Abstract:
A coupling profile has, in a plane transversal to the axis of the bottom bracket, outer arcs belonging to the same outer circumference of the coupling, each of such outer arcs being flanked and filleted on one side to a power transmission line and on the opposite side to an idle line, in which the power transmission line and the idle line are symmetrical with respect to the outer arc that separates them. The outer arc has an angular extension about the axis of the bottom bracket equal to at least one tenth of the angular extension of the power transmission line, and the power transmission line and the idle line are filleted to the outer arc according to an angle smaller than 45°.

Description:
FIELD OF INVENTION  
       [0001]     The present invention is directed at the coupling between a central axle of a bottom bracket of a bicycle transmission and a pedal crank, and more specifically a coupling profile, as well as a central axle and a pedal crank shaped according to said profile.  
       BACKGROUND  
       [0002]     In relation to a central axle and a pedal crank of a bicycle transmission, “coupling” means the mutual mechanical interaction between axle and pedal crank that makes the two elements integral in rotation about the axis of the bottom bracket thereby, allowing the torque or power transmission between the pedal crank and the axle. In the same context, “attachment” means the mutual mechanical interaction that makes the two elements integral in translation in the direction of the axis of the bottom bracket, preventing the pedal crank from slipping off, thus ending the coupling.  
         [0003]     The coupling between the ends of the central axle and a pedal crank (right or left) of the bicycle is obtained, according to the prior art, through insertion of the aforementioned ends, projecting outside of a bicycle frame&#39;s bottom bracket housing, into suitable receiving seats made at the ends of the two pedal crank&#39;s elongated body. Suitable means make the central axle and each of the pedal cranks integral in rotation; an attachment screw then ensures that the coupling between the axle and the pedal crank is maintained.  
         [0004]     Herein, “coupling profile” means the ideal outline that separates the body of the central axle from the body of a pedal crank coupled with it. Normally, such a line defines both the outer profile of the axle and the inner profile of the receiving seat in the pedal crank, apart from the working tolerances; it is nevertheless possible for the aforementioned outer profile of the axle and inner profile of the seat to slightly depart from said ideal outline, leaving small empty spaces between axle and seat.  
         [0005]     The axle-pedal crank coupling must ensure high mechanical strength since during pedaling it is subjected to high and discontinuous stresses, in traction, in bending and in twisting. For such a purpose, known axle-pedal crank couplings provide for coupling profiles with particular geometric shapes (polygonal or with grooved profiles), so as to make shape couplings that make the pedal cranks integral in rotation with the central axle.  
         [0006]     In such profiles, two or possibly three types of lines are defined that follow each other sequentially:  
         [0007]     a power transmission line, which is the line through which the pressing contact between the material of the pedal crank that pushes the material of the axle during pedaling forwards takes place;  
         [0008]     an idle line, which is the line through which, during forward pedaling, there is contact but not pressing contact, thus without power transmission, since the material of the pedal crank is in front of the material of the axle in the direction of rotation; through this idle line there would be power transmission if backward pedaling were hypothetically provided, but stresses are in any case also transmitted during certain travel conditions, typically when the cyclist is standing up on the pedals and does not pedal (the cyclist&#39;s weight, possibly accentuated by holes or irregularities in the road, weighs down not only on the pedal facing forwards but also on the pedal facing backwards, thus causing a counterthrust on the pedal crank);  
         [0009]     possibly, finally, a peripheral line that is formed from an outer arc of circumference of the coupling, or rather of the outer circumference of the axle, and that therefore cannot transmit power either in one direction or the other, since it develops in the same direction as the rotation movement.  
         [0010]     Therefore, the coupling profile is formed from a succession along all 360° about the axis of the axle—in the direction of rotation during pedaling forwards—of triads each formed from a power transmission line, a peripheral line or outer arc of circumference, and an idle line. On the axle and in the receiving seat in the pedal crank, this succession determines a corresponding succession of ribs and grooves, extending axially; on the axle, each rib is defined by a power transmission line, an outer arc and an idle line, whereas conversely every groove is defined by an idle line and by a power transmission line; in the seat of the pedal crank, vice-versa, each rib is defined by an idle line and by a power transmission line, whereas conversely every groove is defined by a power transmission line, an outer arc and an idle line.  
