Device for protecting bicycle brake rotors and other components

Abstract

A device is disclosed that can be used for protecting disc brake rotors 1 such as those commonly found on modern bicycles while the wheels are removed from the bicycle frame for transport or storage or while the rotors are removed from wheels. The protection device offers a degree of isolation from contact, impact or other loading that would otherwise cause damage to the disc brake rotor 1 by bending, scratching, notching or contaminating it, thus diminishing its performance or rendering it unfit for use. Embodiments of the device are described wherein a main guard flange 100 is applied to the outward facing side of the disc brake rotor, thus substantially guarding it from contact with other objects while the wheel is not installed in a bicycle frame. Importantly, a planar separation between the inward facing aspect 20 of the main guard flange 100 and the outer parts of the disc brake rotor, particularly the braking surface 12 is created by a standoff structure 21 that is pressed and held onto the robust part of the disc brake rotor 1 near its central axis, where is strongest and supported by the robust mounting flange 8 features of the bicycle wheel hub 3 by way of a tensioning axle 31 that extends all or part of the way through the axle bore 10 of the wheel hub assembly 3. Accompanying parts of embodiments are also described that provide a complete assembly of parts for front and rear wheels in a single set and perform the added function of a durable transport mounting for disc brake rotors when they are not installed so that they are substantially isolated from each other and from external objects that may damage or contaminate them. Parts of embodiments of the invention are also disclosed to protect objects from damage by the drive cog or cog assembly 18 on the rear wheel of a bicycle while it is removed from the bicycle. Particular embodiments of the invention are also described that incorporate suitable rotor tooling 68 to facilitate the efficient removal and installation of disc brake rotors 1.

Description

[0001] AUSTRALIA

[0002] PATENTS ACT 1990

[0003] SPECIFICATION FORAN INVENTION ENTITLED:-

[0004] "DEVICE FOR PROTECTING BICYCLE BRAKE ROTORS AND OTHER COMPONENTS"

[0005] This invention is described in the following statement:- TECHNICAL FIELD

[0006] The present invention relates generally to the protection of brake rotors from contact with other objects and specifically to the protection from impact that may cause physical damage, warping or contamination of the braking surface.

[0007] BACKGROUND

[0008] In the evolution of modern bicycles, led by the increased needs for powerful braking encountered in the sport or pastime of mountain bike riding, modern bicycles of many types are equipped with disc brakes. The disc brakes are akin to those that have been used on motorbikes and cars for many decades. Such disc brakes have become nearly ubiquitous on modern bicycles, owing to the increased safety and reduced maintenance compared with other forms of brakes such as rim brakes or drum brakes. Disc brakes function by incorporating a thin (1.5 - 2.5 mm) disc of metal that is affixed concentrically and to one side of the wheel hub. In this manner, the rigid disc structure, that is typically in the diameter range 100 mm - 220 mm turns in unison with the wheel in a plane-parallel manner around the same axis of rotation as the wheel and wheel hub. The entire rotating structure, which may be a single piece or made of several pieces is known collectively as the brake "rotor”. In all cases, the 1.5-2.5 mm outer part of the rotor passes between two opposing brake "pads” that are mounted in a brake "caliper”. Through the operation of a brake lever that is generally mounted on the handlebars of the bicycle, the rider is able to operate the caliper. In doing so, the rider uses the braking system to simultaneously supply opposing force to each of the brake pads in a direction perpendicular to the plane of the rotor. The brake pads are consequently forced into contact with the outer part of the brake rotor, known as the "braking surface”. The brake caliper is resiliently mounted to the frame of the bicycle such that the friction force between the brake pads and the braking surface is resisted by the brake caliper mounting, and the resulting tangential force on the brake rotor rotating about its axis acts against the direction of rotation and is used to decrease the speed of the bicycle or prevent the wheel from rotating with respect to the bicycle frame altogether.

[0009] The disc of metal or another material is often, but not always, strengthened toward the centre of the disc structure by the use of a thicker section of metal, allowing for more robust fitment to the supporting hub structure. For a single-piece structure, the disc itself is known as the brake "rotor”. For instances where the disc structure is comprised of several parts, the entire assembly is known as the brake "rotor”. Herein the term disc brake rotor is used to describe both single piece rotors and rotor assemblies made from a plurality of components.

[0010] The gap between the opposing brake pads and the braking surface of the rotor is very narrow, usually in the range 0.1 - 0.8 mm or thereabouts. This means that the braking surface part of the brake rotor must be substantially co-planar, so that as it passes through the space between the brake pads as the wheel turns, the space between the brake pad and the braking surface on each side of the rotor is maintained. Since the gap is small, a commensurate deviation from planarity (a slight bend) in the rotor will lead to interference and friction that opposes the tangential motion of the braking surface against the brake pad. This results in a drag force that impedes bicycle performance and produces noise that is an annoyance. In cases where the brake rotor is significantly deformed or notched, the bicycle may be rendered not usable or not safe for use.

[0011] Structure of rotor is strong through the thin plane of the rotor in order to withstand significant tangential braking loads. However, brake rotors are poorly resistant to lateral loads, that is, in any direction other than tangential to the plane of the rotor and tangential to the circular shape. This makes brake rotors highly susceptible to damage. During the use of the bicycle, rotor damage is rarely of concern, since it is relatively unlikely they will be impacted. This is due to their position on the bicycle and the protection that is offered by the bicycle forks at the front wheel and the bicycle frame at the back wheel. For further protection in use, if desired, commercial fork-mounted brake rotor protectors are available to protect the front part of the front brake rotor from impacts. These are often used in motorsports such as motocross.

[0012] The current disclosure relates to protection for brake rotors when the bicycle is not in use. It is common for cyclists of all types to deliberately transport their bicycle to a riding destination using a car, airline, or another form of transport Bicycle transport is performed routinely by both recreational and competitive cyclists. Very frequently, this involves some form of dismantlement of the bicycle so that it can fit into a transporting vehicle or into a specialised bicycle transport case. Examples of this practice may be simply removing one or both wheels of a bicycle to fit it in the back of a small car or to racks mounted to the roof of a car. Alternatively, both wheels may be removed for stowage in a bicycle transport bag for air transport to a cycling destination. In either case, the separation of the wheel from the frame results in the full brake rotor that is attached to the wheel becoming exposed and more susceptible to damage. This is especially so, since the loads applied to the stowed wheel, whether in the back of a car or in a travel bag are unlikely to be purely tangential to the braking surface, where the rotor is most strong. In transit or stowage while the wheel is not installed on the bicycle, the impinging loads to the brake rotor are more likely to be in a direction normal to the plane of the rotor. In practice, this causes brake rotors to become deformed out of plane, that is, they are no longer flat. The braking surface may also incur impact damage by another hard object, often another part of the stowed bicycle or a bicycle tool causing a scratch, a notch or other type of plastic deformation of the braking surface. This damage may be cosmetic, or it may impact the braking performance of the rotor. While the bicycle is stowed, the braking surface may also make contact with one of the many sources of lubricated / greased surfaces on a bicycle such as the chain, or other mechanical paraphernalia associated with the sport of cycling and bicycle maintenance. Contamination of the braking surface with oils or grease leads to contamination of the brake pads upon reinstallation of the wheel, which causes dangerously reduced braking performance that may remain until the brake pads are replaced.

[0013] With only very slight bending of the brake rotors, the deformed part of the rotor will become decentralised in the gap between the brake pads within the caliper. This causes a rubbing sound each time the part of the rotor that is deformed out of plane passes through the caliper. This causes annoyance, drag and impacts the braking performance. In more severe cases, the deformation may be so great that it prevents the wheel and rotor from being properly re-installed on the bicycle, or the rotor may interfere with the brake caliper body, causing further damage to the rotor and to the expensive caliper body. The most severe impacts to a brake rotor during transport may result in fracture of some part of the brake rotor or rotor assembly, making the bicycle dangerous.

[0014] In some cases, rotor truing tools can be used by expert bicycle mechanics or other skilled person to correct the deformation by bending it back into plane or filing and sanding notches and gouges that affect braking performance. Each of these corrective actions impedes upon the time available for the bicycle rider to ride the bicycle, since if the rider has sufficient skills and the right tools to repair the damage, they will be delayed in using the bicycle upon re-assembly or they will have to find a mechanic with the suitable skills and tools to be able to perform the repair. The subsequent riding experience is subsequently dependent on the quality of repair, and repeated repair is likely to decrease the strength of the rotor through stress-hardening, fatigue, or undetected fracture of some parts of the rotor. Avoidance of these problems is clearly beneficial.

[0015] Some specialised bicycle transport baggage manufacturers incorporate stiffened structures into the fabric construction of the wheel compartments to reduce the likelihood of damage to the disc brake rotors while bicycles are in transit Such structures do increase the degree of protection; however, they are prone to fail to protect disc brake rotors during heavy handling or impacts sustained in challenging environments such as airports, baggage handling, or in transport trailers, for example, that are often driven over very rough terrain to access remote cycling destinations.

