Lever device for the operation of the brake or clutch of a vehicle provided with a handlebar
The lever device adjusts the empty stroke of the piston and control lever through an eccentric cam mechanism, addressing ergonomic and reliability issues in vehicle brake and clutch systems without increasing bulk or complexity.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- BREMBO NV
- Filing Date
- 2025-12-12
- Publication Date
- 2026-06-25
AI Technical Summary
Existing lever devices for vehicle brakes and clutches with handlebars face challenges in adjusting the empty stroke of the piston and control lever without increasing complexity, bulk, or risking leakage, especially in high-performance vehicles.
A lever device with an empty stroke adjustment mechanism using a cam eccentric to a rotation axis, allowing adjustment between the control lever and pump body, avoiding direct modification of the piston, thus maintaining piston strength and preventing leakage.
Enables adjustable and reliable operation with reduced complexity and size, ensuring ergonomic grip and quick response, while minimizing piston weakening and fluid leakage.
Smart Images

Figure IB2025062787_25062026_PF_FP_ABST
Abstract
Description
" LEVER DEVICE FOR THE OPERATION OF THE BRAKE OR CLUTCH OF A VEHICLE PROVIDED WITH A HANDLEBAR" DESCRIPTION FIELD OF APPLICATION
[0001] The present invention relates to a lever device for the operation of the brake or the clutch of a vehicle provided with a handlebar.PRIOR ART
[0002] In vehicle provided with handlebars, such as bicycles and motorcycles, the brake and / or clutch are operated by means of a pump comprising a lever device mounted on the handlebar and connected to a conduit comprising the operating fluid fluidly associated with the brake or the clutch to be operated. Said pump usually comprises a control lever and a cylinder-piston assembly, wherein the control lever is arranged along the grip of the handlebar and is pivoted on a portion of the handlebar itself.
[0003] In this way, the rider, who grips the handlebar grip together with the control lever, when squeezing the hand, causes a rotation of the control lever around its fulcrum, which brings the overhanging free end portion of the control lever closer to the handlebar grip, producing a pushing force acting on the piston, whose position causes a thrust on the operating fluid to control theoperation of the brake or clutch downstream.
[0004] Usually, the cylinder-piston assembly comprises a return spring which elastically biases the position of the piston so as to bring it, when the control lever is not pressed by the rider, back to its top dead centre, thereby causing, as a consequence, the return of the control lever to its rest position.
[0005] As is known, there are various types of handlebars having various shapes and sizes; moreover, the size of the hand gripping the handlebar also varies depending on the rider. Therefore, in order to provide comfortable riding and maximum ergonomic conditions for each rider, lever device solutions have been proposed wherein it is possible to adjust the inclination of the control lever with respect to the handlebar grip, so as to bring closer or move away, as needed, the overhanging free end of the control lever from the handlebar grip. For example, documents WO-2005-049416 and WO-2007-026383, in the name of the same Applicant, show lever devices of this type, in which the control lever comprises a joint arranged between the fulcrum of the control lever and the overhanging end of the lever, which allows adjusting the inclination of the control lever with respect to the handlebar grip. However, these solutions do not fully solve the technical problem and impose an increasednumber of movable joints, which results in an increased constructive complexity of the control lever and greater likelihood of malfunction of the lever device.
[0006] Indeed, some riders, while comfortably and ergonomically gripping the handlebar grip, wish to slightly press the control lever without thereby activating the brake or the clutch, while other riders desire a quicker response of the brake or the clutch as soon as the lever is pressed.
[0007] The distance travelled by the piston without thereby activating the brake or the clutch is generally referred to as the "empty stroke" of the piston. Correspondingly, the control lever that actuates the piston also travels an empty stroke of the control lever.
[0008] There is therefore a strong felt need to adjust the empty stroke of the piston, and consequently the empty stroke of the control lever that actuates the piston, while still ensuring the rider an ergonomic and comfortable grip on the handlebar.
[0009] Particularly in the field of high-performance vehicles equipped with handlebars, there is a felt need to customise the extent of the empty stroke of the piston, and consequently the empty stroke of the control lever that actuates the piston.