         [0011]     A conventional type of axle-pedal crank coupling is that known as ISIS standard (see “ISIS Drive—The International Spline Interface Standard, ISIS Drive Standard Committee, 2001), which provides a grooved coupling profile with a defined shape and precise size values for ribs and grooves.  
         [0012]     In particular, according to said standard, the axle has ten equally angularly spaced ribs on its outer surface that extend longitudinally along the axis of the axle, such ribs consisting of crest zones joined by as many depressions having, in section, a circular profile. The fitting between each crest and the adjacent depression consists of a corner having an angle of about 60°; this means that at the fitting point the straight line tangent to the circular depression and the straight line tangent to the crest form an angle of about 60°.  
         [0013]     Correspondingly, the pedal crank has a receiving seat with a profile having a shape substantially matching that of the outer profile of the axle and therefore has ten equally angularly spaced grooves that extend longitudinally along the axis of the hole; such grooves consist of corresponding bottom zones joined by as many protrusions projecting towards the axis of the hole, such protrusions having a substantially circular profile in section. The fitting between each bottom and the adjacent protrusion consists of a corner of about 60°.  
         [0014]     Another axle-pedal crank coupling is known, where a coupling profile of undulating shape is provided, with a succession of completely rounded grooves and protrusions, substantially the same as each other, which follow each other along the periphery of the profile.  
         [0015]     A problem associated with this type of coupling is a lack of mechanical strength, and this problem is particularly serious since bicycle manufacture requires that the weight of each component is limited.  
       SUMMARY  
       [0016]     The present invention in particular tackles this problem by trying to make a axle-pedal crank coupling in which the mechanical stresses are distributed in a more homogeneous way, with respect to known solutions.  
         [0017]     The invention is thus, in one aspect, a coupling profile between a central axle of a bottom bracket of a bicycle transmission and a pedal crank, comprising, in a plane transverse to an axis of the bottom bracket, arcs defining an outer circumference of the coupling profile, each of said outer arcs being filleted on either side thereof to a power transmission line and an idle line, in which the power transmission line and the idle line are symmetrically separated by the outer arc, wherein the outer arc has an angular extension about the axis of the bottom bracket equal to at least one tenth of the angular extension of the power transmission line, and in that the power transmission line and the idle line are filleted to the outer arc according to an angle smaller than 45°. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]     Further characteristics and advantages of the invention shall become clearer from the following description of preferred embodiments thereof, made with reference to the attached drawings. In such drawings:  
         [0019]      FIG. 1  is an exploded isometric view of a first pedal crank-central axle pair according to the invention;  
         [0020]      FIG. 1   a  is a side view of the pedal crank of  FIG. 1 ;  
         [0021]      FIG. 1   b  is an enlarged view of a detail of  FIG. 1   a;    
         [0022]      FIG. 2  is an exploded isometric view of a second pedal crank-central axle pair according to the invention;  
         [0023]      FIG. 3  is a partial view of a coupling profile according to the invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS INTRODUCTION  
       [0024]     Generally, the present invention concerns, in a first aspect thereof, a coupling profile and pedal crank and/or pedal crank defined in the claims.  
         [0025]     A first aspect of the invention concerns a coupling profile between a central axle of a bottom bracket of a bicycle transmission and a pedal crank, comprising, in a plane transversal to the axis of the bottom bracket, outer arcs belonging to the same outer circumference of the coupling, each of such outer arcs being flanked and filleted on one side to a power transmission line and on the opposite side to an idle line, in which the power transmission line and the idle line are symmetrical with respect to the outer arc that separates them, wherein the outer arc has an angular extension about the axis of the bottom bracket equal to at least one tenth of the angular extension of the power transmission line, and in that the power transmission line and the idle line are filleted to the outer arc according to an angle smaller than 45°.  
         [0026]     Such a configuration allows uniform distribution of the stresses transmitted between pedal crank and axle. This profile, in particular, ensures more strength with respect to the profile of the ISIS standard quoted above, thanks to the absence of sharp edges in the zones subjected to high stresses; it also ensures easier assembly in general and centering in particular with respect to the prior art&#39;s undulating profiles that have no portions extending along the outer circumference of the profile.  
         [0027]     Preferably, the outer arc has an angular extension about the axis of the bottom bracket equal to at least two tenths, and more preferably four tenths, of the angular extension of the power transmission line. The greater extension of the outer arcs implies a smaller number of ribs on the axle, but also greater extension thereof in the circumferential direction; it has been found that by increasing the angular extension of the outer arc the distribution of the stresses is overall more uniform, provided that, however, said angular extension does not exceed the angular extension of the power transmission line.  
