Control line router for a headset of a bicycle and device for a bicycle

Abstract

A control line wiring harness for one of the head components of a bicycle includes a barrier disposed within one of the head tubes of the bicycle between one of the bicycle components and a section of a control line.

Description

Technical Field

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 592,062, filed on October 20, 2023, the contents of which are incorporated herein by reference in their entirety.

[0002] The present disclosure relates generally to cable routing for bicycles, and more particularly to internal cable routing through a head assembly of a bicycle. Prior Art

[0003] Internally routed control wires of a bicycle, including, for example, hydraulic hoses, shifter wires (e.g., metal reinforced shifter wires), brake wires (e.g., including a cable and housing), and / or electrical conductors, may enter a head tube of a frame of the bicycle via a stem or a head assembly attached to the frame. The control wires may travel between an inner surface of the head tube and an outer surface of a control tube of a fork rotatably attached to the frame via the head assembly. The control wires extend through the head tube and exit the head tube into a top tube of the frame or a down tube of the frame. The control wires may be control wires used to operate, for example, brakes, shifters, a dropper seatpost, suspension controls, and / or sensors. Summary of the invention

[0004] An example control cable routing device for a bicycle head assembly has a barrier disposed within the bicycle head tube between a component of the bicycle and a section of a control cable.

[0005] Another example is a device for a bicycle having a barrier positioned between one or more components in a head tube of the bicycle. Simple diagram description

[0006] The objects, features and advantages of the present invention will become apparent after reading the following description in conjunction with the drawings, in which:

[0007] FIG. 1 is a side view of an example of a bicycle that may be combined with a head assembly cable routing device according to the teachings of the present disclosure;

[0008] Figure 2 is an exploded perspective view of a bicycle assembly of Figure 1 including a first embodiment of a cable routing device for the head assembly;

[0009] Figure 3 is a close-up of an exploded perspective view of the components of the first embodiment of the cable wiring device of the head assembly of Figure 2;

[0010] Figure 4 is a first plan view of a frame and fork assembly of the components of Figure 2;

[0011] Figure 5 is a close-up of a top view of the frame and fork assembly of Figure 4;

[0012] Figure 6 is a first side view of the frame and fork assembly of Figure 4;

[0013] Figure 7 is a close-up side view of the frame and fork assembly of Figure 6;

[0014] FIG8 is a cross-sectional side view of the frame and fork assembly of FIG6, illustrating the internal cable routing using the first embodiment of the head assembly cable routing device;

[0015] Figure 9 is a close-up of the cross section of Figure 8;

[0016] Figure 10 is a front view of the frame and fork assembly of Figure 4;

[0017] Figure 11 is a second top view of the frame and fork assembly of Figure 4;

[0018] Figure 12 is a cross-section of the frame and fork assembly of Figure 11 taken along the axis AA of Figure 11;

[0019] Figure 13 is a close-up of the cross section of Figure 12;

[0020] Figure 14 is a second side view of the frame and fork assembly of Figure 4;

[0021] Figure 15 is a cross-section of the frame and fork assembly of Figure 14 taken along the axis BB of Figure 14;

[0022] Figure 16 is a close-up of the cross section of Figure 15;

[0023] Figure 17 is a perspective view of a steerer sheath of the first embodiment of the head assembly cable wiring device of Figure 2;

[0024] Figure 18 is a top view of the operating member sheath of Figure 17;

[0025] Figure 19 is a side view of the operating member sheath of Figure 17;

[0026] Figure 20 is a cross-section of the operating member sheath of Figure 19 taken along the axis CC of Figure 19;

[0027] Figure 21 is an exploded perspective view of a bicycle assembly of Figure 1 including a second embodiment of a cable routing device for the head assembly;

[0028] Figure 22 is a close-up of an exploded perspective view of the components of the second embodiment of the cable wiring device of the head assembly of Figure 21;

[0029] FIG23 is a cross-section of a side view of a frame and fork assembly of the assembly of FIG21, illustrating the internal cable routing of the second embodiment of the head assembly cable routing device;

[0030] Figure 24 is a close-up of the cross section of Figure 23;

[0031] Figure 25 is a front view of the frame and fork assembly of Figure 23;

[0032] Figure 26 is a top view of the frame and fork assembly of Figure 23;

[0033] Figure 27 is a cross-section of the frame and fork assembly of Figure 26 taken along the axis DD of Figure 26;

[0034] Figure 28 is a close-up of the cross section of Figure 27;

[0035] Figure 29 is a side view of the frame and fork assembly of Figure 23;

[0036] Figure 30 is a cross-section of the frame and fork assembly of Figure 29 taken along the axis EE of Figure 29;

[0037] Figure 31 is a close-up of the cross section of Figure 30;

[0038] Figure 32 is a perspective view of a first-line sheath of the second embodiment of the cable wiring device of the head assembly of Figure 21;

[0039] Figure 33 is a top view of the wire sheath of Figure 32;

