Abstract:
A braking apparatus for a fishing reel comprising: a side cover; a brake dial rotatably positioned in the side cover such that the brake dial is externally accessible and operable from outside of the side cover, the brake dial having a plurality of predetermined positions; at least one interacting boss provided on either the brake dial or the side cover; and a resilient boss operably provided on the other of the brake dial or the side cover for interaction with the interacting boss such that, as the dial is rotated in a given direction to a point where the resilient boss contacts an interacting boss, further rotation in that direction is inhibited until the user exerts sufficient force on the dial to deform the resilient boss thereby allowing the resilient boss to traverse the interacting boss.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to braking systems for fishing reels. More particularly, but not by way of limitation, the present invention relates to adjustable braking systems for baitcast fishing reels. 
     2. Background 
     Baitcast fishing reels are well known in the art. A baitcasting reel will typically comprise: a split frame having a pair of opposing side plates; a foot extending from the frame for attaching the reel to a fishing rod; a line spool, rotatably positioned between the frame side plates, for retrieving and holding a fishing line; a spool shaft, on which the spool is secured, having ends extending through the frame side plates; a pinion gear (typically a helical gear) provided on the spool shaft; a manually rotatable crank handle; a gear train and crankshaft assembly mechanically linking the crank handle to the spool shaft pinion gear; a level-wind mechanism which transverses the spool during winding to ensure that the fishing line is properly wound along the length of the spool; a clutch mechanism for preventing reverse rotation of the crank handle; an exterior actuator (typically a thumb lever) for disengaging the pinion gear from the spool shaft to allow the spool to rotate freely during casting; and a spool drag or spool braking mechanism. 
     In most cases, right and left side covers are removably attached to the frame side plates for housing the reel&#39;s various operating mechanisms. A right-handed baitcasting reel (i.e., a reel designed for a right-handed user) will typically be structured such that the spool drag or spool braking mechanism is housed under the left side cover, the crank handle is rotatably mounted outside of the right side cover, and the crankshaft, gear train, pinion gear, clutch, and anti-reverse mechanism are housed under the right side cover. As will be understood by those skilled in the art, a left-handed version of generally any baitcasting reel can be produced by simply reversing the arrangement and structure of the reel&#39;s components such that the left-handed reel is a mirror image of the right-handed version of the reel. 
     Spool drag or spool braking systems are commonly used in baitcasting reels to alleviate line backlashing (also referred to as “line nesting”) problems. Because they utilize transversely-oriented spools which rotate during casting, baitcasting reels are more prone to backlashing problems than are spinning reels and spin casting reels. Such problems result primarily from the rotational momentum carried by the spool during casting. The most common types of drag/braking mechanisms used in baitcasting reels are magnetic drag brakes and centrifugal (friction) braking systems. 
     Many environmental factors, as well as personal preferences, affect the amount of braking force which may be appropriate for a given cast. This has led to the development of adjustable braking systems for baitcasting reels. For example, U.S. Pat. No. 5,108,042, incorporated herein by reference, discloses an adjustable, magnetic drag mechanism which exerts a magnetic drag force on the end of the reel spool. The magnetic force slows rotation of the spool during casting. The mechanism disclosed in the &#39;042 patent comprises: a magnet carrier ring having a plurality of magnets attached thereto; an axially movable cam disc to which the magnet carrier ring is secured; and an adjustment dial projecting through a recess in the left cover. The dial includes cams which are operably associated with the cam disc for selectively moving the carrier ring toward and away from the end of the spool in order to adjust the amount of magnetic drag force applied to the spool. 
     U.S. Pat. No. 5,950,949, also incorporated herein by reference, discloses a centrifugal braking system wherein the braking force exerted by the system can be selectively adjusted. Like the magnetic system of U.S. Pat. No. 5,108,042, the centrifugal braking system of the &#39;949 patent employs an externally adjustable brake dial having a plurality of smooth cam ramps provided thereon. In the centrifugal braking system of the &#39;949 patent, the cam ramps provided on the brake dial convert rotary movement of the dial into axial movement of a brake ring to thereby selectively adjust the number of braking pieces which can contact the brake ring. 