         [0028]     In a particularly preferred embodiment, the profile comprises twenty triads each comprising a power transmission line, an outer arc and an idle line, in which the outer arc has an angular extension about the axis of the bottom bracket equal to about 3° and each of the power transmission line and the idle line has an angular extension of about 7.5°.  
         [0029]     Preferably, the power transmission line and the idle line are filleted to the outer arc according to an angle less than 45°. Greater angles create stress concentration points and consequently structural weakness points on the bottom of the grooves in the seat of the pedal crank.  
         [0030]     Preferably, the power transmission line and the idle line are filleted tangentially to the outer arc.  
         [0031]     Preferably, the power transmission line and the idle line comprise line portions all filleted adjacent each other tangentially. The tangent fitting where the curvature changes is such as to minimize the concentration of the stresses.  
         [0032]     The power transmission line and the idle line can have a variously defined curved progression. For the sake of simplicity of construction, the idle line and the power transmission line each comprise a first arc of circumference that is concave towards the axis of the bottom bracket and a second arc of circumference that is convex towards the axis of the bottom bracket; for the same reason of simplicity of construction, preferably, the second convex arc of the idle line and the second convex arc of the adjacent power transmission line are extensions of each other.  
         [0033]     Again for the sake of simplicity of construction, but also to ensure uniformity in the distribution of stresses, the first concave arc and the second convex arc of the idle line and of the power transmission line have the same radius.  
         [0034]     In its second aspect, the invention concerns a central axle of a bottom bracket of a bicycle transmission, comprising two coupling zones for pedal cranks close to each of its two ends, such zones being externally shaped according to a coupling profile in accordance with the first aspect of the invention.  
         [0035]     For the screwing engagement with an attachment element of the pedal crank, the axle can be hollow and comprise an internal threading at least one or both of its ends, or else, on the other hand, it can comprise, at least one or both of its two ends and adjacent to the respective coupling zone for the pedal crank, a shank provided with an external threading for screwing engagement with an attachment element of the pedal crank. In the first case, the attachment element shall have a substantially screw-type configuration, whereas in the second case it shall have a substantially ring nut-type configuration.  
         [0036]     Preferably, the axle is made from steel.  
         [0037]     In the third aspect thereof, the invention concerns a pedal crank of a bicycle transmission, comprising a receiving seat for a central axle of a bottom bracket, wherein said seat is shaped according to a coupling profile in accordance with the first aspect of the invention.  
         [0038]     Preferably, at least the zone of the pedal crank in which the receiving seat is formed is made from aluminum alloy. The rest of the pedal crank can be either made from the same material, or be made from composite materials, such as carbon fiber and the like.  
       DESCRIPTION  
       [0039]      FIG. 1  represents a left pedal crank  1  comprising an elongated body having, at one end, a hole  2  for the attachment of the pedal (not shown) and, at the other end, a receiving seat  3  for a central axle  4 . The central axle  4  belongs to the bottom bracket of a bicycle transmission, which is in turn mounted in a suitable hole formed in the bicycle frame; only the axis X of the bottom bracket is shown in  FIG. 1 .  
         [0040]     If the pedal crank  1  is made entirely of metal, the seat  3  is formed directly in the material that constitutes the pedal crank  1  itself. In a variant embodiment, the pedal crank  1  can be made from composite materials (such as structural fibers incorporated in a matrix of polymeric material, for example carbon fiber in thermo-setting resin) and in such a case the seat  3  can be formed directly in the material that constitutes the pedal crank  1  itself, or else it can be formed on an insert associated with the body of the pedal crank  1 , for example a metal or carbon fiber insert, incorporated in the body of the pedal crank  1 .  
         [0041]     The central axle  4  is hollow and substantially tubular and at its ends it comprises respective coupling zones  5  with the left pedal crank  1  and with the right pedal crank (the latter of which is not shown).  
         [0042]     Each coupling zone  5  of the central axle  4  is provided with a central hole  6  with an internal threading  7  for screwing engagement with an attachment element of the pedal crank  1 , such as an attachment screw  9 .  
         [0043]     The attachment screw  9  comprises a threaded shank  10 , a flanged head  11 , and a hexagonal recess  12  for engagement with a maneuvering tool (not illustrated).  