[0016] Another aspect of transporting bicycles with one or more wheels removed, is that in addition to the disc brake rotors being susceptible to damage, the other parts of the bicycle are prone to damage by the disc brake rotor, which is most often a hard, metallic surface. This is of particular concern to bike frames constructed from carbon fibre, where scratching and gouging can be deleterious to the integrity and performance of the frame through creating scratches or gouges that lead to dangerous stress concentrations in the material. This makes the frame more prone to cracking. The effect may be dramatic and dangerous dependent on the scale and location of the damage, along with the construction material and engineering tolerances of the frame. In transport, the hard mounting surfaces of the axle spindle are also exposed which may also be damaged themselves or (more likely) cause damage to another part of the bicycle by knocking against it, concentrating a lateral load applied to a bike bag into a small region et cetera. The hard drive cogs or multiple cog assemblies often referred to as "cassettes,” or "clusters” attached to the rear wheel of bicycles is another source of mechanical damage and contamination to bicycle frames and other objects while the rear wheel is uninstalled, and likely in transit

[0017] In light of the many reasons presented, the advice of most bicycle mechanics as "best practice” is to remove brake rotors prior to transport This is indeed an effective way to protect the rotors from damage, provided they can adequately stowed in another form of containment that facilitates their transport. However, this practice requires the correct tools and skills to perform the removal and safe re-installation of the rotors. This may require access to a skilled bicycle mechanic at both the origin and destination and requires significant effort and time regardless of who performs the task. While relatively easy to avoid for a skilled person, there is an inherent risk of contamination of the braking surface with oil from the fingers or elsewhere any time the rotors are removed or installed.

[0018] There is clear and unmet need for a device that can be easily mounted by a relatively unskilled person to provide protection of brake rotors from substantial stress, impact damage or other form of plastic deformation while they remain mounted in place on the bicycle wheel. At the same time there is a need for a device to provide some protection of the brake rotors from accidental contact with lubricated parts of the bicycle or other objects that may cause contamination of the braking surface. There is also a need to provide a means of protection for the bicycle frame or other bicycle parts from damage by the brake rotors, the hard axle spindles, the gearing parts (rear cassette / sprockets / cogs et cetera) while the wheels are not installed in the bicycle frame and not "in use”. There is an additional need for a resilient device that may be used as a means of protecting brake rotors that have been uninstalled from the wheel from impacts, bending loads or incidental contamination by oils while in transit or otherwise not installed on a bicycle and to facilitate rotor removal and or re-assembly.

[0019] The invention disclosed herein is designed generally to provide protection to the disc brake rotors. Particularly, the present disclosure is designed to protect bicycle brake rotors from damage that may occur in transit when the wheel is removed from the bicycle while limiting damage to other parts of the bicycle such as the frame, by the disclosed device, the disc brake rotors themselves, or other hard axle or gearing parts associated with the bicycle wheel. SUMMARY

[0020] The present disclosure relates to products and methods for guarding the brake rotors of bicycle or other wheels while the wheels and brake rotors are separated from the bicycle.

[0021] In certain uses of the disclosed device, the guard device is fixed via a resilient mount to the outward facing side of the disc brake rotor 1 while the wheel is removed from the bicycle.

[0022] In embodiments of the device, a disc structure that is plane-parallel and concentric to the disc brake rotor 1 incorporates a means to resiliently fix the device in place to the outward facing side of the disc brake rotor 1 by a means that engages with the strong, central part of the disc brake rotor 1 close to the axis of rotation where it is mounted to the bicycle wheel hub assembly.

[0023] Herein, the part of the embodiment of the invention that is substantially a flat disc structure that is plane-parallel and concentric to the disc brake rotor 1 will be referred to as the "main guard flange 100”.

[0024] Certain embodiments of the invention incorporate a mgf and a means to resiliently fix the main guard flange 100 in place to the outward facing side of the disc brake rotor 1 by a means that engages with the axle bore that extends from one side of the wheel to the other.

[0025] In certain embodiments of the device, the means of resiliently fixing the main guard flange 100 to the disc brake rotor 1 and hub structure is by means of a tensioning axle that extends from the outward-facing side of the main guard flange 100 through the wheel axle bore to the other end of the bore, engaging with the face perpendicular to the axis of the bore on the opposite side of the wheel to the disc brake rotor 1 and main guard flange 100.

[0026] In alternate embodiments of the invention, the means of fixing the main guard flange 100 to the outward facing part of the disc brake rotor 1 and robust rotor mounting flange of the wheel hub assembly is by a tensioning axle that engages with the inner bore surface of the wheel axle bore. Alternatively, the main guard flange 100 may incorporate features that engage directly with the disc brake rotor 1 robust mounting flange 8.

[0027] In certain embodiments of the device, the diameter of the predominantly disc-shaped main guard flange 100 is at least as large as the diameter of the brake rotor to which it is applied. In this way, the radial protrusion of the disc brake rotor 1 in planar proximity to the outer circumference of the disc brake rotor 1 provides a means of mechanical interference to substantially prevent contact of the disc brake rotor 1 with contaminating surfaces or other objects that may damage the outer part of the rotor in the radial direction. The extent of the radial protection offered by the embodiment of the invention is improved by increasing the extent to which the main guard flange 100 exceeds the radius of the disc brake rotor 1. For similar geometric reasons, the radial protection offered by the embodiment of the invention is improved as the separation between the plane of the disc brake rotor 1 and the plane of the main guard flange 100 decreases.

[0028] In certain embodiments of the device, a protrusion at the outer circumference of the main guard flange 100 may extend in an axial direction away from the inward-facing surface of the main guard flange 100 as a lip structure that overlaps with the brake rotor. In this way, the outer perimeter of the disc brake rotor 1 is further enclosed and the extent of protection is increased.

[0029] In certain embodiments of the device, a standoff structure positioned close to the robust supporting flange near the axis of rotation protrudes towards the brake rotor face. In this way, the axial load created by the tensioning axial structure is borne exclusively by the standoff structure, thus concentrating the distribution of load imposed by the tensioning axle to the region of the disc brake rotor 1 close to its axis and in close proximity to the support offered by the disc brake rotor 1 mounting structures of the wheel hub. Importantly, in this manner, the outer part of the inward- facing surface of the main guard flange 100 is separated from the outward- facing surface of the disc brake rotor 1. In such embodiments of the device, the planar clearance space between the main guard flange 100 and the disc brake rotor 1 created by the standoff structure increases the degree of protection against mechanical loads applied in the direction normal to the plane of the disc brake rotor 1 and main guard flange 100. The presence of the planar clearance space provides a means of accommodating some deflection of the main guard flange 100 in response to the application of a normal load without the inner face of the main guard flange 100 contacting the disc brake rotor 1. The elastic deflection out of plane of the main guard flange 100 provides a resisting force to the applied load without transfer of that load to the outer part of the disc brake rotor 1, particularly the braking surface. Instead, the load that would be applied to the disc brake rotor 1 in the absence of the main guard flange 100 is distributed via the main guard flange 100 to the robust central part of the disc brake rotor 1 via the standoff structure. A large load can be borne by the central part of the disc brake rotor 1, since it is supported by the robust disc brake rotor 1 mounting features of the wheel hub assembly.

[0030] In certain embodiments of the disclosed device one complete assembly of an embodiment of the invention may be fixed to another complete assembly of an embodiment of the invention by way of features designed to tether the two sets together in a single assembly that is easy to store and transport. In this manner, complete sets of all parts for front and rear wheels are efficiently encased in one complete assembly.

[0031] In other embodiments of the invention, a disc brake rotor 1 mounting boss may be incorporated with a pair of main guard flange 100s to provide a resilient storage structure for disc brake rotors 1 that have been removed from the bicycle wheel. In such an embodiment of the invention, the mounting boss is ideally comprised of a concentric disc brake rotor 1 mounting boss with an outside diameter substantially the same as the internal wheel mounting diameter of the disc brake rotor 1, a flange or similar structure to maintain separation between two disc brake rotors 1, a substantially concentric boss structure to locate the mounting boss at the central axle inner ring clearance hole and a means of fastening the mounting boss and supported disc brake rotors 1 together into a robust single assembly. Such an embodiment of the invention provides a means of transporting disc brake rotors 1 if they are not fitted to the bicycle wheel. Disc brake rotors 1 are fixed in place on a bicycle wheel by a limited number of industry standard retaining mechanisms designed to resiliently fix the disc brake rotor 1 to the mounting surfaces of the wheel hub. Examples of such standard retaining mechanisms are a spline fitting at the centre of the disc brake rotor 1 slides onto a reciprocal spline on the wheel hub. The disc brake rotor 1 is then retained axially by means of a threaded flange with standardised dimensions. Such a mechanism is commonly known as a "centrelock” mechanism. Another standard disc brake rotor 1 mounting standard is comprised of 6 equally spaced screw fasteners that are passed through clearance holes concentrically arranged on the same radius around 20 mm from the axis of the rotor, engaging with reciprocal female screw threads in a robust mounting flange of the wheel hub. Such a mounting mechanism is commonly known as a "6-bolt mounting”. In certain embodiments of the invention, it is envisaged that at least one part of the assembly comprises a tool that may be used to facilitate the removal of disc brake rotor 1 mounting fixtures. An example of such an embodiment is a male or female spline tool accommodated into the body of the embodiment of the invention to facilitate centrelock fixing removal and re-installation. In this way, the embodiment of the invention provides a means of removing, storing and reinstalling disc brake rotors 1.