[0010] For example, document US-2012-0124991 shows asolution of a bicycle brake pump in which the pump piston is transversely pierced with respect to the pushing direction to accommodate an adjustment cam used to adjust the empty stroke of the piston.
[0011] However, such a solution is not without drawbacks, since it requires a high number of parts assembled together compared to a standard pump. At the same time, it requires providing a hydraulic seal where the cam is mounted, in order to avoid even the slightest leakage of the operating fluid. In addition, adjustment by means of a cam housed in such a hole extending transversely to the pushing axis of the piston, in proximity to the pushing axis itself, allows a variation of the piston stroke which is necessarily limited to a portion defined by the size of the hole into which the cam is inserted. Such a variation is therefore necessarily smaller than the transverse extension of the piston, and in particular the variation is substantially equal to the difference between the diameter of the hole opening and the transverse dimension of the cam.
[0012] Furthermore, the provision of a hole in the piston body necessarily weakens the strength of the piston itself. Particularly for applications in high-performance vehicles, it is therefore necessary to make a piston with a larger cross-section, for the same strength, whichresults in an increase in the size of the brake pump. The transverse dimension of the cam must also withstand the stresses arising during operation and requires the cam to have a certain transverse bulk. In addition, the provision of such a hole in the piston body makes the brake pump potentially subject to brake fluid leaks.
[0013] Therefore, there is a felt need to adjust the empty stroke of the piston, and consequently of the control lever that actuates the piston, without thereby increasing the bulk of the piston and the brake pump.
[0014] There is also a strong felt need to adjust the empty stroke of the control lever without thereby increasing the constructive complexity of the pump or reducing its reliability.
[0015] Further examples attributable at least in part to the types of solutions previously discussed are shown in documents US-4840082, EP-0893337, US-4560049, EP-1972537, US-2013-220064, DE-102010040045, US-2009-229927 and EP-1864903.DISCLOSURE OF THE INVENTION
[0016] There is a felt need to solve the above-mentioned problems related to the known art.
[0017] Therefore, there is a felt need to adjust the empty stroke of the piston, and consequently of the control lever that actuates the piston, in a simple and reliablemanner, in real time during a short stop, without thereby requiring a subsequent new calibration of the brake or the clutch.
[0018] There is also a strong felt need to provide a pump solution that is compact and reliable and that, at the same time, is capable of allowing fine adjustment of the empty stroke of the control lever, without thereby disassembling the pump or the control lever.
[0019] These needs are met by a lever device for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to claim 1.
[0020] In particular, this need is met by a lever device for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar comprising at least one pump assembly comprising:- a pump body comprising connection means to the handlebar of a vehicle, said pump body delimiting a cavity,- at least one piston operatively associated with said pump body, so as to be adapted to slide inside said cavity along a pushing direction;- wherein said lever device further comprises at least one control lever assembly, rotatably associated with said pump body so as to be rotatable around a fulcrum axis, said control lever assembly being directly orindirectly connected to said piston and comprising at least one control lever;- wherein said piston comprises a piston bottom that defines, with cylinder walls of the pump body, at least one chamber for receiving the operating fluid of the brake or clutch of the vehicle, wherein at least one of said cylinder walls of the pump body being interrupted to delimit at least one supply channel, adapted to put said chamber in fluid communication with at least one associable brake / clutch fluid reservoir;- and wherein said piston bottom is movable with respect to said cylinder walls of the pump body within at least one end-of-stroke position, in which the volume of said chamber is maximum, and at least a first working position, in which said piston bottom fluidically isolates said chamber from said supply channel,- said piston defining an empty stroke between said endstroke position and said first working position;- wherein said control lever assembly comprises a hub portion opposite to said control lever with respect to said fulcrum axis, and wherein the pump body comprises at least one abutment surface, adapted to form an abutment for said hub portion opposite to said control lever with respect to said fulcrum axis,- wherein an empty stroke adjustment device is associatedwith the hub portion, adapted to adjust the distance along the pushing direction between said end-stroke position and said first working position,- wherein said empty stroke adjustment device is rotatable about a rotation axis and comprises a cam which is eccentric with respect to said rotation axis, so as to abut against the abutment surface.
