Handlebar Integrated Master Cylinder for Bicycle Hydraulics
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Solution Overview
Problem
The integration of wireless shifting and remote technology in bicycles has eliminated many cables and housings from the cockpit area, but brake hydraulic hoses remain, which can compromise aesthetics, increase weight, and pose a risk of catching on obstacles.
Innovation Solution
A handlebar-integrated master cylinder assembly where the fluid cylinder is partially positioned within the handlebar and partially within a grip, with hydraulic hoses routed through the handlebar to improve aesthetics, reduce weight, and enhance aerodynamics, while maintaining structural integrity by exiting through a single hole outside strength-critical areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brake hydraulic hoses are routed externally on the bicycle, then the system is simple to install and maintain, but the aesthetics are compromised, weight increases, and there is a risk of hose entanglement on obstacles
Solution Approach 1:
The hydraulic hoses are routed through the hollow interior of the handlebar, nesting the hose path within the existing handlebar structure. This eliminates external hose routing while maintaining installation simplicity, as the handlebar itself serves as the conduit.
Solution Approach 2:
The hose routing function is merged with the handlebar structure. Instead of separate external hose routing and handlebar components, the handlebar is designed to incorporate internal hose passages, combining aesthetic cleanliness with structural functionality.
2Ease of manufacture
If brake hydraulic hoses are routed externally on the bicycle, then the system is simple to install and maintain, but the weight increases and aerodynamics are compromised
Solution Approach 1:
The hydraulic hoses are nested within the handlebar's internal cavity, eliminating the need for separate external hose routing structures. This integration reduces overall system weight by removing redundant external mounting components and hose protective sleeves.
3Ease of manufacture
If brake hydraulic hoses are routed externally on the bicycle, then the system is simple to install and maintain, but the hoses may catch on obstacles
Solution Approach 1:
The hydraulic hoses are routed through the internal cavity of the handlebar, nesting them within a protected pathway. This prevents external entanglement with trail obstacles while the handlebar structure serves as the protective conduit.
4Object-affected harmful factors
If the fluid cylinder is integrated into the handlebar, then aesthetics are improved and weight is reduced, but the structural integrity of the handlebar may be compromised
Solution Approach 1:
The handlebar is segmented into distinct functional zones: external load-bearing sections maintain structural integrity, while an internal cavity section accommodates the fluid cylinder and hose routing. This segmentation allows aesthetic integration without compromising overall strength.
Solution Approach 2:
The handlebar exhibits local quality variations: external regions maintain full structural thickness for strength, while an internal cavity is created in a non-critical zone to accommodate the fluid cylinder and hose routing, achieving aesthetic integration without compromising load-bearing capacity.
5Weight of moving object
If the fluid cylinder is integrated into the handlebar, then weight is reduced and aerodynamics are improved, but the complexity of the assembly increases
Solution Approach 1:
The fluid cylinder assembly is merged with the handlebar structure, combining what would traditionally be separate components into a unified assembly. This integration reduces overall system weight and improves aerodynamics while the modular design keeps assembly complexity manageable.
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
The solution provides a cleaner cockpit appearance, reduced weight, improved aerodynamics, and reduced risk of hose entanglement, while maintaining the structural integrity of the handlebar by routing hydraulic hoses through the handlebar and exiting them through a single hole outside strength-critical areas.
Implementation Method 1
The actuator is configured to translate the piston from a first position to a second position when the actuator is actuated
Implementation Method 2
The pull rod member is under tensile load when the actuator is actuated
Implementation Method 3
a fluid cylinder for a hydraulic actuation system for a bicycle
Data Source
AI summary
A fluid cylinder assembly for a hydraulic actuation system for a bicycle is provided. The fluid cylinder assembly includes a fluid cylinder. The fluid cylinder includes a housing and a piston that is movable within the housing. The fluid cylinder assembly also includes a force applicator connected to the piston of the fluid cylinder, a support, and an actuator pivotably attached to the support. The actuator is operatively connected to the piston of the fluid cylinder via the force applicator, such that the actuator is configured to translate the piston from a first position to a second position when the actuator is actuated. The fluid cylinder is attachable to a handlebar of the bicycle, such that part of the fluid cylinder is positioned within the handlebar and at least part of the force applicator is radially outer relative to the handlebar.