[0032] In certain embodiments of the invention, the key standoff structure that provides a planar clearance space between the inward facing surface of the main guard flange 100 and isolation of normal loads placed on the main guard flange 100 to the robust mounting flange of the wheel hub is formed in such a way that it may be fitted to any of the standardised disc brake rotor 1 mounting mechanisms without compromising the function of the standoff structure or the embodiment of the invention. For example, the depth and shape of the standoff structure is such that the screw-heads of a 6-bolt mechanism are accommodated by reciprocal clearance recesses in the standoff structure, distributing axial load to the intervening space and the areas of the disc brake rotor 1 immediately surrounding the fasteners. Similarly, a larger diameter concentric standoff recess is provided around the axis of the standoff structure so that a centrelock fixing flange is accommodated. In use, the load bearing surface that transfers load from the main guard flange 100 to the robustly supported region at the centre of the disc brake rotor 1 may be the inward facing surface of the standoff structure 21, or it may be the inward facing surface of the standoff recess 23, whereby the load is transferred to the outward facing surface of the centrelock mounting flange, or to the outer prominence of the 6-bolt mounting screw 7 heads.

[0033] The disc brake rotor 1 is typically mounted to the opposite side of the bicycle where the drive mechanisms such as cogs, chanins, chainrings and gearing systems are found. Such drive mechanisms are almost ubiquitously found on the right-hand side of the bicycle from the point of view of the rider. This right-hand side of the bicycle is known as the "drive-side”, and the other side, where the braking mechanisms are found is known as the "non-drive-side”. In certain embodiments of the invention, the tensioning axle is comprised of two parts with slightly different shape to provide a main guard flange 100 retention mechanism with one part particularly suited to the non-drive side of the wheel and the other part particularly suited to the drive side of the wheel. In another embodiment of the invention, a separate guard structure is provided for the purpose of covering the drive cog or cogs that are attached to the wheel hub of the rear wheel. The teeth of such drive cogs typically have hard, sharp edges that are coated in lubricants. The provision of a guard that covers the outward-facing surface of the rear-wheel drive cogs provides a means of preventing contact of the drive cogs with other nearby bicycle parts in transit, thereby preventing impact or abrasion damage to other parts of the bicycle, or their contamination by grease. Such an embodiment of the invention also provides protection from soiling or mechanical damage to nearby objects such as a transporting vehicle or case.

[0034] It is envisaged that embodiments of the disclosed invention are made primarily from a material that provides sufficient toughness to resist the typical loads that may be reasonably imposed on a bicycle wheel in transit It is envisaged that the materials used for different parts of embodiments of the invention differ, depending on their use; however, it is envisaged that the main guard flange 100 part of the disclosed invention would be typically made primarily from a robust polymer such as polyethylene, nylon, polylactic acid, polymethylmethaciylate or other engineering polymers capable of being thermoformed or injection moulded. It is also envisaged that the main guard flange 100 and other parts of the embodiment of the invention may be formed from metals, timber or timber-based products or engineering composites such as carbon fibre or other fibre- reinforced polymer materials. The descriptions and examples of embodiments of the disclosed device are intended to provide examples of several different embodiment of the invention that can be readily manufactured with simple or standard manufacturing techniques and in a cost-effective manner. It is appreciated that the design of any particular embodiment of the invention or part of an embodiment of the invention may be changed to suit many manufacturing methods obvious to those skilled in the art without departing from the function or mechanisms of the device or devices disclosed.

[0035] BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

[0036] Certain embodiments of the invention are illustrated by the following figures. It is to be understood that the following description is for the purpose of describing particular embodiments only and is not intended to be limiting with respect to the description.

[0037] Figure 1 shows a perspective illustration of a bicycle wheel with a disc brake rotor 1 installed;

[0038] Figure 2A shows an exploded close-up perspective illustration of a bicycle wheel hub with a disc brake rotor 1 with a centrelock design highlighting the male and female mounting spline structures on the wheel hub assembly and disc brake rotor 1 respectively;

[0039] Figure 2B shows a close-up perspective illustration of a bicycle wheel hub with a disc brake rotor 1 in place showing an example of a typical centre lock mounting mechanism;

[0040] Figure 3A shows a close-up perspective illustration of a bicycle wheel hub highlighting the robust disc brake rotor 1 mounting flange structure for a standard 6-bolt mounting design;

[0041] Figure 3B shows a close-up perspective illustration of a bicycle wheel hub fitted with a disc brake rotor 1 highlighting a standard 6-bolt mounting design;

[0042] Figure 4A shows a plan view of the non-drive side of a front bicycle wheel with an embodiment of the invention fitted to the wheel hub and covering the disc brake rotor 1;

[0043] Figure 4B shows a plan view of the drive side of a front bicycle wheel with an embodiment of the invention fitted to the wheel hub and covering the disc brake rotor 1; Figure 5 shows a perspective view of a front wheel hub with a 6-bolt disc brake rotor 1 fitted;

[0044] Figure 6 shows a perspective view of a front wheel hub with parts of an embodiment of the invention fitted highlighting the outer surface of the main guard flange 100 with the drive side part of the tensioning axle in place and the the non-drive side part of the tensioning axle removed to show concentric fitment;

[0045] Figure 7 shows a perspective view of the main guard flange 100 of an embodiment of the invention highlighting the outward-facing surface features;

[0046] Figure 8 shows a perspective view of the main guard flange 100 of an embodiment of the invention highlighting the inward- facing surface features;

[0047] Figure 9 shows a cut-away perspective view of an embodiment of the invention fitted to a front wheel hub highlighting the orientation of the main guard flange 100 over the disc brake rotor 1;

[0048] FigurelO shows a cut-away perspective view of an embodiment of the invention fitted to a front wheel hub highlighting the orientation of the main guard flange 100 over the disc brake rotor 1;

[0049] Figure 11 shows an axial cross section view of a front wheel hub assembly with a 6-bolt disc brake rotor 1 fitted;

[0050] Figure 12 shows an axial cross section view of a front wheel hub assembly with a 6-bolt disc brake rotor 1 and a main guard flange 100 part of an embodiment of the invention fitted highlighting the concentric location of the main guard flange 100 over the disc brake rotor 1 with planar and radial clearance spaces visible between the outer parts of the main guard flange 100 and the disc brake rotor 1;

[0051] Figure 13 shows an axial cross section view of a front wheel hub assembly with a 6-bolt disc brake rotor 1 and a main guard flange 100 part of an embodiment of the invention fitted highlighting the placement of the non-drive side tensioner; Figure 14 shows an axial cross section view of a front wheel hub assembly with a 6-bolt disc brake rotor 1 with main guard flange 100 and complete tensioning axle in place highlighting the placement of tension load via the tensioning axle through the main guard flange 100 and standoff structure to the inner part of the disc brake rotor 1 supported by the robust mounting flange;

[0052] Figure 15 shows an axial cross-section view of a front wheel hub assembly with a centrelock disc brake rotor 1 with main guard flange 100 installed and tensioning axle parts removed. An inset detailed view 81 of the cross-section is indicated by the dotted line box 80 to highlight the load-bearing interaction between the centrelock fixing flange and the inward facing surface of the standoff recess with planar clearance visible between the inward facing surface of the standoff structure and the disc brake rotor 1;

[0053] Figure 15A is a close-up axial cross-section of an embodiment of the invention highlighting the contact surfaces between non-drive side tensioner handle, the main guard flange 100 and the axial clearance space between the tensioner inner ring clearance bore and the wheel hub bearing inner ring;

[0054] Figure 16A shows an axial cross-section view of an expanding tensioner axle part of an embodiment of the invention;

[0055] Figure 16B shows a perspective view of an expanding tensioner axle part of an embodiment of the invention;

[0056] Figure 17 shows an axial cross-section view of a front wheel hub and disc brake rotor 1 assembly with an embodiment of the invention installed highlighting an expanding tensioner axle part of an embodiment of the invention;

[0057] Figure 18 shows a perspective view of the main guard flange 100 of an embodiment of the invention highlighting the inward- facing surface features including axle packing features and interference retainer features;

[0058] Figure 19 shows a perspective view of the main guard flange 100 of an embodiment of the invention highlighting the inward- facing surface features including front and rear tensioning axle parts retained in place via axle packing features and interference retainer features;

[0059] Figure 20 shows a line drawing of an embodiment of the invention not in use packed as a complete set containing front and rear main guard flange 100 and tensioning axle parts clamped in place by mechanical interference between the tensioning axle parts and the main guard flange 100 parts. A plan view with projected views and cross sections are shown as indicated;

[0060] Figure 21 shows a perspective line drawing of a packing spacer part of an embodiment of the invention;

[0061] Figure 22 shows a partially exploded perspective line drawing of an embodiment of the invention with two disc brake rotors 1 concentrically mounted on a packing spacer part of an embodiment of the invention packed in between a pair of main guard flange 100 parts with a fixing nut removed;

[0062] Figure 23 shows a perspective axial cut-away section of drawing of an embodiment of the invention with two disc brake rotors 1 concentrically mounted on a packing spacer part of an embodiment of the invention packed in between a pair of main guard flange 100 parts with fixing nuts in place highlighting the planar clearance space and radial clearance space;

[0063] Figure 24 shows a line drawing of an embodiment of the invention with two disc brake rotors 1 concentrically mounted on a packing spacer part of an embodiment of the invention packed in between a pair of main guard flange 100 parts with fixing nuts in place highlighting the planar clearance space and radial clearance space. A plan view with projected views and cross sections are shown as indicated;

[0064] Figure 25 shows a perspective line drawing of an embodiment of the invention highlighting the inward facing surface and features of a main guard flange 100;

