) and is shaped to fit into the recess (115) of the first dropout (90) to prevent rotation of the axle (105) relative to the frame (25) in response to a torque from the motor (255), characterized in that the recess (115) is defined by converging side walls (120) and is accessible adjacent to a bottom of the frame (25) to accommodate the torque element (230).

Description

[0001] The present invention relates generally to bicycles and in particular to motor-driven electric bicycles, as well as to a method for preventing rotation of an axle of a bicycle.

[0002] Bicycles typically have a main frame and a front fork that pivots on the main frame. The main frame typically includes a top tube, a down tube, a seat tube, and a rear axle mount. The front fork typically includes a front axle mount. Steering is achieved via handlebars, which are usually attached to the front fork by a stem.

[0003] A bicycle according to the preambles of claims 1 and 7 and a method for preventing rotation of an axle of a bicycle according to the preamble of independent claim 13 are known from US 2011 / 0 303 471 A1. The document describes a bicycle hub with an integrated motor, wherein the motor housing has a recessed section that can accommodate a bicycle frame.

[0004] Other state-of-the-art bicycles are known, for example, from DE 602 09 510 T2, CN 2 01 245 225 Y, JP 2000- 168 665 A and WO 2009 / 041 820 A1.

[0005] Some bicycles also include a hub motor mounted on the rear axle to assist the bicycle's propulsion. In existing motorized e-bikes, torque is transferred from the motor to the frame. Often, the torque exceeds the clamping forces on the rear axle, causing the axle to rotate freely relative to the frame. In some cases, a torque arm is externally bolted to the frame using a special connector and is further coupled to the axle to prevent rotation. Existing torque arms are prone to failure, and if they fail, wires connected to the motor can become entangled and / or damaged, potentially injuring the rider.

[0006] It is an object of the present invention to eliminate the problems described above. According to the invention, this object is achieved by a bicycle according to claims 1 and 7 and a method according to claim 13.

[0007] The present invention provides a bicycle with a wheel having an axle with a first end and a second end, a motor coupled to the axle, and a frame supported by the wheel. The frame includes a first dropout and a second dropout. The first dropout defines a recess, and the bicycle includes a torque element attached to the first end of the axle, shaped to fit into the recess of the first dropout to prevent rotation of the axle relative to the frame in response to a torque from the motor. The recess is defined by converging side walls and is accessible adjacent to a bottom surface of the frame to accommodate the torque element.

[0008] In one design, the present invention provides a bicycle with a wheel having an axle with a non-cylindrical first end and a second end, and a motor coupled to the axle. The bicycle also includes a frame supported by the wheel, which has a dropout with a first wall defining a recess, and a torque element non-rotatably coupled to the first end of the axle. The torque element comprises a second wall that can engage with the first wall to prevent rotation of the axle in response to a torque from the motor. The first wall comprises converging side walls that define the recess as wedge-shaped. The torque element has an outer surface that engages with at least one of the converging walls to prevent rotation of the axle.

[0009] In another embodiment, the present invention provides a method for preventing the rotation of an axle, wherein the bicycle has a dropout with a recess. The method comprises coupling a motor to the axle, attaching a torque element to one end of the axle, engaging the torque element in the dropout within the recess, preventing rotation of the axle in response to a torque from the motor, and shaping the torque element such that the outer surface of the torque element substantially corresponds to the recess defined as wedge-shaped by the inner wall.

[0010] Advantageous further developments of the invention result from the dependent claims.

[0011] Further features and advantages of the invention will become apparent from the description of embodiments of the invention with reference to the figures. The figures show: Fig. 1 a side view of a bicycle with a frame embodying the present invention. Fig. 2 a perspective view of a rear axle area of ​​the in Fig. 1. Bicycle shown with a left and a right dropout, an axle, a motor and a torque element located between the left dropout and the axle. Fig. 3 a perspective view of a section of the rear axle and the right dropout. Fig. 4 a view of a section of the in Fig. 2 rear axle area shown in a spread-out arrangement, with the dropouts, the axle and the torque element. Fig. 5 a perspective view of the left dropout, the axle and the torque element in a spread-out arrangement. Fig. 6 A perspective view of the right dropout, axle and derailleur hanger in a spread-out arrangement. Fig. 7 A perspective view of the axis and torque element before assembly. Fig. 8 a perspective view of the torque element attached to the axis. Fig. 9 a perspective view of the inside of the torque element that is inserted into the left dropout.