[0040] FIG34 is a side view of the wire sheath of FIG32; and

[0041] FIG. 35 is a cross-section of the wire sheath of FIG. 34 taken along the axis FF of FIG. 34 . Implementation

[0042] Control wires used to operate, for example, brakes, shifters, a dropper post, suspension controls and / or sensors of a bicycle may be anchored at one end to a handlebar of the bicycle and at another end to a frame of the bicycle. Since the control wires are anchored at both ends, manipulation (e.g., of the handlebars and fork relative to the frame) causes the control wires to move relative to the steering anchoring components (e.g., a handle tube of a fork, a stem) and frame anchoring components (e.g., a head tube of the frame, a portion of a head assembly). This movement of the control wires may cause the wires to rub against and wear adjacent components (e.g., at least some of the steering anchoring components and / or frame anchoring components).

[0043] The present disclosure provides an example of a head assembly cable routing device that solves or improves one or more disadvantages of previously known internal cable routing in a bicycle. The disclosed head assembly cable routing device includes ports on a head assembly cap of a head assembly to allow control wires to be routed through the vertical rods and into the frame of the bicycle via the ports on the head assembly cap.

[0044] In one embodiment, a head assembly cable routing device includes a barrier for protecting control wires, components, and frame components from each other. In one embodiment, the barrier is disposed within a head tube of a bicycle between components of the bicycle. Components may include, but are not limited to, a steering tube of a bicycle, a control wire or a section of the control wire, or any other component that is typically at least partially disposed within a head tube of a bicycle.

[0045] In another embodiment, a barrier is flexible.

[0046] In another embodiment, where a component of a bicycle is a steering tube of a fork, a barrier is assembled to at least partially surround the steering tube. In one embodiment, the barrier may be a reducer offset from the steering tube, the reducer being assembled so that the reducer does not contact the steering tube. In another embodiment, the barrier is attached to either or both of an upper cup and a lower cup of a head assembly of the bicycle. In yet another embodiment, the barrier contacts the steering tube.

[0047] In another embodiment of the control line routing device, a barrier is configured to surround a section of a control line. In this embodiment, the barrier can extend into a top tube, a down tube, a vertical bar, a fork, or any combination of top tube, down tube, vertical bar or fork.

[0048] In another embodiment of the control line router, a barrier has a circular cross-section. In this embodiment, the barrier may include a seam along a length of the barrier.

[0049] In another embodiment of a control wire router, a barrier has: a control tube sheath configured to at least partially surround a control tube of a fork; and a control wire sheath configured to at least partially surround a section of the control wire.

[0050] In another embodiment of the control line router, a barrier is made of one or a combination of: a plastic, a polymer, a carbon fiber composite, a composite, PTFE, an elastomeric material or a metal.

[0051] In another embodiment of the control line router, a barrier has an outer wall comprising a friction reducing coating, wherein the friction reducing coating comprises any one or a combination of a PTFE coating, a wet lubricant, or a dry lubricant.

[0052] In another embodiment, a control wire router has a cap through which a steering tube of a fork extends, the cap having one or more ports extending through the cap, wherein the control wire extends through the cap via the one or more ports.

[0053] In another embodiment, the control line router has an upper cup with a play configured to allow radial and / or rotational play for the control line.

[0054] In another embodiment, a control line is a hydraulic hose or a bowden cable.

[0055] In another embodiment, a device for a bicycle has a barrier positioned between one or more components in a head tube of the bicycle.

[0056] In one embodiment, the device is a barrier configured to surround a section of the actuator tube.

[0057] In one embodiment, the device is a barrier configured to surround a section of the control line.

[0058] In one embodiment, the device is a barrier having at least two sheaths, wherein a first sheath is assembled to surround a section of a steering tube of a fork and a second sheath is assembled to surround a section of a control line.

[0059] In another embodiment, the barrier is a sheath. The sheath is configured to act as a barrier between components of a bicycle.

[0060] It should be understood that a sheath is one type of barrier. Other types of barriers may also be considered, including but not limited to covers, covers, shields, curtains, sheets, walls, etc., without departing from the present disclosure.

[0061] In one embodiment, a boot system of a head assembly cable router includes a handle boot disposed around a portion of the handle tube of the fork. The handle boot can be a hollow cylinder (e.g., having a circular cross-section) and can be thin-walled. In one embodiment, the handle boot can be tapered and closely offset from the handle tube so that radial play and head tube access are maximized. In another embodiment, the handle boot is non-tapered and / or contacts the handle tube.

[0062] The control cover can be made of a variety of materials, including, for example, plastic, polytetrafluoroethylene (PTFE), carbon fiber, polymer, an elastomeric material, a smooth metal, or another material. The control cover can be rigid or flexible. In one embodiment, a wet or dry lubricant is applied to an outer surface of the control cover. The control cover can be fixedly or rotationally attached to an upper cup and / or a lower cup of the head assembly.

[0063] The lever guard creates a low friction barrier between the lever tube of the fork and the control wire. When the lever guard is positioned around a portion of the lever tube of the fork, the control wire may not rub or wear the lever tube. This prevents loss of communication between one or more control devices of the bicycle and one or more components of the bicycle (e.g., shifters, brakes, sensors).