[0021] In accordance with one embodiment, said empty stroke adjustment device comprises an adjustment pin having a head, a stem defining said rotation axis and passing through said hub portion and said cam, so as to abut against the abutment surface.
[0022] In accordance with one embodiment, the head, the stem and the cam are integral with one another, in particular they are rotationally integral with respect to said rotation axis.
[0023] In accordance with one embodiment, the head comprises seats for at least one stop, so as to create detents to define discrete adjustment positions of the empty stroke.
[0024] In accordance with one embodiment, said seats comprise grooves made on an outer side wall of the head.
[0025] In accordance with one embodiment, said at least one stop comprises a ball or a set screw influenced by a spring adapted to urge the stop into abutmentagainst said seats.
[0026] In accordance with one embodiment, the head of the empty stroke adjustment device is provided with a hole adapted to allow the insertion of a tool for its rotation, such as an Allen key.
[0027] In accordance with one embodiment, a knob is associated with said head of the empty stroke adjustment device.
[0028] In accordance with one embodiment, the cam is in turn provided with a spherical support.
[0029] In accordance with one embodiment, said spherical support is eccentric with respect to said rotation axis.DESCRIPTION OF THE DRAWINGS
[0030] Further features and advantages of the present invention will become more apparent from the following description of its preferred and non-limiting embodiments, in which:
[0031] Figures 1-2 show perspective views of a lever device in accordance with the present invention;
[0032] Figures 3-7 show perspective views of portions of the lever device of figures 1-2;
[0033] Figures 8-9 show perspective views of an empty stroke adjustment device applied to the lever device of figures 1-2;
[0034] Figures 10-11 show sectional views of a lever device in accordance with the present invention, respectively in end-OF-stroke and working configuration of the piston of the pump body.
[0035] The elements or parts of elements in common among the embodiments described hereinafter will be indicated with the same reference numerals.DETAILED DESCRIPTION
[0036] In accordance with a general embodiment, a lever device 1 is provided for the hydraulic operation of the brake or the clutch of a vehicle provided with a handlebar.
[0037] Said lever device comprises a pump assembly 2.
[0038] Said pump assembly 2 comprises a pump body 3 comprising connection means 47 to the handlebar of the vehicle.
[0039] Said pump body 3 delimits a cavity 5. In this way, said pump body 3 can act as a cylinder of a cylinder-piston assembly.
[0040] Said pump assembly 2 further comprises at least one piston 6 operatively associated with said pump body 3 so as to be adapted to slide inside said cavity 5 along a pushing direction X-X. Said pushing direction X-X is substantially coincident with the direction of movement of the piston 6 with respect to the pump body 3.
[0041] Said lever device 1 further comprises at least one control lever assembly 4, rotatably associated with said pump body 3 so as to be rotatable about a fulcrum axis Y-Y.
[0042] Preferably, said control lever assembly 4 comprises at least one control lever 7, adapted to be operated by a rider of the vehicle. The control lever assembly 4 comprises said control lever 7 extending in cantilever up to an overhanging end 23 and a base portion 32 connecting said control lever 7 to the pump body 3. Preferably, said base portion 32 is pivoted on a portion of said pump body 3, so as to be rotatable about said fulcrum axis Y-Y.
[0043] Preferably, the control lever 7 and the base portion 32 are made as separate pieces and assembled by means of at least one fastening element of the control lever 7 to the base portion 32. Alternatively, said control lever 7 and said base portion 32 are made as a single piece. Preferably, said control lever assembly 4 comprises a grip portion 24 interposed between said base portion 32 and said overhanging end 23.
[0044] The control lever assembly 4 is directly or indirectly connected to the piston 6. In this way, when the user of the vehicle provided with a handlebar actuates the control lever 7, an action is exerted on thepiston 6.