[0065] Figure 26 shows a perspective line drawing of an embodiment of the invention highlighting the outward facing surface and centrelock rotor tool; Figure 27A shows a partially exploded perspective line drawing of an embodiment of the invention highlighting the fitment of an example of a rotor tool disposed on the outward facing side of the main guard flange 100 part of an embodiment of the invention to a centrelock fixing flange;

[0066] Figure 27B shows a perspective line drawing of an embodiment of the invention highlighting the fitment of an example of a rotor tool disposed on the outward facing side of the main guard flange 100 part of an embodiment of the invention to a centrelock fixing flange;

[0067] Figure 28A shows a plan view of a rear bicycle wheel highlighting the drive cog assembly on the drive side of the wheel;

[0068] Figure 28B shows a plan view of the drive side of a rear bicycle wheel with a cog assembly cover part of an embodiment of the invention fixed in position over the drive cog assembly of the wheel;

[0069] Figure 29A shows a perspective line drawing of a rear hub assembly with disc brake rotor 1 and drive cog assembly;

[0070] Figure 29B shows a perspective line drawing of a rear hub assembly with disc brake rotor 1 and drive cog assembly with a main guard flange 100 part of an embodiment of the invention placed over the disc brake rotor 1;

[0071] Figure 30 shows a perspective line drawing of a rear hub assembly with disc brake rotor 1 and drive cog assembly with a main guard flange 100 part of an embodiment of the invention placed over the disc brake rotor 1 and a cog assembly cover part of an embodiment of the invention in place over the drive cog assembly;

[0072] Figure 31 shows an axial cross-section drawing of a rear hub assembly with disc brake rotor 1 and drive cog assembly with a main guard flange 100 part of an embodiment of the invention placed over the disc brake rotor 1 and a cog assembly cover part of an embodiment of the invention in place over the drive cog assembly; Figure 32 shows a side-view line drawing of a rear hub assembly with disc brake rotor 1 and drive cog assembly with a main guard flange 100 part of an embodiment of the invention placed over the disc brake rotor 1 and a cog assembly cover part of an embodiment of the invention in place over the drive cog assembly;

[0073] Figure 33 shows a drive-side plan-view line drawing of a rear hub assembly with a main guard flange 100 part of an embodiment of the invention placed over the disc brake rotor 1 and a cog assembly cover part of an embodiment of the invention in place over the drive cog assembly with the drive cog assembly visible through the holes in the cog assembly cover part;

[0074] Figure 34A shows a perspective line drawing of a rear hub assembly from the non-drive side with disc brake rotor 1 and drive cog assembly with a main guard flange 100 part of an embodiment of the invention placed over the disc brake rotor 1 and a cog assembly cover part of an embodiment of the invention in place over the drive cog assembly. The non-drive-side tensioning axle is not in place for clarity;

[0075] Figure 34B shows an axial cut-away perspective line drawing of a rear hub assembly from the non-drive side with disc brake rotor 1 and drive cog assembly with a main guard flange 100 part of an embodiment of the invention placed over the disc brake rotor 1 and a cog assembly cover part of an embodiment of the invention in place over the drive cog assembly. The non-drive-side tensioning axle is not in place for clarity.

[0076] DETAILED DESCRIPTION OF EMBODIMENTS

[0077] The present disclosure relates to products and methods for substantially isolating disc brake rotors 1 from contact with other objects when the disc brake rotor 1 is installed on a bicycle wheel 2 that is otherwise not installed on the bicycle, or when the disc brake rotor 1 is not installed on a bicycle wheel. Herein, the term "in-use” refers to the situation where a bicycle wheel is installed on a bicycle with its disc brake rotors in place. "Not in-use” refers to other situations where a bicycle wheel is not installed on a bicycle with disc brake rotors and other attachments such as drive cog assemblies in place, or it may also refer to disc brake rotors that are not installed on a bicycle wheel.

[0078] The present disclosure is based, at least in part on the need to prevent impact damage to a disc brake rotor 1 while the wheel to which the disc brake rotor 1 is installed, is not installed in the bicycle frame, that would otherwise provide protection to the disc brake rotor 1 while the bicycle is in normal use. Rather, the present disclosure addresses, at least in part the need to protect a disc brake rotor 1 from abnormal loads compared with the in-use forces that the disc brake rotor 1 is designed to withstand, such as impact damage that may deform, scratch or notch the disc brake rotor 1 while the wheel to which it is attached is uninstalled from a bicycle and in storage or transit

[0079] In certain embodiments of the disclosed invention, the present disclosure is also suitable for the protection of at least one disc brake rotor 1 while it is not installed on a bicycle wheel.

[0080] The present disclosure is also based, at least in parton the substantial prevention from damage, conatamination or soiling that may occur to other parts of a bicycle due to contact or pressure between the disc brake rotor 1, axle or gearing components such as a cog assembly 18 while the bicycle is at least partially disassembled during transport

[0081] One embodiment of a means of protector for a disc brake rotor 1 while it is installed on a bicycle wheel 2 comprises a main guard flange 100 that is of a substantially similar or greater diameter than the disc brake rotor 1 and wheel hub assembly 3 to which it is installed, a means of centring the main guard flange 100 on the wheel hub assembly 3 and disc brake rotor 1, and a means of resiliently tethering main guard flange 100 to the wheel hub assembly 3.

[0082] In certain embodiments of the invention, the main guard flange 100 is comprised of a substantially planar guarding disc of a stiff polymer or other material that is positioned on the outward facing side of the disc brake rotor 1. The main guard flange 100 may also incorporate geometric features that stiffen the substantially planar structure to help withstand load and prevent transfer of such load to the disc brake rotor 1 to which it is installed. It may also incorporate features that provide a clearance between the main guard flange 100 and the disc brake rotor 1 so that small deflections away from substantial planarity may occur without contact between the main guard flange 100 and the outer parts of the disc brake rotor 1, particularly the braking surface 12.

[0083] Figure 1 shows a typical bicycle wheel 2 with a disc brake rotor 1 in position and fixed concentrically to the wheel hub assembly 3. For simplicity, the well-known spokes, rim and tyre parts of the wheel are generally excluded from figures and descriptions; however, it is anticipated that, where a disc brake rotor 1 and other parts are represented in association with a wheel hub assembly 3, the wheel hub assembly 3 would generally form part of a bicycle wheel 2. Figure 1 depicts a typical front wheel, that does not incorporate any drive parts such as cogs. A typical rear wheel assembly with drive parts such as a cog assembly 18 is shown in Figure 28A.

[0084] The mounting of a disc brake rotor 1 to a wheel hub assembly 3 is typically via one of two main mechanisms. Both of these mechanisms are primarily designed fix the disc brake rotor 1 to a robust mounting flange 8 that fixes the disc brake rotor 1 in the same plane of rotation as the wheel 2 and prevents angular displacement between the disc brake rotor 1 and the wheel hub assembly 3 about their common axis of rotation. Figure 2A depicts one typical disc brake rotor 1 mounting mechanism, commonly known as a "centrelock” mechanism where the robust mounting flange 8 is a male spline structure that registers into a reciprocal female spline structure at the centre of the disc brake rotor 1. Figure 2B shows a complete assembly of a typical centrelock disc brake rotor 1 to a wheel hub assembly 3 with one type of typical centrelock fixing flange 15 in place. Figure 3A shows a wheel hub assembly 3 with features for another standard disc brake rotor 1 mounting mechanism commonly known as a "6-bolt” mechanism. In this instance, the robust mounting flange is comprised of a shallow concentric boss that centralises the inner diameter of the disc brake rotor 1 in a coaxial manner with the wheel hub assembly 3 and six female threaded holes that accommodate mounting screws 7. The complete wheel hub assembly 3 and disc brake rotor 1 assembly is shown in figure 3B.

[0085] It can be seen in figures 1, 2B and 3B, that the thickness of the disc brake rotor 1 is very small in comparison to the diameter of the disc brake rotor 1. This is typical of a disc brake rotor 1 by design, since in use it must be extremely strong to withstand tangential braking forces applied through the plane of the disc brake rotor 1; however, it must be thin to minimise weight and fit reasonably into the bicycle assembly as a whole. It can also be seen that the disc brake rotor 1 is highly susceptible to deformation when loads out of the dominant plane of the disc brake rotor 1 are applied, especially at the outer parts such as the braking surface 12 where the moment of the applied load is greater, and where deformation out of plane near the centre of the disc brake rotor 1 is exaggerated.

[0086] Figure 4A and figure 4B depict an embodiment of the invention installed on a bicycle wheel 2. In figure 4A, a main guard flange 100 is concentrically fixed in place over the disc brake rotor 1 by means of a tensioning axle 31 that passes through the bore 10 of the wheel hub assembly 3 from the non-drive side and engages with another part of the tensioning axle 31 on the drive side. In this case, the two parts of the tensioning axle are engaged in a manner such via a screw thread or another helically- wound structure known to those skilled in the art apply a tension force by engagement with the end faces of the inner ring 11 on the drive side and with the outward-facing aspect 26 of the main guard flange 100 to retain the main guard flange 100 in place and force it toward the robust mounting flange 8 of the wheel hub assembly 3 .