     Each of the dial cam systems of U.S. Pat. Nos. 5,108,042 and 5,950,949 provides an almost infinite number of possible braking positions within the available rotational range of the dial. Thus, such systems can provide a high degree of adjustability. However, they can also require significant experimentation both to identify preferred braking positions and to relocate such positions when making desired adjustments. Additionally, when used in centrifugal braking devices of the type disclosed in the &#39;949 patent, such systems do not ensure that the braking surface is always properly positioned such that the brake elements are prevented from rubbing and/or binding against the leading edge of the brake ring. 
     It is thus an object of the present invention to provide an adjustable braking system for a baitcast fishing reel which includes a discreting adjustment mechanism to provide an appropriate number of discrete braking ranges while allowing fine adjustment within each range when appropriate. 
     It is a further object of the invention to provide an adjustable braking system whereby a fisherman can easily return to a previous braking position. 
     SUMMARY OF THE INVENTION 
     The present invention provides a fishing reel braking apparatus which satisfies the needs and alleviates the problems discussed above. The inventive apparatus preferably comprises a brake dial rotatably positioned in a reel side cover such that the brake dial is externally accessible and operable from outside of the side cover, the brake dial having a plurality of predetermined discrete positions; at least one resilient, deformable boss provided on either the brake dial or the side cover; and at least one interacting boss located on the other of the brake dial or the side cover for interaction with the deformable boss such that, when the dial is rotated, the deformable boss will contact the interacting boss, thereby preventing further rotational movement of the dial until the user exerts sufficient force on the dial to temporarily deform the deformable boss and thereby allow the dial to rotate past the point of interference. There are thus provided at least two, and preferably three, predetermined discrete ranges of braking force. 
     In another aspect of the present invention there is provided a fishing reel braking apparatus incorporating an adjustable braking assembly wherein a discreting mechanism defines ranges of breaking force such that the brake dial allows fine adjustments between a plurality of predetermined discrete positions. In the preferred embodiment the brake dial includes a circular dial plate which is provided with a serrated edge along an arc concentric with the dial plate. A clicker spring cooperates with the serrated edge to provide an audible indication as the brake dial is rotated. 
     In another aspect of the present invention, an aperture is provided in the deformable boss to set the force required to deform the deformable boss to a desired level. 
     Further objects, features, and advantages of the present invention will be apparent to those skilled in the art upon examining the accompanying drawings and upon reading the following description of the preferred embodiments. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 provides a perspective view of a baitcasting reel  2  having the discreting backlash control apparatus incorporated therein. 
     FIG. 2 provides a cutaway view of the left side assembly of baitcasting reel  2 . 
     FIGS. 3A and 3B provide an exploded perspective view of the left side assembly of reel  2 . 
     FIG. 4 provides an elevational interior view of the left side cover  20  of reel  2 . 
     FIG. 5 provides a perspective view of inventive brake dial  24 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The preferred embodiment of the inventive, discreting backlash control apparatus (as incorporated in a baitcasting reel  2 ) is shown in FIGS. 1-5. As best seen in FIG. 1 baitcasting reel  2  comprises: a split frame  4  having a right side plate  6  and a left side plate  8 ; a line spool  10  rotatably mounted in frame  4  between side plates  6  and  8 ; a spool shaft  11  (FIG. 3B) extending through spool  10 ; a right side cover  14  secured over side plate  6 ; a crank handle  16 , operably extending from right cover  14 , for rotating spool  10 ; a reel foot  18 , provided on the bottom of frame  4 , for attaching reel  2  to a fishing rod; and a left side cover  20  secured over left side plate  8 . When reel  2  is assembled, the brake dial  24  of inventive brake apparatus projects through a circular aperture  26  formed in left cover  20 . 
     Although for convenience, the inventive apparatus is shown herein and described as incorporated in a right-handed baitcasting reel, the inventive apparatus is equally adaptable for use in left-handed reels. As will be understood by those skilled in the art, a left-handed version of generally any baitcasting reel can be produced by simply reversing the arrangement and structure of the reel&#39;s components such that the left-handed reel is a mirror image of the right-handed version of the reel. 
     Referring now to FIGS. 3A and 3B, the inventive braking apparatus preferably comprises: inventive brake dial  24  operably retained in side cover  20 ; and a brake assembly, such as, for example, a magnetic brake assembly  28  (FIG.  2 ). It should be understood that although the inventive apparatus is shown herein and described as incorporated in a baitcasting reel having a magnetic braking assembly, it is equally adaptable for use in a baitcasting reel having an adjustable centrifugal braking assembly such as the braking assembly described in U.S. Pat. No. 5,950,949 previously incorporated by reference. 