[0045] The piston 6 comprises a piston bottom 10 that defines, with cylinder walls 9 of the pump body 3, at least one chamber 11 for receiving the operating fluid of the brake or the clutch of the vehicle. In accordance with one embodiment, said piston bottom 10 comprises a piston bottom seal 14. In accordance with one embodiment, said piston 6 further comprises an additional piston seal 46.
[0046] At least one of said cylinder walls 9 of the pump body 3 is at least partially interrupted to define at least one supply channel 12, adapted to put said chamber 11 in fluid communication with at least one associable fluid reservoir, namely a brake / clutch fluid reservoir 70. For example, said brake / clutch fluid reservoir 70 is housed on said handlebar. In accordance with one embodiment, said brake / clutch fluid reservoir 70 is made in one piece with the pump body 3.
[0047] In accordance with one embodiment, the piston bottom 10 is movable with respect to the cylinder walls 9 of the pump body 3 within at least one end-stroke position, in which the volume of said chamber 11 is maximum, and at least a first working position, in which said piston bottom 10 fluidly isolates said chamber 11 from said supply channel 12. Said piston 6, together withthe piston bottom seal 14, defines an empty stroke 100 between said end-stroke position and said first working position.
[0048] When the rider squeezes the control lever 7, this causes the movement of the piston 6 so as to progressively decrease the volume of the chamber 11. As long as the supply channel 12 is in fluid communication with said chamber 11, the operating fluid can flow towards the brake / clutch fluid reservoir 70. When instead said piston bottom 10 moves the piston bottom seal 14 to occlude the supply channel 12, a pushing action on the operating fluid is generated, which leads to the activation of the system connected downstream of said pump assembly 2, which may be the brake or the clutch of the vehicle provided with a handlebar. By increasing the pressure on the control lever 7, a further displacement of the piston 6 is obtained, further decreasing the volume of the chamber 11. In the absence of mechanical action by the rider, the piston 6 returns to the endstroke position thanks to the action of a piston return spring 15, pushing said control lever 7 into the rest position.
[0049] Advantageously, said lever device 1 comprises at least one empty stroke adjustment device 13, or adjustment device 13, adapted to adjust the distancealong the pushing direction X-X between said end-stroke position and said first working position.
[0050] The provision of the empty stroke adjustment device 13 allows a user to quickly adjust the empty stroke 100 of the piston 6 at any time, for example during a short stop or, if necessary, even while the vehicle is in motion.
[0051] Preferably, said at least one empty stroke adjustment device 13 is arranged between the control lever assembly 4 and the pump body 3.
[0052] The provision of said at least one empty stroke adjustment device 13 placed between the control lever assembly 4 and the pump body 3 makes it possible to adjust the empty stroke while maintaining a low number of parts assembled together. In addition, it avoids placing said at least one empty stroke adjustment device 13 directly in the body of the piston 6. In this way, weakening of the piston 6 is avoided, for example through adjustment holes provided in the body of the piston 6, as occurs in some known art solutions. Consequently, it is possible to obtain a more resistant piston 6 with equal dimensions and material compared to known solutions. Moreover, the risk of leakage and loss of operating fluid that would result from the presence of holes in the piston body is minimised.
[0053] In accordance with one embodiment, said lever device 1 further comprises at least one push action transmission element 8, interposed between said piston 6 and said control lever assembly 4 and adapted to transmit the pushing action between said control lever assembly 4 and said piston 6. In accordance with one embodiment, said push action transmission element 8 is made in one piece with said control lever assembly 4. For example, said push action transmission element 8 is made in one piece with said base portion 32 of said control lever assembly 4.
[0054] In accordance with one embodiment, said push action transmission element 8 is made in one piece with said piston 6. In accordance with one embodiment, said push action transmission element 8 comprises a lever contact portion 50, associated with said control lever 4. In accordance with one embodiment, said push action transmission element 8 comprises a push rod, of known type. In accordance with one embodiment, said push action transmission element 8 is associated with a dust boot 33 that prevents impurities from entering the cavity 5 of the pump assembly 2.