[0012] Before any embodiments of the invention are explained in detail, it should be understood that the invention is not limited in its application to the details of the construction and arrangement of components set out in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or implemented in various ways.

[0013] Fig. Figure 1 shows a bicycle 10 comprising a front wheel 15, a rear wheel 20, and a frame 25. The frame 25 has a head tube 30 and a front fork 35, which is rotatably supported by the head tube 30 and which attaches the front wheel 15 to the frame 25. A steering rod assembly 40 is coupled to the head tube 30 and is attached to the front fork 35 by a stem assembly 45. The frame 25 also has a top tube 50, which is connected to the head tube 30 and extends rearward from it, and a down tube 55, which is connected to the head tube 30 below the top tube 50 and generally extends downward toward a drivetrain 60. A seat tube 65 is connected to the top tube 50 and the down tube 55, and a seat 70 is supported by the seat tube 65.

[0014] With reference to Fig. 1 and Fig. The frame 25 also includes a rear triangle connected to the rear wheel 20. The rear triangle comprises opposing seat stays 75 (one shown), a left chainstay 80, and a right chainstay 85. A left dropout 90 is located at the lower end of one seat stay 75 and is connected to the left chainstay 80. A right dropout 95 is located at the lower end of the right seat stay 75 and is connected to the right chainstay 85. Fig. 2 and Fig. Figure 4 shows that a rear axle system 100 of the rear wheel 20 comprises an axle 105 extending between the dropouts and an axle rod 110 that secures the rear wheel 20 in the dropouts 90, 95 to rotatably attach the rear wheel 20 to the frame 25. Although not shown, a bearing set (not shown) couples a hub (not shown) to the axle 105, allowing the rear wheel 20 to rotate freely about the axle 105.

[0015] Fig. 4 and Fig. Figure 5 shows that the left dropout 90 has a recess 115 adjacent to a lower edge or underside of the dropout 90 and accessible from the inner or wheel side of the frame 25. The recess 115 is defined by converging side walls 120 (inner walls) and a planar bottom surface 125. Each of the converging side walls 120 shown has a planar section and is connected to the other wall 120 at a vertex of the recess 115. A hole 130 extends through the left dropout 90 near the vertex of the converging walls 120, and the axle 105 is aligned with the hole 130.

[0016] With reference to Fig. 2-4 and 6 a derailleur hanger 135 is connected to the right dropout 95 using a fastening device 137 (see Fig. 4), which is screwed into a hole 138. As in Fig. 3 and Fig. As shown in Figure 6, the eye 135 is wedged into a recessed area 140 of the right dropout 95 and has a recess 145 on one side of the eye body. The recess 145 is shaped to accommodate the axle 105 and is adjacent to a lower edge or underside of the right dropout 95 and accessible from an inner or wheel side of the frame 25. In particular, the recess 145 of the right dropout 95 is defined by converging side walls 150 and a planar bottom surface 155 similar to the recess 115 of the left dropout 90. Also like the recess 115, each of the converging side walls 150 shown has a planar section and is connected to the other wall 150 at a vertex of the recess 145. A hole 160 ( Fig. 6) of the eye 135 near the apex of the converging walls 150 is aligned with a threaded hole 162 which extends through the right dropout 95 near the apex of the converging walls 150 to accommodate the axle rod 110, as detailed below.

[0017] In other designs, the derailleur hanger 135 can be formed as a single piece with the right dropout 95, the hanger 135 can be connected in another way (e.g., by welding, brazing, or adhesive), or the hanger 135 can be attached to another component (e.g., the rear right chainstay 85, the right seatstay 75). Furthermore, the left chainstay 80 and the left seatstay 75 can be formed as a single piece or connected in another way. Likewise, the right chainstay 85 and the right seatstay 75 can be formed as a single piece or connected in another way, as desired.

