Bicycle Cable Routing System for Adjustable Stem Aerodynamics
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Solution Overview
Problem
Prior art internal cable routing systems for bicycles complicate handlebar stem length adjustments and increase costs by requiring adjustments to cable and housing lengths, and can reduce aerodynamic efficiency due to large headset components.
Innovation Solution
A cable routing system that routes cables internally through the handlebar and stem without external housings, using housing stops to manage cable routing within the handlebar and stem, allowing for independent adjustment of stem length without altering cable housing lengths, and utilizing a split design for the second housing stop to accommodate varying headset diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cables are routed internally through the handlebar and stem, then aerodynamic efficiency is improved and external appearance is enhanced, but it becomes difficult to adjust the length or height of the handlebar stem
Solution Approach 1:
The cable routing system is divided into multiple segments: cable housing within the handlebar, exposed cable through the stem, and cable housing within the head tube. This segmentation allows the stem to be adjusted independently while the cable housing remains fixed in the handlebar and head tube, resolving the contradiction between internal routing and adjustability
Solution Approach 2:
The cable housing is extracted from the stem portion, allowing the cable to run exposed through the stem while remaining housed in the handlebar and head tube. This extraction enables stem length adjustment without requiring modification of the cable housing system, maintaining both aerodynamic efficiency and adjustability
2Object-affected harmful factors
If cables are routed between the steerer tube and upper headset bearing, then internal cable routing is achieved, but the diameter of the head tube and bearing must be quite large, increasing cost and reducing aerodynamic efficiency
Solution Approach 1:
The cable housing is extracted from the headset bearing area and routed through the head tube instead. This allows the use of smaller, more aerodynamic headset components while still achieving internal cable routing, as the cable housing can accommodate the cable without requiring enlarged bearing diameters
Solution Approach 2:
The head tube acts as an intermediary pathway for the cable housing, allowing the cable to route from the handlebar to the front derailleur without passing through enlarged headset bearings. This mediator approach enables internal routing with standard-sized components, reducing cost and improving aerodynamics
Data Source
AI summary
A bicycle including a frame, a fork rotationally coupled to the frame within a head tube of the frame, and a wheel rotationally coupled to the fork. The fork has a steerer tube, and the bicycle further includes a stem that is coupled to the steerer tube, and a handlebar coupled to the stem for steering the wheel. The handlebar supports an actuator adapted to control a bicycle component. The bicycle also includes a cable housing that is disposed in the handlebar, and a cable that is coupled to the actuator and routed internally within the handlebar and the stem toward the head tube. The portion of the cable within the handlebar is routed through the cable housing, and the portion of the cable within the stem is exposed.