         [0044]     The seat  3  of the pedal crank  1  comprises a first coupling zone  14  with the coupling zone  5  of the central axle  4  and a second zone  15 , adjacent to the first coupling zone  14  and with a greater diameter than it. Between the two zones  14  and  15  an annular abutment surface  16  is defined. An anti-loosening washer  13  is arranged between the head  11  of the screw  9  and the annular abutment surface  16  in the seat  3  of the pedal crank  1 .  
         [0045]     When the pedal crank  1  is assembled to the central axle  4 , the internal threading  7  of the coupling zone  5  of the central axle  4  is in screwing engagement with the threaded shank  10  of the screw  9 . The head  11  of the attachment screw  9  is arranged completely inside the second zone  15 ; said zone can then possibly be closed through the application of a lid.  
         [0046]      FIG. 2  illustrates a pedal crank  1  (the same as that of  FIG. 1 , and therefore numbered in the same way) and a central axle  94 . The axle  94 , close to its ends, comprises both two respective coupling zones  95  with the left pedal crank  1  and with the right pedal crank (the latter of which is not shown), and two respective cylindrical shanks  96 , projecting axially with respect to the zones  95  and provided with an external threading  97  for screwing engagement with an attachment element of the pedal crank, such as an attachment ring nut  99 . The attachment ring nut  99  consists of an annular element provided with internal threading  98  that engages on the external threading  97  of the shank  96  of the central axle  94  and with four outer notches  91  for engagement with a maneuvering tool (not illustrated). As for the embodiment of  FIG. 1 , an anti-friction washer  103  is arranged between the ring nut  99  and the annular abutment surface  16  in the seat  3  of the pedal crank  1 .  
         [0047]     When the pedal crank  1  is assembled to the central axle  94 , the external threading  97  of the cylindrical shank  96  of the central axle  94  is in screwing engagement with the internal threading  98  of the attachment ring nut  99 . The ring nut  99  is arranged completely inside the second zone  15  of the seat  3 ; as for the embodiment of  FIG. 1 , said zone can then possibly be closed through the application of a lid  11 .  
         [0048]      FIG. 3  illustrates an enlarged view of a portion of a coupling profile  30  according to the invention; it should be understood that the coupling profile  30  extends with regularity on all 360° about the axis X of the bottom bracket, possibly with a discontinuity having a key assembly function. For greater clarity, in  FIG. 3  the direction of rotation of the pedal crank  1  during forward pedaling is indicated with V; moreover, again for the sake of clarity, the zones around the coupling profile  30  are respectively numbered 1 and 4 to indicate the arrangement of pedal crank and axle; however, it is clear-as already explained-that the illustrated coupling profile  30  is an ideal outline, and that the actual outer profile of the axle  4  and inner profile of the seat  3  of the pedal crank  1  can possibly depart from such an ideal outline.  
         [0049]     The coupling profile  30  comprises a periodically repeated succession about the axis X of three close lines that are filleted adjacent each other, indicated hereafter and in the figures through the respective end points: a power transmission line AC, an outer arc CD, and an idle line DA.  
         [0050]     The power transmission line AC comprises a first portion of line AB formed from an arc of circumference having radius R 1 , convex towards the axis X, and a second portion of line BC formed from an arc of circumference having radius R 2 , concave towards the axis X. The two portions AB and BC are filleted adjacent each other tangentially, i.e. in point B the tangent to the portion AB coincides with the tangent to the portion BC; said tangent T 1  is inclined with respect to the radial direction R by an angle a equal to about 30°. Preferably, the radii R 1  and R 2  are the same.  
         [0051]     The outer arc CD comprises a portion of an outer circumference  31  of the coupling profile  30 , and therefore has a radius Rest. The outer arc CD is filleted to the power transmission line AC in point C according to an angle β (defined between the respective tangents T 2  and T 3  in which T 2  is the tangent of the outer arc CD and T 3  is the tangent of the portion BC of the power transmission line) of less than 45°, preferably less than 20°, and even more preferably substantially equal to 0°; in the illustrated example β is set different to zero, in order to be able to highlight it better.  
         [0052]     The idle line DA is equal and symmetrical to the power transmission line AC with respect to the outer arc CD, and thus comprises a first portion of line DE formed from an arc of circumference having radius R 2 , concave towards the axis X, and a second portion of line EA formed from an arc of circumference having radius R 1 , convex towards the axis X. The two portions DE and EA are filleted adjacent each other tangentially, i.e. in the point E the tangent to the portion DE coincides with the tangent to the portion EA; said tangent is inclined with respect to the radial direction by the angle a equal to about 30°.  