[0018] As shown, the recesses 115, 145 of both dropouts 90, 95 are generally wedge-shaped (see Fig. 5 and Fig. 6) when viewed from the inside of the frame 25, although one or both of the recesses 115, 145 may have other shapes. The wide mouth or opening defined by each recess 115, 145 near the lower edge of the respective dropouts 90, 95 creates a relatively large access opening for receiving the axle 105, so that the rear wheel 20 can be easily attached to the frame 25 within the dropouts 90, 95. Although the recess 145 of the right dropout 95 is shown to be shallower than the recess 115 of the left dropout 90, the recess 145 may have the same or a different depth relative to the recess 115.

[0019] With reference to Fig. The drive train 60 comprises a crankset 165, which is rotatably mounted on a bottom bracket (not shown). A front derailleur 170 moves a chain 175 between different chainrings 180 (one shown) and is actuated by the handlebar assembly 40. Several rear sprockets 185 are mounted on the rear wheel 20 and connected to the crankset 165 by the chain 175. A rear derailleur 190 is attached to the derailleur hanger 135 and moves the chain 175 between the different rear sprockets 185 and is actuated by the handlebar assembly 40.

[0020] Fig. Figures 2-4 show that the axle 105 comprises a first end 195, which is arranged in the left dropout 90, and a second end 200, which engages with the derailleur hanger 135 and is arranged in the right dropout 95. With reference to Fig. 4 and Fig. 5 The first end 195 has a wedge or hexagonal shape, although the first end 195 may have any suitable non-cylindrical or polygonal shape. In other words, the first end 195 has a non-circular cross-section. As in Fig. 4 and Fig. As shown in Figure 6, the second end 200 is essentially cylindrical and has a stepped taper 205. A central section 210 of the axis 105 extends between the first and second ends 195, 200 to support bearings (not shown).

[0021] With reference to Fig. 4, Fig. 7 and Fig. 8 A passage 215 extends through the axle 105 from the first end 195 to the second end 200 to accommodate the axle rod 110 when the rear axle system 100 is mounted on the bicycle 10.

[0022] Fig. Figure 4 shows that the axle 110 has a head 220, which can be engaged with a tool (e.g., Allen key or other wrench, screwdriver, etc.), and a distal threaded end 225. As shown, the axle 105 is aligned with the holes 160, 162, so that the axle 110 can extend through the left dropout 90, the axle 105, and the eye 135, and engage with the right dropout 95 within the hole 162 to secure the rear wheel 20 to the frame 25. In some cases, the right dropout 95 may include a threaded insert (not shown) to secure the axle 110 to the right dropout 95. When installed, the head 220 of the axle 110 rests against the left dropout 90. The axle rod 110 shown is only an example and can be replaced by other suitable components (e.g. a quick-release fastener, etc.).) are replaced, which are suitable for the desired connection between the rear wheel 20 and the frame 25.

[0023] With reference to Fig. 2, 4, 5 and 7-9 a torque element 230 is attached to the first end 195 of the axle 105 and is shaped to fit into the recess 115 of the left dropout 90. Fig. Figures 5 and 7-9 show that the torque element 230 is wedge-shaped and inserted into the recess 115, so that the torque element 230 is essentially hidden from view when the bicycle 10 is viewed adjacent to the outer sides of the frame 25. That is, the torque element 230 is shielded by the left dropout 90 on its upper and outer surface. As in Fig. 2 and Fig. As shown in Figure 4, the torque element 230 is received in the dropout 90 when the rear wheel 20 is coupled to the frame 25, so that the torque element 230 is positively engaged in the dropout 90. As shown, an outer wall or surface 235 of the torque element 230 is shaped to correspond to the converging side walls 120 when the torque element 230 is arranged in the recess 115.