     The exemplary magnetic brake assembly  28  includes a movable magnet carrier ring  34  carrying a plurality of permanent magnets  36  thereon and a cam follower  40  for interacting with brake dial  24  to move magnet carrier ring  34  in response to adjustments made by the user. 
     As is commonly the case with baitcasting reels, reel  2  includes an interior spool cover  32  comprising: a cylindrical interior cavity  50  for holding a spool shaft bearing or bushing  52 ; a plurality of (preferably two) radially projecting ears  54 ; apertures  56  provided through radial ears  54 ; and a radially projecting, partial ear structure  58  having a semicircular notch  60  formed in the outer end thereof. Apertures  56  and notch  60  are sized and positioned to receive internally-threaded bosses  62 , provided in the interior of side cover  20 , such that spool cover  32  can be secured to side cover  20  by means of bolts or screws  64 . 
     As used herein, the terms “outer” and “outwardly facing” describe features facing and/or positioned away from end  12  of line spool  10 . The terms “inner” and “inwardly facing”, on the other hand, describe features facing and/or positioned toward end  12 . 
     The left end of spool shaft  11  is retained in bearing  52  which is held in spool cover  32  to axially fix the position of spool  10 . Therefore, as magnet carrier ring  34  is positioned axially toward and away from the left end  12  of spool  10 , the magnetic force acting on spool  10  as a result of permanent magnets  36  is likewise varied, thereby varying the drag force acting upon the spool. 
     As best seen in FIGS. 1,  4 , and  5 , brake dial  24  preferably comprises: a circular dial plate  180 ; a grasping structure  182  provided on the outer face of dial plate  180 ; a cylindrical cup  184  extending from the center of the inner face of dial plate  180  and sized for rotatably receiving cylindrical guide post  48  (FIG.  3 A); a curved cam  186  projecting from the inner face of dial plate  180 ; a serrated edge  196  located on the inner face of dial plate  180  along an arc concentric with dial plate  180 ; and a resilient, deformable boss  200  (FIG. 4) provided on the edge of dial plate  180  having an aperture  198  therein to allow deformation of boss  200  while operably traversing one or more interacting bosses  202  provided in left side cover  20 . Preferably, brake dial  24  is formed as a unitary structure from a resilient, elastomeric material such that deformable boss  200  is integral to dial plate  180 . 
     Cam  186  is preferably arranged in a circular pattern around cylindrical cup  184 . Cam  186  interacts with cam interacting member  66  of cam follower  40  to thereby selectively move magnet carrier ring  34  (FIG. 2) axially toward and away from spool end  12  through a series of braking positions. 
     Grasping structure  182  projects outwardly from the outer face of dial plate  180  and includes an exterior wall  188  and an indexing pointer  240 . 
     As best seen in FIG. 3A, brake dial  24  is rotatably held between (a) an internal radial shoulder  216  formed in side cover  20  around circular aperture  26  and (b) the guidepost  48  of spool cover  32 . 
     As depicted in FIGS. 2,  3 A, and  3 B, the inventive braking apparatus is preferably assembled such that brake dial  24  is positioned in cover aperture  26 ; cam follower  40  is positioned inwardly of dial  24  such that cam ramp  186  provided on dial  24  operably interacts with interacting member  66  provided on follower  40 ; retainer guidepost  48  extends outwardly through cam follower bore  68  and is received in interior dial cup  184 ; cam follower bosses  44  slidably extend through apertures  46  provided in spool cover  32 ; magnet carrier ring  34  is reciprocatably secured between spool cover  32  and spool  10  by attaching carrier ring  34  to cam follower bosses  44  using bolts  38 ; and clicker spring  31  interacts with serrated edge  196  to provide an audible indication as the dial is rotated. The assembled braking apparatus preferably also includes both a friction reducing O-ring  70  provided in interior dial cup  184 , for facilitating the rotation of dial  24 , and a spring  30  positioned around cover guidepost  48  between spool cover  32  and cam follower  40 . The outer end of spring  30  is received in cam follower groove  72  and exerts a continuous, outward biasing force on cam follower  40  whereby cam ramps  186  of dial  24  and interacting members  66  of cam follower  40  are maintained in operative contact. 