[0064] In another embodiment, a sheath system of a head assembly cable router includes one or more wire sheaths, which are respectively disposed around portions of one or more control wires. One of the one or more wire sheaths can be a hollow cylinder (e.g., having a ring-shaped cross-section) and can be thin-walled. In one embodiment, the wire sheaths are in contact with the respective control wires.

[0065] The wire guard may be made of a variety of materials, including, for example, plastic, polytetrafluoroethylene (PTFE), carbon fiber, polymer, an elastomeric material, a smooth metal, or another material. The wire guard may be rigid or flexible. In one embodiment, a wet or dry lubricant is applied to an outer surface of the wire guard. The wire guard may be fixedly or rotationally attached to the upper cup and / or lower cup of the head assembly.

[0066] The cable guard creates a low friction barrier between the fork's control tube and the individual control cables. When the cable guard is positioned around a portion of the individual control cable, the individual control cable may not rub or wear the control tube. This prevents loss of communication between one or more control devices of the bicycle and one or more components of the bicycle (e.g., shifters, brakes, sensors).

[0067] In another embodiment, a sheath system for a head assembly cable router includes: a control sheath disposed around a portion of a control tube of a fork; and one or more wire sheaths disposed around portions of one or more control wires, respectively. The combination of the control sheath and the one or more wire sheaths acts as a dual barrier against friction and wear.

[0068] The disclosed head assembly cable router may also include a play within the head assembly upper cup. For example, the head assembly upper cup may be a hollow cylinder having a varying inner diameter (e.g., and varying outer diameter). For example, an inner surface (e.g., an inner annular surface) of the upper cup may have a bevel at and near one end of the upper cup. The bevel provides the play. The play within the head assembly upper cup allows the control wire to move freely radially and circumferentially as the fork's control tube rotates relative to the bicycle frame.

[0069] These and other objects, features and advantages of the disclosed control device will become apparent to those having ordinary skill in the art after reading this disclosure. In the drawings where similar reference numerals are used throughout, such similar reference numerals represent the same or substantially similar components in the various disclosed examples. Furthermore, specific examples utilizing specific combinations of the disclosed aspects, features and components of the present disclosure are disclosed and described herein. However, it is possible that each aspect, feature and / or component disclosed in the present disclosure may be used independently of or in different combinations with other aspects, features and components of the present disclosure in other examples not disclosed or described herein.

[0070] Referring now to the drawings, FIG. 1 generally illustrates a bicycle 50 that utilizes a head assembly cable routing device constructed in accordance with the teachings of the present disclosure. The bicycle 50 includes: a frame 52; a front wheel 54 and a rear wheel 56, each rotatably attached to the frame 52; and a drive chain 58. A front brake 60 is provided to brake the front wheel 54, and a rear brake 62 is provided to brake the rear wheel 56. The bicycle 50 also generally has a seat 64 proximate a rear end of the frame 52 and carried on a seat bar 66 connected to the frame 52. The bicycle 50 also has handlebars 68 proximate a front end of the frame 52. A brake lever 70 is carried on the handlebars 68 for actuating the front brake 60, the rear brake 62, or both the front brake 60 and the rear brake 62. If the brake lever 70 actuates only one of the front brake 60 or the rear brake 62, a second brake lever (not shown) may also be provided to actuate the other brake. A front and / or forward riding direction or orientation of the bicycle 50 is indicated by the direction of arrow X in FIG. 1 . Thus, a forward direction of the bicycle 50 is indicated by the direction of arrow A. Although the illustrated bicycle 50 of FIG. 1 is a mountain bike having flat handlebars 68, the present disclosure is applicable to any type of bicycle, including road bicycles having curved handlebars.

[0071] The drive chain 58 has a chain C and a front sprocket assembly 72, which is coaxially mounted with a crank assembly 74 having a pedal 76. The drive chain 58 also includes a rear sprocket assembly 78, which is coaxially mounted with the rear wheel 56 and a rear gear change mechanism such as a rear derailleur 80.

[0072] As shown in FIG. 1 , the front sprocket assembly 72 may include one or more coaxially mounted chain rings, gears or sprockets. In this example, the front sprocket assembly 72 has one sprocket F. The one sprocket F has teeth 82 around a respective circumference. As shown in FIG. 1 , the rear sprocket assembly 78 may include a plurality of coaxially mounted gears, cogs or sprockets G. Each sprocket G1-G11 also has teeth 84 arranged around a respective circumference. The number of teeth 84 on the rear sprockets G1-G11 may gradually decrease from the rear sprocket G1 of the largest diameter to the sprocket G1 of the smallest diameter. Although not described in detail herein, a front gear shifter may be operable to move from a first operating position to a second operating position to move the chain C between the front sprockets F. Similarly, the rear derailleur 80 may be operable to move between different operating positions to shift the chain C to a selected one of the rear sprockets G1-G11. In one embodiment, the rear sprocket assembly 78 may have more or fewer sprockets G. For example, in one embodiment, the rear sprocket assembly 78 may have twelve or thirteen sprockets. The size and configuration of the rear derailleur 80 may be modified to accommodate a plurality of sprockets for a particular implementation. For example, an angle and length of a linkage and / or a configuration of a cage of the rear derailleur 80 may be modified to accommodate a particular sprocket combination.