[0087] The distribution of load during installation and in use, especially upon the application of a load that would otherwise damage or deform the disc brake rotor 1 is of key importance to the performance of the invention. Figure 5 shows a wheel hub assembly 3 with a standard 6-bolt disc brake rotor 1 attached in place. The wheel hub assembly 3 is designed to accommodate large loads in all directions and provides a means of connecting the wheel to the bicycle. The connecting means is via an axle that passes through a central bore 10 and communicates with the wheel mounting structures of the bicycle frame at the rear wheel and forks at the front. The wheel hub contains bearings to allow support and rotation of the wheel, with the bearing inner rings 11 ultimately transferring loads from the wheel to the frame and forks. In practice, the inner rings of the bearings may be joined via a continuous cylinder that rotates about the axis with relation to the wheel. In the drawings provided, it is intended that the inner ring 11 is a depiction of the robust structure that rotates about its axis in relation to the body of the wheel hub to which the spokes are attached.

[0088] Since the inner ring 11 of the wheel hub assembly 3 is designed to accommodate large loads both on its end faces and in other directions, it is an ideal mounting structure to fix the main guard flange 100 in place. It can be seen in figure 5 that the central part of the disc brake rotor 1 that is fixed in place via mounting screws 7 to the wheel hub assembly is substantially more capable of withstanding loads in any direction that the outer parts of the disc brake rotor 1 such as the braking surface 12. This makes the part of the disc brake rotor 1 in proximity to the mounting structures of the hub an ideal place to support the main guard flange 100 and to which loads applied to the main guard flange 100 should be distributed.

[0089] Figure 6 highlights the main guard flange 100 positioned over the disc brake rotor 1. The drive side tensioner 32 is in place; however, the non-drive side tensioner 33 is absent to highlight the orientation of the main guard flange 100 over the inner ring 11. An inner ring clearance bore 23 that has a diameter at least as large as the outside diameter of the inner ring 11 provides a substantially concentric relation between the main guard flange 100 and the disc brake rotor 1. In this case the diameter of the main guard flange 100 is only slightly greater than that of the disc brake rotor 1.

[0090] Figure 7 highlights outward facing aspect 26 of the main guard flange 100, also showing the inner ring clearance bore 23 and an outer projection 40 that may be in place in certain embodiments of the invention to provide additional protection from impacts or interference to the disc brake rotor 1 in the radial direction. The inward facing aspect 20 of the main guard flange 100 is shown in figure 8. Key features of certain embodiments of the invention are seen from the inward facing aspect of the main guard flange 100. The standoff structure 21 protrudes axially from the plane of the inward facing aspect 20 of the main guard flange 100 so that load applied in the same direction applied to the main guard flange 100 is distributed onto a well-defined region close to where the disc brake rotor 1 attaches to the robust mounting flange 8. The presence of the standoff structure provides a means of separating the outer parts of the inward facing aspect 20 of the main guard flange 100 from the outward facing aspect 13 of the disc brake rotor 1. The standoff recess 24 provides clearance for the screw heads of the disc brake rotor 1 mounting screws 7 for 6-bolt mounting mechanisms and a central pocket that provides clearance for the centrelock fixing flange 15 in the case of centrelock mechanisms. In certain embodiments of the invention, the depth of the standoff recess is approximately 4 mm, which coincides with the approximate standard depth of a centrelock fixing flange and exceeds the height of 6-bolt mounting screw 7 heads. In this way, regardless of the fixing mechanism, a suitable separation between the braking surface 12 and the inward facing aspect 20 of the main guard flange 100 is created. In some cases, the axial load may be satisfactorily borne between the planar face of the standoff recess 24 and the robust outward facing substantially planar face of the centrelock fixing flange 15 without compromising the function of the device and without substantially changing the separation between the outer parts of the disc brake rotor 1 and the main guard flange 100.

[0091] An embodiment of the invention is shown in the axial cross section perspective views in figure 9 and 10. The positioning of a main guard flange 100, held in place by a tensioning axle 31 comprised of a drive-side tensioner 32 and a non-drive-side tensioner 33. The tensioning axle 31 parts are made from materials and are of a design that enable it to withstand substantial tension loads. Tension applied through the tensioning axle 31 applies load to the outward facing aspect 26 of the main guard flange 100. The non-drive side tensioner 33 has features to provide diametric and axial clearance between the end face of the inner ring 11 and the outer diameter of the inner ring 11. In this way, the tensioning force applied by the tensioning axle is directed to the outward facing aspect 26 of the main guard flange 100. The main guard flange 100 is made from a substantially incompressible and rigid material. Therefore, the load applied to the outward facing aspect 26 of the main guard flange 100 is transferred through the main flange guard 100 structure to the standoff structure 21 that in-train transfers the load to the region of the disc brake rotor 1 that is well-supported by the robust mounting flange 8 of the wheel hub assembly 3. Highlighted in figures 9 and 10 are the key features of the planar clearance space 30 and radial clearance space 41 that allow for a degree of deflection of the main guard flange 100 structure without making contact with the braking surface 12 or other outer parts of the disc brake rotor 1 where it is most susceptible to damage.

[0092] Figures 11-14 show successive axial cross section views of an embodiment of the invention in an order that follows a typical order in which the assembly may in practice be installed onto a front wheel hub assembly 3 with a standard 6-bolt mounted disc brake rotor 1. Figure 11 highlights a representation of the key features of the wheel hub assembly 3 and disc brake rotor 1. This highlights the robust nature of the robust mounting flange 8, the orientation of the attached disc brake rotor 1 , the mounting screws 7, the axle bore 10 and the inner ring 11. It is common that the inner ring 11 structures depicted in the drawings are present as a continuous, bearing-mounted, single cylinder that passes from one side of the wheel hub assembly 3 to the other along the axis of rotation. The detail of the bearing structure is not shown, but would usually comprise a ball bearing or roller bearing sub-assembly, for example, both of which are well known.

[0093] Figure 12 is a similar representation of the described features as in figure 11, but shows the placement of an embodiment of the main guard flange 100 onto the disc brake rotor 1 and wheel hub assembly 3. The non-drive-side inner ring 11 is concentrically inserted into the inner ring clearance bore 23 of the main guard flange 100 to orient the main guard flange 100 and the wheel hub assembly 3 in a substantially concentric manner. The non-drive side end face of the inner ring 11 is shown slightly proud of the outward facing aspect 26 of the main guard flange 100. This is not a necessaiy feature of the embodiment of the invention , but it highights the need for the tensioner inner ring clearance bore 36 shown in other figures, since the presence or the extent of the protrusion of the inner ring 11 varies with the particular design of disc brake rotor 1 , the hub assembly 3 and the thickness of the material or otherwise depth of the main guard flange 100 structure in the axial direction. The standoff structure 21 contacts the disc brake rotor 1 in the region where it is supported by the robust mounting flange 8 of the wheel hub assembly 3 with the planar clearance space 30 created between the disc brake rotor 1 and inward facing aspect 20 of the main guard flange 100 and the disc brake rotor 1. The radial clearance space 41 between the outer projection ring 40 and the radial periphery of the disc brake rotor 1 is also highlighted. The outer projection ring 40 may extend fully or partly around the outer circumference of the main guard flange 100. Clearly, the extent of protection offered by the embodiment of the invention to the disc brake rotor 1 increases with the depth to which the outer projection 40 extends toward the plane of the disc brake rotor 1. It is envisaged that the outer projection may extend past the plane of the disc brake rotor 1 and in certain embodiments, there may be an additional returning structure that provides planar protection to the inward facing aspect of the disc brake rotor 1. In most applications this has been found to be an unnecessary feature that would complicate manufacture and assembly without substantially improving the performance of the embodiment of the invention. In the embodiment depicted, the outer projection 40 also serves the function of a structural stiffening feature that would facilitate the use of thinner and ligther materials in fabrication of the main guard flange 100. It is envisaged that a similar function would be served by a peripheral scalloped hip section or corrugation swept around all or part of the circumference that may suit formation of the main guard flange 100 by vacuum forming or pressure forming of sheet materials. In this way, a similar stiffening function that resists deflection out of plane of the main guard flange 100 would be provided in attrition to favourably adding a degree of curvature to soften the circumferential edges of the main guard flange 100.

[0094] Figure 13 is a similar representation of the described features as in figure 12, but shows the positioning of the non-drive side tensioner 33 inserted concentrically into the axle bore 10 and positioned over the inner ring 11 with the end face and outer surface of the inner ring 11 positioned in the tensioner inner ring clearance bore 36 without interference, so that load applied axially toward the wheel hub assembly 3 by the nondrive side tensioner 33 is supported by the outward facing aspect 26 of the main guard flange 100 rather than the inner ring 11. In figure 14, the particular embodiment of the invention depicted in figures 11-13 is shown completely assembled in a way that it offers protection to the disc brake rotor 1. The male-threaded section 37 of the non-drive side tensioner 33 is engaged with the female threaded section 38 the drive side tensioner 32. In the embodiment represented, the threaded sections are a right-hand helically wound thread, so that rotating the nondrive side tensioner 33 clockwise with respect to the drive side tensioner 32 shortens the tensioner axle 31 assembly and provides an axial tension force that is countered by pressure against the end face of the inner ring 11 on the drive side and provides an axial clamping force that forces the inward facing side of the standoff structure against the region of the disc brake rotor 1 supported by the robust mounting flange 8. In this way, the main guard flange 100 is held in place and substantially prevents contact of objects with the most exposed, outward facing aspect 13 face of the disc brake rotor 1. In the event that a force impinges upon the outward facing aspect 26 of the main guard flange 100 somewhere near the periphery, the standoff structure 21 acts as a fulcrum, transferring the force of the impinging load to the inward facing surface of the standoff feature. The impinging force is resisted by the stiffness of the main guard flange 100. In this instance, the main guard flange 100 is maintained substantially plane parallel to the disc brake rotor 1, since the unbalanced load is resisted by the tension force in the tensionaing axle 31 about the fulcrum created by the load bearing surface 27 of the standoff structure 21. In this way, contact between the inward facing aspect 20 of the main guard flange 100 with the braking surface 12 or other peripheral part of the disc brake rotor 1 is prevented. The deflection in the main guard flange 100 toward the disc brake rotor 1 in this instance is at least in part accommodated by the planar clearance space 30.

