Bicycle Hydraulic Device Integrated Passageway Design
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Solution Overview
Problem
Existing bicycle hydraulic systems face challenges in conserving space and eliminating unnecessary components within their hydraulic fluid passageways, which can lead to inefficiencies and increased complexity.
Innovation Solution
The design incorporates a base member with hydraulic fluid passageways and plugs that are secured using threaded connections and bonded methods, allowing for a compact and efficient fluid flow path with seals to prevent leakage, and the use of non-metallic materials for lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional hydraulic systems use separate components and conventional passageway configurations, then the system is easier to manufacture with standard parts, but the system occupies more space and has increased complexity
Solution Approach 1:
The patent integrates the hydraulic fluid passageway directly into the body of the hydraulic device, merging what would traditionally be separate components (body and passageway) into a single integrated structure. This eliminates the need for separate passageway components and reduces overall space occupation while simplifying the system configuration.
Solution Approach 2:
The body of the hydraulic device serves multiple functions: it provides structural support, contains the hydraulic fluid, and forms the fluid passageway itself. This multi-functionality reduces the number of separate components needed, thereby reducing space occupation and system complexity.
2Ease of manufacture
If the hydraulic fluid passageway is formed using traditional methods with separate components, then the manufacturing process is more standardized, but the assembly requires more parts and increases complexity
Solution Approach 1:
The passageway is formed as an integral part of the body through molding or machining operations performed directly on the body material. This eliminates the need for separate passageway components and their associated fasteners, seals, and assembly steps, thereby reducing the number of parts while maintaining manufacturing feasibility.
Solution Approach 2:
The passageway is designed as a integrated feature of the body that can be formed in single-piece construction, eliminating the need for multiple assembled components. This segmentation approach actually reduces part count by making the passageway inseparable from the body structure.
3Reliability
If plugs are used to seal openings in the hydraulic system, then fluid sealing is achieved, but the assembly requires additional components and assembly steps
Solution Approach 1:
The sealing function is integrated into the body structure itself through features such as recesses, grooves, or molded-in seals that are part of the body manufacturing process. This eliminates separate plug components and their associated sealing elements, reducing assembly complexity while maintaining sealing reliability.
Solution Approach 2:
Sealing features are pre-formed as integral parts of the body during the manufacturing process, rather than being added as separate components during assembly. This preliminary integration of sealing functions reduces the number of assembly steps and components required.
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 enables the formation of a compact, lightweight, and efficient hydraulic fluid passageway system that conserves space and simplifies manufacturing, while maintaining effective fluid flow and sealing, suitable for both actuating and hydraulically actuated devices.
Implementation Method 1
the receiving hole of the first plug includes an internal thread and the protrusion of the second plug includes an external thread that is threadedly engaged with the internal thread
Implementation Method 2
the protrusion of the first plug is bonded within the receiving hole of the second plug by a bonded connection therebetween
Implementation Method 3
a first seal disposed between the first plug and the base member, and a second seal disposed between the second plug and the base member
Implementation Method 4
The master cylinder contains a hydraulic fluid. The cylinder bore of the master cylinder is in fluid communication with a disc brake caliper housing
Data Source
AI summary
A bicycle hydraulic device is basically provided with a base member, a first plug and a second plug. The base member has a hydraulic fluid passageway, a first opening communicating with the hydraulic fluid passageway and a second opening communicating with the hydraulic fluid passageway. The first plug is disposed in the first opening, and having a receiving hole. The second plug is disposed in the second opening. The second plug has a protrusion extending into the receiving hole of the first plug to couple the first and second plugs to the base member.