[0073] The rear derailleur 80 is illustrated as a wireless, electrically actuated rear derailleur that is mounted or mountable to the frame 52 or frame attachment structure of the bicycle 50. The electric rear derailleur 80 has a base member 86 (e.g., a b-knuckle) that is mountable to the bicycle frame 52. A linkage 88 has two links L that are pivotally connected to the base member 86 at a base member linkage connection portion. A movable member 90 (e.g., a p-knuckle) is connected to the linkage 88 at a movable member linkage connection portion. A chain guide assembly 92 (e.g., a cage) is assembled to engage the chain and maintain tension in the chain and has one or more cage plates 93 having a proximal end pivotally connected to a portion of the movable member 90. The cage plate 93 is rotatable or pivotable about a cage rotation axis in a damping direction and a chain tensioning direction. Other gear changing systems may also be used, such as mechanically or hydraulically controlled and / or actuated systems.

[0074] A motor module may be carried on the electric rear derailleur 80 having a battery pack 89. The battery pack 89 supplies power to the motor module. In one example, the motor module is located in the movable member 90. However, the motor module may alternatively be located elsewhere, such as in one of the links L of the linkage 88, or in the base member 86. The motor module may include a gear mechanism or transmission system. As is known in the art, the motor module and gear mechanism may be coupled to the linkage 88 to laterally move the cage plate 93 and thereby switch the chain C between the rear sprockets (e.g., G1-G11) on the rear sprocket assembly 78.

[0075] The cage plate 93 also has a distal end that carries a tensioner cog or wheel. The wheel also has teeth around a circumference. The cage plate 93 is biased in a chain tension direction to maintain tension in the chain C. The chain guide assembly 92 may also include a second cog or wheel, such as a guide wheel, disposed closer to the proximal end of the cage plate 93 and the movable member 90. In operation, the chain C is routed around one of the rear sprockets (e.g., G1-G11). An upper section of the chain C extends forward to the front sprocket assembly 72 and is routed around the one sprocket F. A lower section of the chain C returns from the front sprocket assembly 72 to the tensioner wheel and then routes forward to the guide wheel. The guide wheel guides the chain C to the rear sprockets (e.g., G1-G11). The lateral movement of the cage plate 93, the tensioner wheel and the guide wheel can determine the lateral position of the chain C for alignment with a selected one of the rear sprockets (e.g., G1-G11).

[0076] The bicycle 50 may include one or more bicycle control devices mounted to the handlebars 68. The bicycle control devices may include one or more types of bicycle control and / or actuation systems. For example, the bicycle control device may include a brake actuation system for controlling the front brake 60 and / or the rear brake 62, and / or a gear shifting system for controlling the drive chain 58. Other control systems may also be included. For example, the system may be applied to a bicycle using only a front gear shifter or only a rear gear shifter in some embodiments. In addition, the one or more bicycle control devices may also include a suspension control system for a suspension 94 (e.g., a front suspension system) of the bicycle 50, a seat post control system for a height adjustable seat post assembly 96, and / or other control systems for the bicycle 50.

[0077] Components of the bicycle 50 can be controlled via one or more control cables 100 (e.g., control cables). The control cables 100 can be various types of control cables, including, for example, cable housings, Bowden cables, hydraulic hoses, and / or electrical wires, through which various components of the bicycle 50, including, for example, the rear derailleur 80, the rear brake 62, the front suspension 94, and / or the height adjustable seat post assembly 96, are controlled.

[0078] The control cable 100 is routed into the frame 52 of the bicycle using a head assembly cable router 120. The frame 52 includes a top tube 122 and a down tube 124, which are rigidly attached to a head tube 126 of the frame 52. The front wheel 54 is rotatably attached to a fork 128, and the fork 128 is rotatably (e.g., pivotally) attached to the frame 52 (e.g., the head tube 126 of the frame 52) using a head assembly 130. The head assembly cable router 120 includes a port 132 within the head assembly 130, through which the control cable 100 is introduced into the frame 52 of the bicycle 50 (e.g., the head tube 126 and down tube 124 of the bicycle 50). At least one of the control wires 100 may be attached to the handlebar 68 at one end (eg, via a bicycle control device) and to the frame 52 or a frame component at another end.

[0079] 2-20 illustrate a first embodiment of a head assembly cable routing device 200 that can be used to route the control cable 100 into and through at least a portion of the frame 52 of the bicycle 50. Referring to FIG2 , a control assembly 202 of the bicycle 50 includes, for example, a fork 128, a head assembly 130, and a portion of the frame 52 (e.g., the head tube 126) of the bicycle 50. The fork 128 is rotatably attached to the frame 52 (e.g., the head tube 126 of the frame 52) using the head assembly 130.

