Brake Lever Assembly Segmentation for Handlebar Installation
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Solution Overview
Problem
Conventional bicycle hydraulic brake systems have complex brake lever assemblies that are difficult to manufacture and assemble, complicating the installation process.
Innovation Solution
A brake lever assembly comprising a body, a seat, and a pin, where the body has an axial passage with a piston, and the seat has multiple portions for secure engagement with the handlebar, allowing easy assembly and preventing axial displacement, utilizing die casting, forging, or aluminum extruding for manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional brake lever assembly design is used, then the brake system can function properly, but the assembly is difficult to manufacture and assemble
Solution Approach 1:
The brake lever assembly is divided into distinct modular components: a body component, a seat component, and a pin component. Each component can be manufactured separately using die casting or forging processes, then assembled together through simple insertion and engagement operations. This segmentation reduces manufacturing difficulty while maintaining structural integrity.
Solution Approach 2:
The patent combines multiple functional elements into integrated components. The body component integrates the hydraulic passage, piston housing, and mounting features. The seat component combines the handlebar mounting interface and lever pivot support. This merging reduces the total number of parts and simplifies the assembly process.
2Reliability
If the brake lever assembly uses multiple interconnected parts, then the brake system functions properly, but the outer appearance becomes complicated and difficult to manufacture
Solution Approach 1:
The assembly is segmented into three main components (body, seat, pin) that can be manufactured using standard die casting or forging processes. Each component is designed with simple geometries suitable for these manufacturing methods, avoiding complex shapes that would be difficult to produce.
Solution Approach 2:
The pin component serves multiple functions simultaneously: it acts as a structural connector, a定位 element, and a retention mechanism. The design of the pin and its interaction with the body and seat components allows for self-aligning and self-locating during assembly, reducing the need for additional fastening operations or complex adjustment procedures.
3Ease of operation
If the body is freely positioned in the receiving hole, then assembly is simple, but the body can rotate relative to the seat
Solution Approach 1:
The outer surface of the body and the inner surface of the receiving hole feature localized engagement surfaces with specific geometries. These surfaces are designed to mate together in a specific orientation, preventing rotation while allowing for straightforward insertion. The engagement surfaces may include tapered features, keyed sections, or complementary shapes that provide both guidance and rotational constraint.
4Reliability
If the brake lever assembly uses a secure connection method, then the body is prevented from dropping axially, but the assembly becomes more complex
Solution Approach 1:
The retention function is extracted as a separate, simple pin component rather than being integrated into a complex locking mechanism. The pin is inserted through aligned holes in the body and seat components, providing axial retention through its physical presence. This approach achieves reliable connection with minimal structural complexity.
Solution Approach 2:
The pin component serves multiple functions: it acts as a structural connector between components, provides axial retention to prevent the body from dropping, and may serve as a reference feature for alignment. This multi-functionality achieves reliable connection without requiring additional separate retention elements or complex assembly operations.
Data Source
AI summary
A brake lever assembly includes a body, a seat and a pin. The body is connected to the seat and includes an outer surface which is engaged with an inner surface of the seat so that the body cannot rotate relative to the seat. The seat is connected to a brake lever and a handlebar. The body is connected to an adapter which is connected with a hydraulic oil pipe. A piston is located in the body and activated by the brake lever. The pin extends through the seat and the body to prevent the body from dropping from the receiving hole axially. The brake lever assembly is easily installed to the handlebar.