Electric Bicycle Brake with Internal Cable Routing
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Solution Overview
Problem
Existing electric bicycle brakes are bulky, aesthetically unappealing, and complicated in design, with external cables that are both unaesthetic and potentially dangerous, and are a significant cost factor limiting their widespread adoption.
Innovation Solution
A compact brake design featuring an external lever with an internal support-piece that houses both the brake and sensor cables, incorporating a cable length adjuster and rotational bush for secure and aesthetic integration within the bicycle frame, eliminating the need for external cables and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If external cables are used to connect the brake to the motor, then the brake can be controlled by the motor, but the design becomes bulky and aesthetically unappealing
Solution Approach 1:
The patent applies nesting by placing the sensor cable routing path inside the brake lever bracket structure. The bracket serves as both a mechanical component and a cable management structure, with dedicated channels and openings that guide the sensor cable from the sensor through the bracket to the motor, eliminating external cable exposure and improving aesthetics.
2Ease of operation
If external cables are used to connect the brake to the motor, then the brake can be controlled by the motor, but the design becomes complicated and potentially dangerous
Solution Approach 1:
The patent applies nesting by placing the sensor cable routing path inside the brake lever bracket structure. The bracket serves as both a mechanical component and a cable management structure, with dedicated channels and openings that guide the sensor cable from the sensor through the bracket to the motor, eliminating external cable exposure and improving aesthetics.
Solution Approach 2:
The brake lever bracket acts as an intermediary structure that mediates between the sensor and the motor. It provides a structured intermediate path for the sensor cable, organizing the connection and eliminating the need for complex external routing arrangements.
3Shape
If a compact brake design is implemented, then the brake becomes aesthetically pleasing and safer, but the manufacturing cost increases
Solution Approach 1:
The patent applies multi-functionality by designing the brake lever bracket to serve multiple purposes: it provides mechanical support for the brake lever, houses the sensor mounting, and simultaneously acts as a cable management structure for the sensor cable. This integration eliminates the need for separate cable routing components, reducing part count and potentially lowering manufacturing costs despite the increased design complexity.
Data Source
AI summary
A brake for an electric bicycle is described, said brake comprising at least one mounting block (21) including a brake lever bracket (13) and a brake lever (5). Suitably, the brake comprises an internal support-piece (17) in turn comprising at least one first hole (17A) for housing a brake cable (11) connected to a suitable braking apparatus and a seating portion (17B) for seating a sensor cable (19) connecting a braking sensor (19A) to an electric motor of said electric bicycle.