[0095] Since the leverage applied to the main guard flange 100 near its periphery in response to a load placed perpendicularly or normal to the principal plane of the main guard flange 100 as well as deflection out of this plane is greater near the periphery than near the central axis of the main guard flange 100, it is envisaged that in certain embodiments of the invention, the shape of the main guard flange 100 may be scalloped or otherwise shaped out of the principal plane of rotation so that the planar clearance space 30 provides greater separation between the main guard flange 100 and the disc brake rotor 1 at the outer part near the braking surface 12 than at the parts of the inward facing aspect 20 of the main guard flange 100 nearer to the axis of rotation and the standoff structure 21.

[0096] Figure 15 highlights the fitment of the main guard flange 100 to a hub assembly with a disc brake rotor 1 mounted by the centrelock mechanism. The required tensioning axle 31 or other means of fastening the main guard flange 100 to the wheel hub assembly 3 is not shown for clarity. In this instance, the centrelock fixing flange 15 is accommodated by the standoff recess 24. Highlighted by the inset detailed cross section view, the thickness of the centrelock fixing flange 15 slightly exceeds the depth of the standoff structure 21 so that the load bearing surface 27 of the standoff structure 21 is notin contact with the disc brake rotor 1 surface, which in this case is partially recessed out of plane from the plane of the braking surface 12. Therefore, in this case, the fulcrum that is otherwise formed by the standoff structure 21 is replaced by an alternate fulcrum formed between the outward facing surface of the centrelock fixing flange 15 and the recessed load bearing surface 28 of the main guard flange 100. In some instances, the fulcrum may be formed by interference between the mounting screw 7 heads and the recessed load bearing surface 28. In each case, the axial load is transferred through the fixing mechanism to the robust mounting flange 8 in a manner that provides robust support against the impinging force and the main guard flange 100 functions as intended. Figure 15 A shows a close-up cross section of the same embodiment of the invention with the non-drive side tensioner 31 in place to detail the clearance space between the end face of the non-drive side inner ring 11 and the inner ring clearance bore 36. The transfer of axial load between the tensioner handle 34, to the planar contact with the outward facing aspect 26 of the main guard flange 100 to the centrelock fixing flange 15 and into the robust mounting flange 8 is highlighted.

[0097] In certain uses, it may be suitable to access the tensioning mechanism of certain embodiments of the invention from only one side using a single tensioning axle 31 assembly. This may be achieved by several different mechanisms that provide engagement with either the drive-side end face of the inner ring 11 or through radial engagement with the inner surface of the inner ring 11. This may be achieved by providing a means of causing a tensioning axle assembly that is of small enough diameter to pass through the main axle bore 10, to expand radially once in place to either push gripping teeth structures or an elastomeric structure capable of accommodating expansion radially outward so that on retraction they interfere with the end face of the inner ring 11. In alternative embodiment depicted by figures 16A and 16B, radial expansion may be used to radially expand the tensioner axle 31 within the bore 10 so that friction increases sufficiently that the force of friction between the axle 31 and the inner ring 11 exceeds in magnitude a tension force that is sufficient to allow the main guard flange 100 to resist reasonable impinging loads. Figures 16A and 16B depict an expanding tensioner axle 45 that is comprised of several parts. The outer diameter of both the static spindle 46 and tensioner spindle 35 is such that it is a close fit with the inner diameter of the inner ring bore 10. Elastomeric o-rings 52 provide slight interference with the inside surface of the inner ring that is sufficient to prevent rotation of the static spindle 46 when the tensioner handle 34 is rotated. In the depicted embodiment, a female threaded section 55 engages with a reciprocal male threaded section attached to a draw bar 47. The draw bar 47 is prevented from rotating with respect to the static spindle 46 by means of a dowel pin 51 that passes through a hole in the body of the static spindle 47 and is engaged with a slot in the draw bar in a manner that allows axial movement of the draw bar 47 with respect to the static spindle 46 but prevents rotation. In this way, rotation of the tensioner spindle 35 causes translation of the draw bar along its axis. Attached to the end of the draw bar 47 opposite the tensioner handle 34 is a male taper 48 that slides inside a reciprocal female taper 49 in such a way that shortening of the draw bar 47 and tensioner spindle 35 assembly created by rotating the tensioner spindle about its axis relative to the static spindle causes the male taper to push radially outwards against the female taper 49. The presence of at least one slot 50 in the expanding gripper 57 section allows the expanding gripper to increase in diameter in response to the taper bung 54 being dragged into the female taper 49. The radial resolved force applied by the male-female taper interaction overcomes the hoop stress applied by the o-rings 52 thereby increasing friction between the outer surface of the expanding gripper section and the inner surface of the inner ring 11. The presence of an elastomeric or other axial compression ring 53 allows shortening of the drawbar 47 into the tensioner spindle 35 and once the expanding gripper 57has gripped the inner ring, continued tightening of the mechanism causes the pressure surface 39 of the tensioner handle 34 to push against the outward facing aspect 26 of the main guard flange 100 and providing the pressure required to mount the main guard flange securely. The tightening action of such an embodiment is highlighted by figure 17, where a main guard flange 100 of an embodiment of the invention is fixed in place onto a hub assembly 3 and disc brake rotor 1. In figure 17, the broad white arrows depict the action of shortening the draw bar 47 and the lines of resolved expanding force created in the expanding gripper 57 as the taper bung 54 is pulled into the female taper 49 section. It is appreciated that there are many different ways to manufacture a tensioning axle 31 that will perform the same or similar function that are known to those skilled in the art of mechanical design. Such mechanisms may include direct push-pull plungers with tapers or the like to provide a rapid tensioning and release function that may be suited to deployment in bicycle racing environments, for example, where a wheel needs to be quickly thrown into the back of a support vehicle or simply for convenience. Such features may be achieved without detracting from the key function or essence of the current disclosure.

[0098] In certain embodiments of the invention, it is convenient to transport the embodiment as two complete sets of parts that provide main guard flange 100 and tensioning axle 31 parts for both the front and rear wheels. It is advantageous that the full sets should themselves assemble into a singlular set for ease of transport and storage and to ensure that the component parts are not lost Figure 18 shows a main guard flange 100 part of an embodiment of the invention with axle packing features 43 that accommodate and retain the tensioning axle 31 parts while the device is not in use. In the depicted embodiment, recesses are provided for the four tensioning axle parts that form the depicted embodiment Shown in figure 18 are interference retainer 42 features that engage with the tensioner inner ring clearance bore 36 feature of the depicted embodiment of the invention. As shown in figure 19, pressing the tensioner handle section into the axle packing feature 43 causes an interference fit that retains the tensioning axle 31 parts to the main guard flange 100 part by means of the interference retainer 42. It is appreciated that the interference retainer 42 may be substituted for an alternate interference fit that provides sufficient resistance that an appropriate, deliberate force is required to separate the tensioning axle 31 parts from the main guard flange 100 parts. It is also envisaged that the same function may be produced by means of an interlocking geometry that tethers all parts together, for example, by rotating the tensioning axle parts of via another tethering mechanism that clamps the main guard flange 100 parts together and retains the tensioning axle parts.

[0099] Figure 20 shows a plan view 82 of an embodiment of the invention with projected side view 83 and projected side view 85 with two cross section views, section A-A 84 and section b-b 86 showing an entire assembly for front and rear wheels packed into a convenient and compact single assembly. In the embodiment of the invention depicted, the retaining force holding each tensioning axle 31 part into the axle packing feature 43 by means of interference retainers 42 clamps two opposing (front and rear) main guard flange 100 parts together so that deliberate manual force is required to separate the parts from each other.

[0100] The singular case style format also lends itself to storage of disc brake rotors 1 1 that have been removed from wheels for protection or storage.

[0101] It is advantageous to provide a secondary usage format for embodiments of the invention so that in certain uses, the main guard flange 100 parts of the embodiment of the invention that in certain uses the same parts of the embodiments of the invention are suited to providing protection for disc brake rotors 1 while they are installed on bicycle wheels may also be used for safely packing loose disc brakes rotors. Figure 21 shows a packing spacer 60 part of an embodiment of the invention that can be used to facilitate the secondary use of the embodiment of the invention described.

[0102] The packing spacer 60 provides structures for mounting at least one disc brake rotor 1 in a concentric manner so that at least one disc brake rotor 1 may be encased or supported by the main guard flange 100 parts of an embodiment of the invention. The packing spacer 60 depicted is suited to packing two 6-bolt disc brake rotors 1 with a separation flange 61 to maintain a substantial plane-parallel relation between the two disc brake rotors 1 and to prevent the two disc brake rotors 1 from contacting each other, a concentric boss 62 of substantially the same inner diameter as the inner diameter of the disc brake rotor 1, a centring boss 63 that engages concentrically with the inner ring clearance bore 23 of the main guard flange 100 and a fixing screw 64 that can be used in concert with a suitable nut 65 (fig 22) to tether the two main guard flange 100 parts together, applying axial force toward the centre of the disc brake rotor 1 by way of the standoff structure 21, in this case supported by the separation flange 61.