[0055] In accordance with one embodiment, said control lever assembly 4 comprises a hub portion 16 opposite to said control lever 7 with respect to said fulcrum axis Y-Y. The provision of said hub portion 16 of said control lever assembly 4 allows the creation of a first-class lever with a favourable arm around said fulcrum axis Y-Y.
[0056] The pump body 3 comprises at least one abutment surface 19, adapted to form an abutment reference for said hub portion 16 opposite to said control lever 7 with respect to said fulcrum axis Y-Y.
[0057] In accordance with one embodiment, said hub portion 16 is made as a separate piece with respect to said control lever 7 of said control lever assembly 4. In accordance with one embodiment, said hub portion 16 is made as a separate piece with respect to said control lever 7 and to said attachment root 32 of said control lever assembly 4.
[0058] Thanks to the configuration of the hub portion 16 comprising a spherical support 58 adapted to abut against said abutment surface 19 of the pump body 3, the user is constrained to operate the empty stroke adjustment device 13 within a range of positions defined during the assembly step of the lever device 1.
[0059] Thanks to the fact that the empty stroke adjustment device 13 is associated with the hub portion 16, it is possible to modify the inclination of the control lever 7 with respect to the pump body 3 and, in particular, with respect to the pushing direction X-X ofthe piston 6.
[0060] Thanks to the provision of such an empty stroke adjustment device 13 associated with the hub portion 16 of the control lever assembly 4, it is avoided to provide adjustment holes for the empty stroke 100 of the piston in the piston body 6, for example directed transversely to the pushing direction X-X, which would cause a structural weakening of the piston 6 itself. Therefore, it is possible to obtain a piston 6 that is more resistant with equal dimensions and material, compared to known solutions. Thus, a user is allowed to adjust the empty stroke in vehicles requiring high braking power without thereby increasing the overall dimensions of the pump assembly 2, such as, for example, motor vehicles provided with a handlebar, racing vehicles provided with a handlebar, high-performance vehicles provided with a handlebar. At the same time, a user is allowed to adjust the empty stroke in lightweight vehicles, such as bicycles, while minimising the overall dimensions of the pump assembly.
[0061] For example, said empty stroke adjustment device 13 comprises an adjustment pin having a head 55, a stem 56 defining a rotation axis R-R, and a cam 57, eccentric with respect to said rotation axis R-R. The cam 57 is in turn provided with a spherical support 58. Thehead 55, the stem 56, and the cam 57 are integral with each other, in particular they are integral in rotation with respect to said rotation axis R-R. The empty stroke adjustment device 13 functions as a spacer between the control lever 7 and the pump body 3 and, therefore, adjusts the position of the piston 6 along said pushing direction X-X so as to vary the empty stroke 100 of the piston 6.
[0062] Based on the angular position of the cam 57 and the spherical support 58 on the abutment surface 19, the distance between the control lever 7 and the pump body 3 is modified and, therefore, the aforementioned empty stroke 100 of the piston 6 is adjusted.
[0063] In accordance with one possible embodiment, the head 55 comprises grooves 59 adapted to form seats for a stop 60, such as a ball or a set screw 61 influenced by a spring 62, so as to create detents to define discrete adjustment positions of the empty stroke 100.
[0064] In accordance with one embodiment, said head 55 of the empty stroke adjustment device 13 is provided with an Allen hole 63 so as to allow the rotation of the stem 56 by means of a suitable Allen key.
[0065] It is also possible to provide a knob (not shown) to allow manual rotation of the stem 56, without the aid of any tool.
[0066] A skilled person in the field, in order to meet contingent and specific requirements, may make numerous changes and modifications to the solutions described above.