[0080] The head assembly 130 includes an upper cup 204, a lower cup 206, and a head assembly cap 208. Each of the upper cup 204 and the lower cup 206 includes bearings that allow low friction rotation of the fork 128 within the frame 52 of the bicycle 50 (e.g., the head tube 126 of the frame 52). The fork 128 includes a handle tube 210 that can be positioned through the head assembly 130 and the frame 52 of the bicycle 50 (e.g., the head tube 126 of the frame 52), and a vertical bar 212 that can be fixedly attached to the handle tube 210 extending through, for example, a portion of the head tube 126 of the frame 52. The vertical bar 212 is configured to connect the handlebars 68 (not shown) to the fork 128 so that rotation of the handlebars 68 relative to the frame 52 causes the fork 128 and, thereby, the front wheel 54 to rotate relative to the frame 52.

[0081] The head assembly 130 can be attached to the frame 52 (e.g., the head tube 126 of the frame 52) in a variety of ways. For example, the upper cup 204 can be attached to a top 214 of the head tube 126, and the lower cup 206 can be attached to a bottom 216 of the head tube 126, using, for example, a top hat 218 and a fastener. The fastener can include, for example, a bolt 220 (e.g., a top hat bolt) and a nut 222 (e.g., a star nut). The star nut 222 can be positioned within the steering tube 210 of the fork 128, and the top hat 218 and top hat bolt 220 can be used to compress the head assembly 130 and the vertical bar 212 (e.g., a pivotable attachment structure) to the frame 52 (e.g., the head tube 126 of the frame 52). The top hat bolt 220 can engage with the star nut 222 in the handle tube 210 of the fork 128 to provide compression. The compression provided can be a preload for the proper function of the head assembly 130.

[0082] The head assembly cable router 200 includes: one or more ports 224 that pass through the head assembly cap 208; and a sheath 226 (e.g., a control sheath). Referring to FIG. 3, in the embodiment, as shown, the head assembly cap 208 includes two ports 224. In other embodiments, the head assembly cap 208 includes more or fewer ports 224. In the embodiment shown in FIG. 3, the two ports 224 extend through the head assembly cap 208 on opposite sides of an opening 228 through the head assembly cap 208 through which the control tube 210 of the fork 128 extends. In other embodiments, the ports 224 may extend through the head assembly cap 208 and be adjacent to each other at a front portion (e.g., toward a front portion of the vertical bar 212) or a back portion (e.g., toward a back portion of the vertical bar 212) of the head assembly cap 208.

[0083] The handle cover 226 is disposed around the handle tube 210 of the fork 128 and disposed within the head tube 126 of the frame 52. In other words, the handle cover 226 covers at least a portion of the handle tube 210 that is disposed within the head tube 126 of the frame 52 (e.g., rotatable therein).

[0084] In the embodiment shown in FIG. 3 , the head assembly cable router 200 also includes a play 230 (e.g., an upper cup play) in the upper cup 204. The upper cup play 230 allows radial and rotational play for the control wire 100 to move freely as the fork 128 and thus the steering tube 210 of the fork 128 rotate relative to the frame 52 of the bicycle 50. The upper cup play 230 can be configured in a variety of different ways. For example, the upper cup play 230 can be formed by a bevel at and near an inner edge 231 (e.g., inner circumferential edge) of the upper cup 204.

[0085] FIG3 shows an example installation of the control line 100. The control line 100 extends through the port 224 in the head assembly cap 208, through the upper cup clearance 230 and along an outer surface of the control member boot 226.

[0086] 4-7 show the components of the assembled control assembly 202 and the routing of the control wires 100 through the ports 224 through the head assembly cap 208 into the frame 52 of the bicycle 50. A first control wire 100a and a second control wire 100b are routed through the vertical bar 212 on opposite sides of the vertical bar 212 and into the ports 224 in the head assembly cap 208. The bicycle 50 shown in the embodiment of FIGS. 4-7 includes two control wires 100a, 100b extending through the head assembly cap 208. In other embodiments, more (e.g., three or more) or fewer (e.g., one) control wires may extend through the head assembly cap 208 into the frame 52 of the bicycle 50.

[0087] 8 and 9, the head assembly cable router 200 can facilitate routing of the control wires 100 through the steering assembly 202 and into, for example, the down tube 124. In another embodiment, the head assembly cable router 200 facilitates routing of the control wires 100 through the steering assembly 202 and into the top tube 122. In yet another embodiment, the head assembly cable router 200 facilitates routing of some control wires 100 into the top tube 122 and facilitates routing of some control wires 100 into the down tube 124.

[0088] The control wire 100 exits the handlebar 68 (not shown) from one or more control devices (e.g., for brakes, shifters, sensors), extends along opposite sides of the vertical bar 212, and enters the port 224 of the head assembly cap 208. The control wire 100 passes through the upper cup clearance 230, through a volume 240 between the control boot 226 and an inner wall 242 (e.g., an inner surface) of the head tube 126 of the frame 52, and enters the down tube 124 of the frame 52 of the bicycle 50, for example.