[0103] Figure 22 shows a partially exploded perspective view of two disc brake rotor 1 mounted in between two main guard flange 100 parts using a packing spacer 60. The centring boss 63 is shown concentrically engaged with the inner ring clearance bore 23. Installation of the threaded nut 65 to the fixing screw 64 provides a means of safely clamping all parts together into a robust package that provides protection to the disc brake rotors 1 in transit or storage. Figure 23 shows a cut-away section through the axis of the assembly depicted in figure 22 to highlight the supporting mechanism for the disc brake rotors 1. Further detail of an example use of an embodiment of the invention is provided in figure 24 showing plan 87, side 88, and section views A-A 90 and B-B 89.

[0104] There are several different means by which the key embodiments of the invention may be made, depending on the available materials and manufacturing infrastructure. Figure 25 depicts the inward facing aspect 20 of the main guard flange 100 part of an embodiment of the invention that is particularly suited to simplified manufacture using parts cut from sheet polymethylmethacrylate (PMMA) or another suitable sheet material. In the embodiment depicted in figure 25 the large planar disc structure is cut from a sheet of PMMA of substantially uniform thickness with a standoff structure 21 produced as a separate part of substantially uniform thickness. The standoff structure 21 is fixed to the larger disc part of the main guard flange 100 by way of standard screw fasteners 70, adhesives or a combination of such means known those skilled in the art In certain embodiments of the invention, the standoff structure 21 may be made using at least one different material from the material used to fabricate the main planar disc part to either improve performance by choosing a more compliant material or a softer material for the standoff structure 21 to produce a gentler interaction of the embodiment of the invention where it contacts other parts of the disc brake rotor 1. It is also envisaged that the standoff recess 24, the inner ring clearance bore 23 or a combination of these structures may be formed as a separate part and may be fabricated from a different material than used for the main planar disc structure to suit manufacturing facilities, cost or to improve or soften the contact interaction with the parts of the disc brake rotor 1, centrelock fixing flange 15, mounting screws 7 or inner ring 11.

[0105] In the embodiment of the invention depicted in figure 25, there is an absence of the outer projection 25 structure of the main guard flange 100 in previously depicted embodiments of the invention and the outer perimeter 22 of the large disc structure is completely planar. In this instance, radial protection is provided by the protrusion of the main guard flange 100 to a diameter substantially equal or larger to that of the disc brake rotor 1 that it is intended to protect

[0106] In certain embodiments of the invention, it may be advantageous to incorporate a means of removing and installing a disc brake rotor 1. While it is appreciated that this could be achieved by many means that suit the manufacturing techniques used to produce the particular embodiment Figure 26 shows an example how this may be achieved using a profile-cut from a substantially parallel sheet providing notch features that engage with the reciprocal notches commonly found on a standard centrelock fixing flange 15. The engagement of the centrelock fixing flange 15 with the rotor removal tool 68 is shown in the partially exploded outward facing aspect 26 of the main guard flange 100 in figure 27A. Figure 27B shows the centrelock fixing flange 15 fully engaged with the rotor removal tool 68. In the embodiment of het invention shown. In the embodiment of the invention depicted in figures 26, 27A and 27B, the placement of metal dowel pins 69 provide a more robust and durable means of transferring the force produced by loosening or tigthening the centrelock fixing flange 15 in instances where the material used to fabricate the other parts of the rotor removal tool 68 are likely to be damaged by the large forces encountered when removing or installing a disc brake rotor 1. It is common for a disc brake rotor 1 mounting fastener such as the 44 mm, 16 notch centrelock fixing flange to require tighntening to a relatively high torque around 40 Newton metres. In the embodiment of the invention depicted, the 4 mm dowel pins 69 are stainless steel and press-fit into reciprocal through holes that pass from the outward facing aspect of the rotor removal tool 68 to the inward facing aspect 20 of the main guard flange 100. In this way, the rotor removal tool 68 withstands sufficient torque to remove and install a disc brake rotor 1. It is intended that the operator grips near the outer perimeter of the main guard flange 100 to apply sufficient torque to the centrelock fixing flange 15. In certain embodiments of the invention, the provision of features such as larger through holes 75 as shown in figure 27B or protrusions from the from or near the outer perimemeter 22 of the main guard flange 100 to facilitate the applicati cation of sufficient torque by the operator. It is also envisaged that certain embodiments of the invention may include torque indicating or torque limiting features to assist the operator in properly installing a disc brake rotor to its mounting. Such an embodiment may be readily achieved by the incorporation of radial springs that support the tightening torque and transfer load from the rotor tool 68 part and the main disc structure of the main guard flange with and torque markers to indicate the degree of torque. Alternatively, a torque limitation may be achieved by the incorporation of a spring-loaded detent and register engagement between the rotor tool 68 part and the main disc structure to which torque is applied by the operator.

[0107] A key function and benefit of the embodiments of the invention is that the isolation of hard, sharp protrusions found on bicycle wheels such as axles, inner ring 11 projections, disc brake rotors 1 and drive mechanisms such as cog assemblies 18 prevents contact with such parts from other parts of a bicycle or other surrounding objects while in transit or storage. It is common, for example, that while a bicycle is partially disassembled for transport in a bicycle bag. The high load applied by parts of the axles, inner ring 11 protrusions and cog assemblies 18 to more silicate parts of the bicycle frame can cause damage to the bicycle frame. This is exacerbated by the repeated agitation through vibration experienced in transit that cause rubbing. For these reasons, it is envisaged that the embodiments of the invention disclosed are fabricated in a way that minimises protrusions with minor deformation incorporated into the design so that the interaction of the embodiments of the invention with other contacting parts occurs in a manner that dissipates and spreads load rather than producing hard, focussed forces that produce stress concentrations in the other part. For this reason, it is envisaged that in certain embodiments of the invention, the protruding features of the current disclosure such as the tensioner handles 34 may be fabricated from rubber, an elastomer or other compliant material to provide further protect nearby items from damage. Similarly, parts of certain embodiments of the invention may be a robust material coated by methods such as dip-coating or over- moulding with a relatively elastic material such as rubber or an elastomer that is capable of dissipating focussed contact forces through their deformation.

[0108] The cog assembly 18 is frequently responsible for causing damage to other parts such as scratching while the wheel is separated from the frame. Since it is also usually coated in lubricants, the drive cog or cog assembly 18 also causes soiling and contamination of nearby objects. Figure 28A shows a plan view of a rear bicycle wheel 2 with a drive cog assembly 18 visible on the drive side of the wheel and the disc brake rotor 1 just visible on the other, non-drive side of the wheel. An alternate embodiment of the invention suited to isolating the drive cog or cog assembly 18 from contacting other objects is shown in figure 28B, figure 29A, figure 29B, figure 30, figure 31, figure 32, figure 33, figure 34A and figure 34B. Figure 28B shows a plan view of the rear wheel 2 shown in figure 28A with a cog assembly cover 29 part of an embodiment of the invention fixed in place over the cog assembly 18.

[0109] Figure 29A shows a rear wheel hub 5 with a disc brake rotor 1 and a cog assembly 18 fixed in place. Figure 29B shows the rear wheel hub 5 with affixed disc brake rotor 1 and cog assembly 18 as shown in figure 29A with an embodiment of the main guard flange 100 installed, covering the disc brake rotor 1 with the inward facing aspect 20 of the main guard flange 100 visible. Figure 30 shows the same assembly depicted in figures 29A and 29B with an embodiment of a cog assembly cover 29 installed in place over the cog assembly 18. Figure 31 shows an example of a complete assembly of embodiments of the invention as a section view through the axis of rotation of the assembly. It can be seen that the cog assembly cover 29 substantially surrounds the outward facing parts of the cog assembly 18, leaving a clearance space between the inward facing surface 73 of the cog assembly cover 29 and the drive cog assembly 18. In this way some deflection of the cog assembly cover 29 is accommodated and contamination of the cog assembly cover 29 with lubricants is prevented or limited. In the embodiment of the invention depicted in figure 31, the cog assembly cover 29 incorporates a mandrel 74 that forms part of the tensioning axle 31 performs the function of engaging with the non-drive side tensioner 33 and providing the requisite tension force that fixes the main guard flange 100 and cog assembly cover resiliently via the wheel hub assembly 5. It is envisaged that a tensioning axle 31 as previously described may be passed through a suitable bore along the axis of the cog assembly cover 29 according to preferred manufacturing methods without departing from the same intended function of the disclosed invention. Figure 32, figure 33, figure 34A and figure 34B provide added views and perspectives of a rear wheel hub 5 assembly incorporating a main guard flange 100 and cog assembly cover 29 installed. The nondrive side tensioner 33 has been excluded from figure 34A and figure 34B for clarity.

[0110] Cycling enthusiasts and competitive cyclists often have need to store multiple drive cog assemblies to provide different gearing for different courses. It is acknowledged that the cog assembly cover 29 may be fabricated in a way that allows it to mount directly to the drive cog or drive cog assembly by mechanical interference or by a clip. In this way, it may be used to protect, contain, collate or cover a drive cog or drive cog assembly when it is not installed on a bicycle wheel. In such uses it may include a back cover and centering mandrel similar in size and shape to that of a freewheel hub, for example, so that cog assemblies comprised of fixed or loose cogs and spacers may be conveniently stored and kept from damage with the provision for appropriate labelling of assemblies that provide different gearing ratios or ranges of ratios.

