Bicycle Brake Lever Layout for Faster Hydraulic Pressure Build-Up
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Solution Overview
Problem
Existing bicycle control devices face challenges in efficiently adjusting the position of the primary seal relative to the timing ports, leading to suboptimal hydraulic pressure build-up and braking performance, and require integration of multiple components for cost and ergonomic improvements.
Innovation Solution
The control device incorporates an adjustable mechanism, such as a multi-position cam, to precisely locate the piston assembly and primary seal, allowing for independent design and material selection of components, and features a high-pivot brake lever and angled master cylinder for ergonomic and mechanical advantage, along with a remote hydraulic reservoir for enhanced fluid volume and air evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the master cylinder portion is positioned closer to the pivot axle, then the mechanical advantage is improved and lever movement is reduced, but the available space for component integration is reduced
Solution Approach 1:
The master cylinder portion is positioned within the housing in a nested arrangement that allows it to be closer to the pivot axle while maintaining space for other components. The housing structure accommodates the master cylinder in an optimized location that balances mechanical advantage with component integration requirements.
Solution Approach 2:
The master cylinder portion is oriented at an angle relative to the outward facing side of the housing, utilizing three-dimensional space efficiently. This angular positioning allows the master cylinder to be closer to the pivot axle in one dimension while maintaining adequate space in other dimensions for component integration.
2Ease of manufacture
If multiple components are integrated into a single housing, then manufacturing cost is reduced and assembly is simplified, but the design flexibility for material selection is reduced
Solution Approach 1:
The housing serves multiple functions: it contains the master cylinder portion, accommodates the pivot axle, provides structural support, and integrates various control device components. This multi-functional design reduces the need for separate housings for each component, lowering manufacturing costs while maintaining design flexibility through modular component design.
Solution Approach 2:
While the housing integrates multiple components, each component (master cylinder portion, pivot axle, etc.) remains a separate, independently designable element. This segmentation allows different materials to be selected for each component based on its specific functional requirements, maintaining material selection flexibility while achieving cost benefits from integrated housing design.
3Reliability
If the primary seal position is precisely adjusted relative to the timing ports, then hydraulic pressure build-up is improved, but the adjustment mechanism complexity increases
Solution Approach 1:
The piston assembly is positioned and the primary seal is pre-adjusted relative to the timing ports during manufacturing to achieve optimal hydraulic pressure build-up. This preliminary positioning eliminates the need for complex field adjustment mechanisms, maintaining reliability while minimizing adjustment mechanism complexity.
Solution Approach 2:
The piston assembly design allows the primary seal to maintain its optimal position relative to the timing ports through self-centering features or pre-set positioning mechanisms that do not require external adjustment. This self-service approach ensures reliable hydraulic pressure build-up without adding complex adjustment mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances braking performance by minimizing lever movement before pressure is felt, reduces component costs through integration, and provides a more ergonomic and durable braking system with improved mechanical advantage and fluid management.
Implementation Method 1
Some of these braking systems utilize a mechanism including a brake lever to generate pressure in a hydraulic fluid. This pressure is transferred through a hydraulic line or conduit to a brake assembly, such that the hydraulic pressure is applied to pads of the brake assembly
Implementation Method 2
The piston assembly is movable relative to the master cylinder portion. The piston assembly is configured to translate in a first direction relative to the master cylinder portion from a first position towards a second position when the lever pivots in a first rotational direction, such that the seal moves towards the opening through the cylindrical wall of the fluid cylinder and pushes a portion of the fluid out of the master cylinder portion
Data Source
AI summary
A control device includes a housing having a base portion and an extension portion. The base portion of the housing has an inward facing side and an outward facing side. The control device includes a lever coupled to and pivotable relative to the housing, and a master cylinder portion supported by the housing. The master cylinder portion has a hollow fluid cylinder. The control device also includes a piston assembly supported by the housing. The piston assembly is movable relative to the master cylinder portion. At least part of the piston assembly is disposed within the master cylinder portion. The master cylinder portion is angled relative to the outward facing side of the base portion of the housing, such that the first end of the fluid cylinder is closer to the outward facing side than the second end of the fluid cylinder is relative to the outward facing side.