[0089] The control sheath 226 creates a low friction barrier between the control tube 210 of the fork 128 and the control line 100. The control sheath 226 can be made of a variety of materials, including, for example, plastic, polytetrafluoroethylene (PTFE), carbon fiber, polymer, an elastomeric material, a smooth metal, or another material. A wet or dry lubricant can be applied to an outer surface of the control sheath 226. In one embodiment, the control sheath 226 is formed by a coating on the control sheath 226. For example, the control sheath 226 can be a hard flame sprayed ceramic of a soft tough polymer.

[0090] The control boot 226 may be fixedly or rotationally attached to the upper cup 204, the lower cup 206, or both the upper cup 204 and the lower cup 206 of the head assembly 130. The control boot 226 may be attached to the upper cup 204 and / or the lower cup 206 of the head assembly 130 in a variety of ways, including, for example, with an adhesive. In one embodiment, a soft interface (e.g., as a tolerance ring) disposed between the bearings of the upper cup 204 and / or the lower cup 206 of the head assembly 130 and the control tube 210 of the fork 128 may be used to secure the control boot 226 to the head assembly 130. With the control boot 226 in place, the control wire 100 is unable to rub or wear the control tube 210 of the fork 128.

[0091] In the embodiment shown in FIGS. 10-13 , the handle boot 226 is attached to the lower cup 206 of the head assembly 130 . The handle boot 226 may be thin walled (e.g., 4 mm, 5 mm, 8 mm, or 10 mm). The handle boot 226 may be a variety of shapes. For example, the handle boot 226 may be a hollow cylinder, although other shapes may be provided. In the embodiment shown in FIGS. 10-13 , the handle boot 226 is tapered and closely offset from the handle tube 210 of the fork 128 to maximize radial play and access to the head tube 126 . In another embodiment, the handle boot 226 is non-tapered and / or contacts the handle tube 210 of the fork 128 .

[0092] 14-16, when the first control line 100a and the second control line 100b enter the port 224 through the head assembly cap 208 on opposite sides of the vertical bar 212, the first control line 100a and the second control line 100b are wrapped around the control member cover 226 and exit the head tube 126 (e.g., enter the lower tube 124 of the frame 52) toward the rear of the head tube 126 (e.g., in a direction away from the vertical bar 212). In one embodiment, the first control line 100a and the second control line 100b may be wrapped around a front portion of the control member cover 226 (e.g., a portion of the control member cover 226 facing away from the top tube 122 and the down tube 124 of the frame 52 of the bicycle 50) one or more times before exiting the head tube 126 toward the rear of the head tube 126. In another embodiment, the first control line 100a and / or the second control line 100b enters the back of the head assembly cap 208 toward the vertical rod 212, and the first control line 100a and / or the second control line 100b can leave the head tube 126 without wrapping around the control member cover 226.

[0093] Referring to FIGS. 17-20 , the handle sheath 226 may have a smooth outer wall. However, in another embodiment, an outer surface 244 of the handle sheath 226 may include a curved or spiral channel to hold the control wire 100 in place. The handle sheath 226 of the embodiment of FIGS. 17-20 has a closed tube geometry. However, in another embodiment, the handle sheath 226 has an opening or a seam along a length of the handle sheath 226 for ease of installation.

[0094] The operating member sheath 226 can be flexible or rigid. In one embodiment, the operating member sheath 226 is made of an injection-molded polymer, wherein the text instructions are on the outer surface 244 of the operating member sheath 226.

[0095] 21-35 illustrate a second embodiment of a head assembly cable routing device 300 that can be used to route the control cable 100 into and through at least a portion of the frame 52 of the bicycle 50. Referring to FIG. 21 , the steering assembly 202 of the bicycle 50 includes, for example, the same components (e.g., the fork 128, the head assembly 130, and a portion of the frame 52 of the bicycle 50 (e.g., the head tube 126)). The fork 128 is rotatably attached to the frame 52 (e.g., the head tube 126 of the frame 52) using the head assembly 130.

[0096] 22, head assembly cable router 300 includes the same components as head assembly cable router 200, except that one or more wire sheaths 302 replace the control member sheath 226. In the embodiment shown in FIG3, control wires 100 extend through ports 224 in head assembly cap 208 and through upper cup clearance 230. However, in the embodiment shown in FIG22, control wires 100 extend through respective wire sheaths 302, rather than along an outer surface of the control member sheath 226 as shown in the embodiment of FIG3.

[0097] In one embodiment, the head assembly cable routing device 300 includes both the wire sheath 302 of the embodiment shown in Figures 21-35 and the control member sheath 226 of the embodiment shown in Figures 2-20. In this configuration, the control wire 100 is installed through the wire sheath 302, and the wire sheath 302 extends through the head tube 126 of the frame 52 of the bicycle 50 outside the control member sheath 226.