[0111] It is acknowledged and envisaged that particular embodiments of the invention and each part of the embodiments may be fabricated using may different materials and manufacturing techniques and that the materials and particular geometry of the embodiments may be varied to suit the chosen or available manufacturing method or materials. For example, the embodiments described as individual parts herein may alternatively be comprised of a plurality of constituent parts that provide an assembly that performs the same or similar function as the parts of the embodiments described. For example, tensioner axle 31 parts maybe easily and economically machined from a single piece of aluminium, or from aluminium tubing with minimal machining used in an assembly with polymer handles that may be separately machined or produced by injection moulding, vacuum forming, pressure forming, casting or additive techniques such as 3D-printing. Other parts of embodiments such as the main guard flange 100 and cog assembly cover 29 may be ideally fabricated by vacuum forming or pressure forming of sheet polymers using a mould to produce the features described including stiffening ribs, outer projections 25 or stiffening scallop structures around the periphery of the main guard flange 100 for example. Other suitable methods of manufacture may be injection moulding, resin or metal casting. For certain applications of embodiments of the invention, manufacture of some parts such as the main guard flange 100 and cog assembly cover may be reasonably performed using techniques such as press-forming or metal spinning.

[0112] Although the present disclosure has been described with reference to particular embodiments, it will be appreciated that the disclosure may be embodied in many other forms. It will also be appreciated that the disclosure described herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the disclosure includes all such variations and modifications. The disclosure also includes all of the steps, features, compositions and compounds referred to, or indicated in this specification, individually or collectively, and any and all combinations of any two or more of the steps or features.

[0113] Also, it is to be noted that, as used herein, the singular forms "a”, "an” and "the” include plural aspects unless the context already dictates otherwise.

[0114] Throughout this specification, unless the context requires otherwise, the word "comprise”, or variations such as "comprises” or "comprising”, will be understood to imply the inclusion of a stated element or integer or group of elements or integers but not the exclusion of any other element or integer or group of elements or integers.

[0115] Reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that this prior art forms part of the common general knowledge in any country.

[0116] The subject headings used herein are included only for the ease of reference of the reader and should not be used to limit the subject matter found throughout the disclosure or the claims. The subject headings should not be used in construing the scope of the claims or the claim limitations.

[0117] The description provided herein is in relation to several embodiments which may share common characteristics and features. It is to be understood that one or more features of one embodiment may be combinable with one or more features of the other embodiments. In addition, a single feature or combination of features of the embodiments may constitute additional embodiments.

[0118] All methods described herein can be performed in any suitable order unless indicated otherwise herein or clearly contradicted by context The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the example embodiments and does not pose a limitation on the scope of the claimed invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential.

[0119] Future patent applications may be filed on the basis of the present application, for example by claiming priority from the present application, by claiming a divisional status and / or by claiming a continuation status. It is to be understood that the following claims are provided by way of example only, and are not intended to limit the scope of what may be claimed in any such future application. Nor should the claims be considered to limit the understanding of (or exclude other understandings of) the present disclosure. Features may be added to or omitted from the example claims at a later date.

Claims

CLAIMS1. A product being a device for substantially covering the outer surfaces of a bicycle disc brake rotor, wherein the product is configured to protect the disc brake rotor from unintended contact while it is not in use.

2. The product according to claim 1, wherein the device covers the disc brake rotor while the disc brake rotor is installed to a bicycle wheel.

3. The product according to claim 1, wherein the device covers at least one disc brake rotor while the disc brake rotor or disc brake rotors are not installed to a bicycle wheel.

4. The product according to claims 1-3, wherein the device incorporates a substantially planar disc structure of substantially the same or a greater diameter than the diameter of the disc brake rotor.

5. The product according to claims 1-4, wherein the substantially planar disc of a diameter greater than the diameter of the disc brake rotor is comprised of a mechanically robust material to substantially prevent transfer of loads applied to the device being transferred to the disc brake rotor.

6. The product according to claim 5 wherein the mechanically robust material is a thermoset or thermoplastic polymer such as polymethylmethacrylate, polyethylene, polypropylene, high-impact polystyrene, polyethylene terephthalate, polyethylene terephthalate glycol, polylactic acid, a metal, timber, engineered timber product or other engineered reinforced natural fibre product, composite material such as fibreglass, terylene or carbon fibre.

7. The product according to claim 5 and 6, wherein the mechanically robust substantially planar disc is formed by vacuum-forming, pressure-forming,casting, injection moulding, laser cutting, waterjet cutting, routing or other of direct machining method.

8. The product according to claims 4-7, wherein the planar disc structure incorporates out-of-plane stiffening ribs or corrugations that extend radially, tangentially or a combination of radially and tangentially.

9. The product according to claims 4-8, wherein at least one protrusion that provides a load-bearing surface or plane is substantially plane-parallel to the dominant plane of the substantially planar disc structure is positioned near the axis of rotation of the disc structure so that it interferes with the disc brake rotor in proximity to the disc brake rotor supporting structures of the wheel hub, the disc brake rotor supporting structures of the wheel hub, the disc brake mounting screws or other fixing mechanism as the substantially planar disc structure is forced toward the wheel along the axis of rotation.

10. The product according to claims 4-9, wherein the protrusion creates a gap between the plane of the substantially planar disc structure and the radially distal parts of the disc brake rotor not in contact with the load-bearing protrusion.

11. The product according to claims 4-10, wherein the substantially planar disc structure is shaped in such a way that the gap between it and the disc brake rotor is greater allocations radially more distal from the axis of rotation and load-bearing protrusion than the gap at radially proximal locations.

12. The product according to claims 4-11, wherein the substantially planar disc structure is fastened directly to the disc brake rotor.

13. The product according to claims 4-11, wherein the substantially planar disc structure is fastened directly to the outer surface of the wheel hub.

14. The product according to claims 4-11, wherein the substantially planar disc structure is fastened to the disc brake rotor and wheel hub assembly by means ofa tensioning axle that communicates via a central bore between the substantially planar disc structure and the face at the opposite side of the wheel axle bore.

15. The product according to claims 4-11, wherein the substantially planar disc structure is fastened to the disc brake rotor and wheel hub assembly by means of a tensioning axle that communicates via a central bore in the substantially planar disc structure and mechanically engages with the inner surface of the wheel axle bore.

16. A tensioning axle according to claim 14 comprised of two parts that mechanically engage with each other from opposing ends of the wheel axle bore in a manner that allows axial tension to be applied.

17. A tensioning axle according to claim 14 comprised of a single assembly that is comprised of a mechanism that, when operated causes one end of the tensioning axle to expand, allowing it to mechanically engage with the end of the wheel axle bore opposite to the side of the disc brake rotor and allows axial tension to be applied.

18. A tensioning axle according to claim 15 comprised of a single assembly that is comprised of a mechanism that, when operated causes one end of the tensioning axle to expand and mechanically engage with the inner surface of the wheel axle bore through friction and allows axial tension to be applied.

19. The product according to claims 4-11 and claim 14, wherein the substantially planar disc structure contains features that accommodate stowage of the tensioning axle or other retaining fixtures.

20. The product according to claims 3-11, wherein a mandrel provides a means of concentrically mounting at least one disc brake rotor with at least one substantially planar disc structure to provide mechanically robust protection to the disc brake rotor or disc brake rotors.

21. The product according to claims 3-11, wherein a disc brake rotor fitting tool is incorporated in the body of the substantially planar disc structure or assembly.

22. A product comprised of a robust material that substantially covers the drive cog or cogs attached to a bicycle wheel.

23. The product according to claim 22, wherein the drive cog cover is comprised of a mechanically robust material to substantially prevent transfer of loads applied to the device being transferred to drive cogs.

24. The product according to claim 22 wherein the mechanically robust material is a thermoset or thermoplastic polymer such as polymethylmethacrylate, polyethylene, polypropylene, high-impact polystyrene, polyethylene terephthalate, polyethylene terephthalate glycol, polylactic acid, a metal, timber, engineered timber product or other engineered reinforced natural fibre product, composite material such as fibreglass, terylene or carbon fibre.

25. The product according to claim 22-24, wherein the mechanically robust drive cog cover is formed by vacuum-forming, pressure-forming, casting, injection moulding, laser cutting, waterjet cutting, routing or other of direct machining method.

26. The product according to claim 22-24, wherein the mechanically robust drive cog cover is fastened to the rear wheel hub assembly by means of a tensioning axle that communicates via a central bore in the drive cog cover and mechanically engages with the rear wheel axle bore or by any of the means according to claims 15-18 or combination of such means.

27. The product according to claim 22-24, wherein the mechanically robust drive cog cover comprises a tensioning axle that communicates via a central bore in the drive cog cover and provides mechanical engagement with the rear wheel hub or rear wheel axle bore by any of the means according to claims 15-18 or combination of such means.

28. The product according to claim 22-24, wherein the mechanically robust drive cog cover mounts directly to the drive cog or drive cog assembly by mechanical interference or clip.

29. The product according to claim 22-24, wherein the mechanically robust drive cog cover mounts directly to the drive cog or drive cog assembly by mechanical interference or clip to protect, collate or cover a drive cog or drive cog assembly when it is not installed on a bicycle wheel.

30. A device or assembly substantially as described herein with reference to the accompanying figures.

31. A device or assembly produced according to the methods substantially described herein and with reference to the accompanying figures.

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