[0024] Fig. 5, Fig. 7 and Fig. Figure 8 shows that the torque element 230 has a non-cylindrical opening 240 (non-circular in cross-section) shaped to fit the first end 195 of the axle 105. Specifically, the torque element 230 shown has a hexagonally shaped opening 240 that engages with the hexagonally shaped first end 195 of the axle 105. A fastening device 245 extends through a threaded hole 250 in the torque element 230 to secure the torque element 230 to the axle 105, so that when the rear wheel 20 is removed from the frame 25, the torque element 230 remains attached to the axle 105. In some designs, the first end 195 and the torque element 230 may have other engagement structures. The first end 195 of the axis 105, for example, may have other polygonal shapes (e.g. triangular, square, trapezoidal, pentagonal, etc.) and the opening 240 may have a complementary polygonal shape.In other designs, the first end 195 and the opening 240 can have any complementary non-circular cross-sectional shapes (e.g., elongated round, oblong, etc.). In some cases, the torque element 230 can be pressed onto the axis 105.

[0025] As in Fig. As shown in Figure 2, the bicycle 10 also includes a motor 255, which is coupled between the drive train 60 and the axle 105 to selectively provide a driving force for the bicycle 10 via the rear wheel 20. In particular, a stator section of the motor is attached to the axle 105, and a rotor section (not shown) of the motor 255 is coupled to the drive train 60. The motor 255 is electrically connected to a power source or battery pack 260 (e.g., housed in the down tube 55) by a power cable (not shown), and a control unit can be used to control the motor 255 and other electrical accessories on the bicycle 10. As shown in Figure 2, the motor 255 is connected to the drive train 60. Fig. As shown in Figures 4, 5 and 7-9, the torque element 230 has a projection 265 (near the underside of the torque element 230, as shown in Figures 4, 5 and 7-9). Fig. 2 to be seen) which defines a compartment 270 to keep the power cable away from other components of the rear wheel 20 (e.g., disc rotor bolts, not shown). With reference to Fig. 7 and Fig. 8 The surfaces of compartment 270 are generally angled upwards towards the inside of torque element 230 adjacent to the outside of torque element 230, so that the power cable does not interfere with the rotation of rear wheel 20.

[0026] The torque element 230 is non-rotatably attached to the axle 105 and interacts with the dropout 90 to resist the torque from the motor 255 and consequently prevent axle rotation in response to the motor torque. To attach the wheel 20 with the motor 255 to the frame 25, the second end 200 of the rear axle 105 is aligned with the recess 145 in the right dropout 95, and the torque element 230 is aligned with the recess 115 in the left dropout 90. The torque element 230 generally slides vertically upward into the recess 115 of the left dropout 90 from the underside of the frame 25, and the second end 200 of the axle 105 is positioned in the recess 145 of the right dropout 95 and aligned flush with the hole 160. The torque element 230 is positioned precisely in the left dropout 90 due to the complementary shapes of the recess 115 and the torque element 230.The axle rod 110 is then inserted through the left dropout 90, the axle 105, and the eye 135, and screwed into the right dropout 95 by engaging the appropriate tool with the head 220. Since the recess 115 is located on the inside of the dropout 90, the torque element 230 is essentially hidden from view.

[0027] When the motor 255 is actuated, a significant amount of torque is applied to the wheel 20, and the axle 105 tends to rotate in the opposite direction to the motor torque. As described, the torque element 230 is attached to the first end 195 of the axle 105 and is firmly seated in the dropout 90 within the recess 115. The torque element 230 is essentially an internal component of the rear axle system 100, positively locked in the dropout 90 and around the axle 105 to prevent axle rotation in response to the motor torque. Due to the complementary elongated or wedge-shaped recess 115 and the torque element 230, the torque element 230 cannot move relative to the dropout 90. Since the torque element 230 is also rigidly attached to the axis 105, any tendency for the axis 105 to rotate in response to the motor torque is prevented by the torque element 230.In other words, any tendency for the axis to rotate due to the motor torque (or other factors) is prevented by the non-rotatable mounting of the torque element 230 on the axis 105 and the tight fit between the recess 115 and the torque element 230.

[0028] Various features and advantages of the invention are set forth in the following claims.