[0098] 23 and 24, the wire sheath 302 on the control wire 100 acts as a low friction barrier between the handle tube 210 of the fork 128 and the control wire 100. The wire sheath 302 can be made of a variety of materials, including, for example, plastic, Teflon, carbon fiber, polymer, an elastomeric material, a smooth metal, or another material. A wet or dry lubricant can be applied to the outer surface of the wire sheath 302, respectively. The wire sheath 302 can be fixedly or rotationally attached to the upper cup 204, the lower cup 206, or both the upper cup 204 and the lower cup 206 of the head assembly 130. The wire sheath 302 can be attached to the upper cup 204 and / or the lower cup 206 of the head assembly 130 in a variety of ways, including, for example, with an adhesive. With the wire sheath 302 in place, the control wire 100 cannot rub or wear the handle tube 210 of the fork 128.

[0099] 25-28, the wire guard 302 acts as a barrier to rotation of the steering tube 210 of the fork 128 relative to the frame 52 of the bicycle 50. The wire guard 302 can be of various sizes and / or shapes. For example, the wire guard 302 can be a hollow cylinder, although other shapes can be provided. The wire guard 302 can have a length long enough to enter the down tube 124 and / or the top tube 122, and / or enter the upper cup clearance 230 for added protection. The wire guard 302 can have various wall thicknesses (e.g., 4 mm, 5 mm, 6 mm).

[0100] 29-31, the cup clearance 230 on the head assembly cable router 300 allows radial and rotational play for the control cable 100 with the cable guard 302 to move freely as the control tube 210 of the fork 128 rotates relative to the frame 52 of the bicycle 50. The control cable 100 may enter the head assembly cap 208 through the port 224 on the opposite side of the stem 212, or may enter the head assembly cap 208 toward the front or back of the stem 212. The control cable 100 with the cable guard 302 is wrapped around the control tube 210 of the fork 128 to exit the head tube 126 of the frame 52 of the bicycle 50 toward the rear. In one embodiment, the control cable 100 with the cable guard 302 may be wrapped around the front of the control tube 210 of the fork 128 one or more times before exiting the head tube 126 of the frame 52 of the bicycle 50 toward the rear.

[0101] Referring to FIGS. 32-35 , a wire sheath 302 may have a smooth outer wall. The wire sheath 302 is shown as having a straight profile, but may be configured to have a curvature or a type of spiral shape to best fit in place. The wire sheath 302 of the embodiment of FIGS. 32-35 has a closed tube geometry. However, in another embodiment, the wire sheath 302 has an opening or a seam along a length of the wire sheath 302 for ease of installation.

[0102] The wire sheath 302 can be flexible or rigid. In one embodiment, the wire sheath 302 is made of an injection molded polymer, wherein the text description is tied on an outer surface 306 of the wire sheath 302.

[0103] Although specific control devices, bicycles, and methods have been described herein according to the teachings of the present disclosure, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the present disclosure teachings that fully fall within the scope of permissible equivalents.

[0104] The examples of the embodiments described herein are intended to provide a general understanding of the structures of the various embodiments. The examples are not intended to serve as a complete description of all elements and features of the devices and systems that utilize the structures or methods described herein. Many other embodiments will be apparent to those skilled in the art after reviewing the present disclosure. Other embodiments may be utilized and derived from the present disclosure so that structural and logical substitutions and changes may be made without departing from the scope of the present disclosure. Additionally, the examples are representative only and may not be drawn to scale. Certain proportions in the examples may be magnified, while other proportions may be minimized. Accordingly, the present disclosure and the drawings are to be considered illustrative rather than restrictive.

[0105] Although this specification contains many details, these should not be construed as limitations on the scope of the invention or what may be claimed, but rather as descriptions of features of specific embodiments of the invention. Certain features described in this specification in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented in multiple embodiments individually or in any suitable subcombination. Furthermore, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination may in some cases be deleted from that combination, and the claimed combination may be directed to a subcombination or a variation of a subcombination.

[0106] Similarly, although operations and / or actions are illustrated in the drawings and described herein in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed to achieve the desired results. In some cases, multiplexing and parallel processing may be advantageous. Furthermore, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that any of the described program components and systems may be generally integrated together in a single software product or packaged into multiple software products.

[0107] The term "invention" may be used herein to refer to one or more embodiments of the present disclosure individually and / or collectively, which is for convenience only and is not intended to voluntarily limit the scope of this application to any particular invention or inventive concept. Furthermore, although specific embodiments have been illustrated and described herein, it should be understood that any subsequent configuration designed to achieve the same or similar purpose may replace the specific embodiment shown. This disclosure is intended to cover any and all subsequent adaptations or variations of the various embodiments. Combinations of the above embodiments and other embodiments not specifically described herein will be apparent to those skilled in the art after reviewing this description.