     When the brake dial  24  is rotated to its full clockwise position, the interacting member  66  of cam follower  40  will be located on the lowest portion of cam  186 , placing magnet carrier ring  34  in its fully outward, minimum braking position. As the user turns brake dial  24  counterclockwise, the sloped cam  186  acts against interacting member  66  to push interacting member  66  and magnet carrier ring  34  inward. Finally, as the user continues to rotate dial  24  to its full counterclockwise position, interacting member  66  will be located on the highest portion of cam  186 , placing the magnet carrier ring  34  in its fully inward, maximum braking position. 
     As best seen in FIG. 4, as the user rotates dial  24 , deformable boss  200  will come into contact with an interacting boss  202 . To rotate the dial  24  beyond the point of contact, the user must exert enough force to deform deformable boss  200  sufficiently to allow it to traverse the interacting boss  202 . Deformation of deformable boss  200  is facilitated by aperture  198  located in boss  200 . Preferably, there are provided two interacting bosses  202 , thereby producing three discrete braking ranges. The beginning of a low braking range is defined when the dial  24  is rotated to its full clockwise, minimum braking position. The low range ends at the point where deformable boss  200  contacts the first interacting boss  202  as the dial  24  is rotated counterclockwise. As the user rotates the dial  24  past the first interacting boss, the brake assembly  28  is placed in its medium braking range. As the user continues to rotate the dial  24  counterclockwise, the medium range ends as deformable boss  200  contacts the second interacting boss  202 . The high braking range begins as the dial  24  is rotated past the second interacting boss  202  and the high range ends when the dial  24  is turned to its full counterclockwise, maximum braking position. 
     Preferably, the brake dial  24  is adjustable within each of the three brake ranges. As the dial is adjusted within a range, clicker spring  31  will interact with serrated edge  196  to produce an audible indication of the dial movement as well as a tactile sensation. 
     It will be obvious to those skilled in the art that a single interacting boss  202  could be provided to produce two operating ranges (e.g., a high range and a low range), or multiple interacting bosses could be provided to produce a greater number of ranges. It will be further obvious to those skilled in the art that the individual, interacting bosses  202  could be located immediately adjacent to one another such that a plurality of discrete braking positions are defined by the interacting bosses rather than discrete ranges of braking positions. 
     Shoulders  234  and  238  on the sides of boss  200  operate to limit the rotation of brake dial  24  such that the cam  186  cannot be rotated past interacting member  66  when turning brake dial  24  in either direction. The rotational movement of brake dial  24  is limited in the clockwise direction by the abutment of shoulder  234  with stop  236  and is limited in the counterclockwise direction by the abutment of shoulder  238  with stop  236 . Stop  236  is provided in the interior of side cover  20 . Thus, the inventive braking system cannot be turned past either the above-mentioned “full braking position” or the above-mentioned “minimum braking position.” The braking position of the inventive apparatus is preferably indicated by an index indicator  240  provided on the exterior of brake dial  24 . Indicator  240  is preferably formed as a separate component so that indicator  240  may be of a different material or different color than brake dial  24 . Preferably, index marks  244  are provided on the exterior of side cover  20  about aperture  26  to provide a visual indication to a fisherman of the current brake setting. 
     As will be understood by those skilled in the art, although the preferred embodiment of the inventive apparatus utilizes one cam  186  and one corresponding interacting member  66 , the inventive apparatus could optionally utilize two, three, or more cams  186 . Further, although the cam  186  of inventive brake dial  24  is of continuous slope, flat areas corresponding to discrete braking positions could also be used. 
     As also will be understood by those skilled in the art, although the above-described preferred embodiment of the inventive apparatus has been explained with reference to a magnetic braking assembly  28 , other types of braking assemblies (e.g., a centrifugal braking assembly) could be employed in the present invention. 
     As will be further understood by those skilled in the art, equivalent operation and feel of the brake dial  24  could be achieved by forming the deformable boss  200  on the side cover  20  about aperture  26 . Interacting bosses  202  could then be located on brake dial  24  such that interacting bosses  202  rotate with brake dial  24  for interaction with stationary deformable boss  200 . 
     It will be further understood by those skilled in the art that the inventive apparatus can be employed in generally any type of baitcasting reel. 
     Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those skilled in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the appended claims.