[0067] The scope of protection of the invention is defined by the following claims.REFERENCE NUMBERS LIST:1. Lever device2. Pump assembly3. Pump body4. Control lever assembly5. Cavity6. Piston7. Control lever8. Push action transmission element9. Cylinder walls10. Piston bottom11. Chamber12. Supply channel13. Empty stroke adjustment device, or adjustment device 14. Piston bottom seal15. Piston return spring16. Hub portion19. Abutment surface23. Overhanging end of the lever24. Grip portion32. Attachment root of the control lever assembly33. Dust boot46. Further piston seal47. Connection means50. Lever contact portion55. Head56. Stem57. Cam58. Spherical support59. Grooves60. Stop61. Ball or set screw62. Spring63. Allen hole70. Brake / clutch fluid reservoir 100. Empty strokeX- X. Pushing directionY-Y. Fulcrum axis
Claims
CLAIMS1. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar comprising at least one pump assembly (2) comprising: - a pump body (3) comprising connection means (47) to the handlebar of a vehicle, said pump body (3) delimiting a cavity (5),- at least one piston (6) operatively associated with said pump body (3), so as to be adapted to slide inside said cavity (5) along a pushing direction (X-X);- wherein said lever device (1) further comprises at least one control lever assembly (4), rotatably associated with said pump body (3) so as to be rotatable around a fulcrum axis (Y-Y), said control lever assembly (4) being directly or indirectly connected to said piston (6) and comprising at least one control lever (7);- wherein said piston (6) comprises a piston bottom (10) defining, with cylinder walls (9) of the pump body (3), at least one chamber (11) for receiving the brake or clutch operating fluid of the vehicle, wherein at least one of said cylinder walls (9) of the pump body (3) being interrupted to delimit at least one supply channel (12), adapted to put said chamber (11) in fluid communication with at least one associable brake / clutch fluid tankand wherein said piston bottom (10) is movable with respect to said cylinder walls (9) of the pump body (3) within at least one end-stroke position, in which the volume of said chamber (11) is maximum, and at least a first working position, in which said piston bottom fluidly isolates said chamber (11) from said supply channel ( 12 ),- said piston (6) defining an empty stroke (100) between said end-stroke position and said first working position; - wherein said control lever assembly (4) comprises a hub portion (16) opposite to said control lever (7) with respect to said fulcrum axis (Y-Y), and wherein the pump body (3) comprises at least one abutment surface (19), adapted to form an abutment for said hub portion (16) opposite to said control lever (7) with respect to said fulcrum axis (Y-Y),- wherein the hub portion (16) is associated with an empty stroke adjustment device (13), adapted to adjust the distance along the pushing direction (X-X) between said end-stroke position and said first working position, - wherein said empty stroke adjustment device (13) is rotatable around a rotation axis (R-R) and comprises a cam (57) which is eccentric with respect to said rotation axis (R-R), so as to abut against the abutment surface (19).
2. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to claim 1, wherein said empty stroke adjustment device (13) comprises an adjustment pin having a head (55), a stem (56) defining said rotation axis (R-R) and passing through said hub portion (16) and said cam (57), so as to abut against the abutment surface (19).
3. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to claim 2, wherein the head (55), the stem (56) and the cam (57) are integral with each other, in particular they are integral in rotation with respect to said rotation axis (R-R).
4. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to claim 2 or 3, wherein the head (55) comprises seats (59) for at least one stop (60), so as to make stops for defining discrete adjustment positions of the empty stroke (100).
5. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to claim 4, wherein said seats (59) comprise grooves obtained on an outer side wall of the head (55).
6. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebaraccording to claim 4 or 5, wherein said at least one stop (60) comprises a ball or a set screw (61) influenced by a spring (62) adapted to influence the stop (60) in abutment against said seats (59).
7. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to any one of claims 2 to 6, wherein the head (55) of the empty stroke adjustment device (13) is provided with a hole (63) adapted to allow the insertion of a tool for its rotation, such as an Allen key.
8. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to any one of claims 2 to 7, wherein said head (55) of the empty stroke adjustment device (13) is associated with a knob.
9. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to any of the claims 1 to 8, wherein the cam (57) is in turn provided with a spherical support (58).
10. Lever device (1) for the hydraulic operation of the brake or clutch of a vehicle provided with a handlebar according to claim 9, wherein said spherical support (58) is eccentric with respect to said rotation axis (R-R).