[0108] The Abstract of the Disclosure is presented to comply with 37 CFR §1.72(b), with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing detailed description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure should not be interpreted as reflecting an intention that the claimed embodiments require more features than those expressly recited in each claim. Rather, as the following claims reflect, the subject matter of the invention may be directed to less than all features of any of the disclosed embodiments. Therefore, the following claims are incorporated into the detailed description, with each claim standing alone as a separately defined claimed subject matter.

[0109] It is intended that the foregoing detailed description be regarded as illustrative rather than limiting, and it should be understood that the following claims, including all equivalents, are intended to define the scope of the invention. The claims should not be construed as limited to the order or elements described unless stated to that effect. Therefore, all embodiments that fall within the scope and spirit of the following claims and their equivalents are claimed as the present invention.

[0110] 50: Bicycle 52: Bicycle frame, frame 54:Front wheel 56: Rear wheel 58: Drive chain 60:Front brake 62: Rear brake 64: Seat 66: Seatpost 68: flat handle, handle 70:Brake lever 72:Front sprocket assembly 74: Crank assembly 76: Pedal 78: Rear sprocket assembly 80: Electric rear derailleur, rear derailleur 82,84: teeth 86: Base member 88: Connecting rod assembly 89:Battery Pack 90: Movable member 92: Chain guide assembly 93: Cage plate 94: Front suspension, suspension 96: Height adjustable seat post assembly 100: Control line 100a: first control line, control line 100b: second control line, control line 120,200,300: Cable routing device for head unit 122: Pipe Top 124: Down tube 126: Head pipe 128: Fork 130: Front assembly 132,224: Port 202: Control assembly 204: Upper cup-shaped part 206: Lower cup-shaped piece 208: Front assembly cap 210: Operating tube 212: Vertical bar 214: Top 216: Bottom 218: Top hat cover 220: Top hat bolt, bolt 222: Star nut, nut 226: Control cover, cover 228: Opening 230: Upper cup clearance, clearance 231: Inner edge 240: Volume 242: Inner wall 244,306: External surface 302: Wire sheath AA,BB,CC,DD,EE,FF: axis C:Chain F:Front sprocket, sprocket G: Sprocket G1-G11: Rear sprocket, sprocket L: Connecting rod X: Arrow

Claims

1. A control line wiring harness for a head assembly of a bicycle, comprising: a barrier disposed within a head tube of the bicycle between a section of the bicycle assembly and a control line.

2. The control line wiring device as requested in item 1, wherein the barrier is flexible.

3. The control line wiring harness of claim 1, wherein the component of the bicycle is a control tube of a fork, and the barrier assembly is configured to at least partially surround the control tube.

4. The control line wiring device as claimed in claim 3, wherein the obstruction is a tapered tube offset from the control tube, the tapered tube being configured such that the tapered tube does not contact the control tube.

5. The control line wiring device as claimed in claim 3, wherein the obstruction is attached to either or both of the upper cup-shaped part and the lower cup-shaped part of the head assembly of the bicycle.

6. The control line wiring device as requested in item 3, wherein the obstruction contacts the control tube.

7. The control line wiring device as claimed in claim 1, wherein the barrier assembly is configured to surround the section of the control line.

8. The control line wiring device as claimed in claim 7, wherein the obstruction extends into a top pipe, a bottom pipe, a vertical rod, a fork, or any combination thereof.

9. The control line wiring device as requested in item 1, wherein the obstruction has an annular cross-section.

10. The control line wiring device of claim 9, wherein the barrier includes a seam along one length of the barrier.

11. The control line wiring device of claim 1, wherein the obstruction comprises: an operating tube sheath configured to at least partially surround an operating tube of a fork; and a control line sheath configured to at least partially surround the section of the control line.

12. The control line wiring device of claim 1, wherein the barrier is made of one or a combination of the following: a plastic, a polymer, a carbon fiber composite, a composite, PTFE, an elastic material, or a metal.

13. The control line wiring device of claim 12, wherein the barrier has an outer wall including a friction-reducing coating, wherein the friction-reducing coating comprises any one or a combination of a PTFE coating, a wet lubricant, or a dry lubricant.

14. The control line router of claim 1, the control line router further comprising a cap, an operating tube of a fork extending through the cap, the cap having one or more ports extending through the cap, wherein the control line extends through the cap via the one or more ports.

15. The control line router of claim 14, the control line router further comprising an upper cup-shaped member having a clearance, which is configured to allow radial and / or rotational clearance of the control line.

16. The control line wiring device as requested in item 1, wherein the control line is a hydraulic hose or a sheathed cable.

17. A device for a bicycle, comprising a barrier disposed between one or more components in a head tube of the bicycle.

18. The apparatus of claim 17, wherein one of the one or more components is a fork of a control tube, and the barrier assembly is configured to surround a section of the control tube.

19. The apparatus of claim 17, wherein one of the one or more components is a control line, and the barrier assembly is configured to surround a section of the control line.

20. The device of claim 17, wherein the barrier comprises at least two sheaths, wherein a first sheath is configured to surround a section of an operating tube of a fork, and a second sheath is configured to surround a section of a control line.

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