Claims

[1] Bicycle (10) comprising the following: a wheel with an axle (105) with a first end (195) and a second end (200); a motor (255) coupled to the axle (105); a frame (25) supported by the wheel and a first dropout (90) defining a recess (115); and a torque element (230) which is attached to the first end (195) of the axle (105) and is shaped to fit into the recess (115) of the first dropout (90) to prevent rotation of the axle (105) relative to the frame (25) in response to a torque from the motor (255), characterized by , that the recess (115) is defined by converging side walls (120) and is accessible adjacent to a bottom of the frame (25) to accommodate the torque element (230). [2] Bicycle (10) according to claim 1, characterized by, that the first end (195) of the axis (105) is defined by a polygonal shape, and wherein the torque element (230) comprises an opening (240) shaped such that it engages with the first end (195) of the axis (105). [3] Bicycle (10) according to claim 2, characterized by , that the first end (195) of the axis (105) has a hexagonal shape and the opening (240) has a complementary hexagonal shape. [4] Bicycle (10) according to claim 3, characterized by , that the torque element (230) is held in engagement with the axis (105) by a fastening device (245). [5] Bicycle (10) according to claim 1, characterized by , that the torque element (230) is inserted into the recess (115) so that the torque element (230) is hidden from view. [6] Bicycle (10) according to claim 1, characterized by, that the converging side walls (120) define the recess (115) as wedge-shaped and the torque element (230) has an outer surface (235) that engages with at least one of the converging side walls (120). [7] Bicycle (10) comprising the following: a wheel with an axle (105) having a non-cylindrical first end (195) and a second end (200); a motor (255) coupled to the axle (105); a frame (25) supported by the wheel and comprising a dropout (90) with a first wall defining a recess (115); and a torque element (230) which is non-rotatably coupled to the first end (195) of the axis (105) and comprises a second wall which can be engaged with the first wall to prevent rotation of the axis (105) in response to a torque from the motor (255), characterized by, that the first wall comprises converging side walls (120) and wherein the converging side walls (120) define the recess (115) as wedge-shaped, and the torque element (230) has an outer surface (235) which engages with at least one of the converging side walls (120) to prevent rotation of the axis (105). [8] Bicycle (10) according to claim 7, characterized by , that the torque element (230) is fully inserted into the recess (115) so that the torque element (230) is hidden from view. [9] Bicycle (10) according to claim 7, characterized by , that the torque element (230) has an opening (240) defined by a non-cylindrical shape corresponding to the non-cylindrical shape of the first end (195). [10] Bicycle (10) according to claim 9, characterized by , that each of the first end (195) of the axis (105) and the opening (240) is defined by a hexagonal shape. [11] Bicycle (10) according to claim 7, characterized by , that the torque element (230) is held in engagement with the axis (105) by a fastening device (245). [12] Bicycle (10) according to claim 7, characterized by , that the torque element (230) has a projection (265) to support a cable. [13] Method for preventing rotation of an axle (105) of a bicycle (10) having a dropout (90) with a recess (115), the method comprising: Coupling a motor (255) to the axle (105); Attaching a torque element (230) to a first end (195) of the axis (105); The torque element (230) engages in the recess (115) in the dropout (90); and Preventing rotation of the axis (105) relative to the dropout end (90) in response to a torque from the motor (255), characterized by, that an inner wall defines the recess (115) as wedge-shaped, wherein the method further comprises shaping the torque element (230) such that an outer surface (235) corresponds to the shape of the inner wall. [14] Method according to claim 13, characterized by , that it further includes the removable fastening of the torque element (230) to the axis (105). [15] Method according to claim 13, characterized by , that it further includes the locking of the outer surface (235) of the torque element (230) onto the inner wall that defines the recess (115) in response to a motor torque. [16] Method according to claim 13, characterized by , that the locking action includes the sliding of the torque element (230) into the recess (115) from an underside of the dropout (90). [17] Method according to claim 13, characterized by, that it further includes inserting the torque element (230) into the recess (115) so that the torque element (230) is hidden from view. [18] Method according to claim 13, characterized by , that it further includes supporting a cable via the torque element (230).

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