Bicycle Disc Brake Cover Structure for Transport Protection
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Solution Overview
Problem
Disc brakes on bicycles are prone to damage during transportation and contamination during maintenance, with existing solutions failing to provide adequate protection.
Innovation Solution
A disc brake protector comprising an inner and outer cover with hook and loop fasteners, which encloses the disc brake, calliper, and brake pads, protecting them from damage and contamination while allowing the wheel to rotate, using flexible materials like polyvinylchloride and polymer foam for durability and cushioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the disc brake is left exposed for easy access during transportation, then the ease of operation is improved, but the disc brake becomes vulnerable to damage and contamination
Solution Approach 1:
The disc brake protector uses a nested structure with an inner cover that fits around the axle and disc brake components, and an outer cover that encloses the inner cover. This nested arrangement provides compact protection while maintaining ease of installation and removal, resolving the contradiction between protected access and vulnerability.
Solution Approach 2:
The inner cover is made from flexible material that can deform to accommodate the wheel and disc brake components, allowing the protector to be easily installed and removed without damaging the disc brake. The flexibility enables the cover to conform to the cylindrical shape of the wheel while providing continuous protection.
2Strength
If the disc brake is enclosed in a rigid protective cover, then the protection from damage is improved, but the wheel rotation and brake operation become restricted
Solution Approach 1:
The flexible material of the inner cover allows it to deform elastically as the wheel rotates and the brake components move, providing protection without restricting the mechanical operations of the disc brake system. The flexibility enables the cover to accommodate radial and axial movements during braking and rotation.
Solution Approach 2:
The protector design allows the covers to dynamically adapt to the movements of the wheel and brake components during operation. The flexible cover expands and contracts with wheel rotation and brake activation, maintaining protection while enabling full functional range of motion.
3Object-affected harmful factors
If a protective cover is added to the disc brake, then the protection from contamination is improved, but the device complexity increases
Solution Approach 1:
The protector is segmented into distinct functional components: an inner cover for direct protection of the disc brake and axle, and an outer cover for additional protection and structural support. This segmentation allows each component to be optimized for its specific function while simplifying the overall assembly and installation process.
Solution Approach 2:
The hook and loop fastening system merges the attachment function into the cover structure itself, eliminating the need for separate fasteners or complex mounting mechanisms. The fastening elements are integrated directly onto the covers, simplifying the overall device while providing secure attachment.
4Reliability
If the disc brake is protected during transportation, then the reliability is improved, but the ease of maintenance and cleaning is reduced
Solution Approach 1:
The flexible cover dynamically adapts during maintenance operations, allowing temporary access to the disc brake components when needed while maintaining protection during storage and transportation. The cover can be easily deformed or removed during maintenance and automatically returns to its protective configuration during normal use.
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
Effectively protects the disc brake components from damage and contamination during transportation and maintenance, ensuring reliable braking performance and extending the lifespan of the brake system.
Implementation Method 1
the inner cover and the outer cover are provided with first and second parts of a hook and loop fastener such that the inner cover can be removably attached to the outer cover
Implementation Method 2
The inner cover may comprise a flexible material. The flexible material may be a plastic.
Implementation Method 3
The outer cover may comprise a foam such as a polymer foam
Implementation Method 4
The closure member may be attached to the inner cover with a rotatable fastener
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
This invention relates to a disc brake protector (1; 101) for a bicycle (200), the disc brake protector comprising (a) an inner cover (10; 110) for fitting around an axle (220) of a bicycle wheel (205, 225) between the wheel and the disc brake, the inner cover comprising a closable opening (15; 115) for insertion of the axle, and (b) an outer cover (5) which is attachable to the inner cover such that, in use, the covers enclose the disc brake. The invention also relates to a method of attaching the disc brake protector, as well as to a bicycle fitted with the disc brake protector.