         [0053]     The portion of line EA and the portion of line AB are not only filleted adjacent each other tangentially, but are more precisely extensions of each other, i.e. they are portions of the same arc of circumference having radius R 1 . Preferably, R 1  is equal to the distance in the radial direction of the point A from the outer circumference  31 .  
         [0054]     Each power transmission line AC (and therefore also each idle line DA) has an extension in the angular direction about the axis X equal to an angle γ, whereas each outer arc CD has an extension in the angular direction about the axis X equal to an angle δ. In accordance with the invention, preferably the angle δ is not greater than the angle γ and is equal to at least one tenth, preferably to at least two tenths and even more preferably to at least four tenths, of the angle γ.  
         [0055]     The triad of lines AB, BD and DA as stated is repeated along the 360° about the axis X and therefore the coupling profile  30  defines a succession of filleted loops, which can be considered from the point of view of the axle  4  or from that of the pedal crank  1 . By adopting the point of view of the axle  4  (which may be more instinctive looking at  FIG. 3 ) the aforementioned loops thus comprise ribs  32  and grooves  33 . The number of ribs  32  and therefore of grooves  33  can be chosen by the designer of the transmission; the greater the number, the lesser the extension in the angular or circumferential direction of the ribs  32  and grooves  33  shall be.  
         [0056]     In the following Table 1, the characteristic values of some example coupling profiles of the invention are summed up, referring to a coupling profile with Rest radius outer circumference equal to 9.8 mm.  
                               TABLE 1                       n o  ribs   angle δ   angle γ   R1 = R2   angle α                   16   7.36°   7.57°   0.75 mm   30°       20   2.86°   7.57°   0.75 mm   30°       22   1.22°   7.57°   0.75 mm   30°       24   2°   6.5°   0.65 mm   28.7°       24   2°   6.5°    0.6 mm   25.6°                  
 
         [0057]     The coupling zones  5  of the axle  4  and the coupling zones  95  of the axle  94  are preferably provided with a respective beveled insertion portion  8  and  90 , close to the respective end of the axle. Characteristic features of the insertion portions  8  and  90  are an axial extension a and a diameter reduction b, best seen in  FIGS. 1   a  and  1   b ; the diameter reduction b is intended as the difference between a diameter measured at the side of the insertion portion  8  or  90  close to the main portion of the coupling zone  5  or  95  and the same diameter measured at the other side of the insertion portion  8  or  90 , close to the end of the axle  4  or  94  and remote from the main portion of the coupling zone  5  or  95 .  
         [0058]     Preferably, the axial extension a is at least 3 times the diameter reduction b, and at most 10 times the diameter reduction b.  
         [0059]     The diameter reduction b can be the same whether calculated in respect of the outer circumference  31  of the coupling profile  30  or in respect of any other characteristic point of the coupling profile  30 , such as points A or B. This means that the whole coupling profile  30  is beveled in the same way. Alternatively, in order to make manufacturing easier and cheaper, the diameter reduction b can be provided only in respect of the outer circumference  31  of the coupling profile  30 ; this option is particularly preferred when the ratio between the axial extension a and the diameter reduction b is high, i.e. where the diameter reduction b is small relative to the axial extension a.  
         [0060]     Thanks to the insertion portions  8  or  90 , insertion of the axle  4  or  94  into the seat  3  of the pedal crank  1  is made easier and more precise. Indeed, the beveled insertion portions  8  or  90  guide the axle  4  or  94  during insertion into the seat  3  and avoid that the coupling profile  30  of the axle  4  or  94  and of the seat  3  become damaged during insertion.  
         [0061]     A coupling profile according to the invention, thanks to the absence of sharp edge zones on the outer surface of the central axle and on the matching surface of the hole made in the pedal crank, allows a homogeneous distribution of the stresses both in the pedal crank and in the central axle; consequently, this coupling profile allows the weight of the transmission to be reduced without reducing its strength increasing the risks of breaking, i.e. it allows strength to be increased without increasing weight.  
         [0062]     A profile according to the invention, moreover, thanks to the presence of relatively extensive portions along the outer circumference of the profile, ensures good ease of assembly and centering of the pedal cranks with respect to the central axle.