Bicycle cable connector for splicing two cables in series

A bicycle cable connector for connecting a first cable to a second cable includes a first connector and a second connector. The first connector include a first cable retaining portion for retaining the first cable and a projection extending along a first connector axis, wherein the projection includes a radially outwardly extending locking member. The second connector includes a second cable retaining portion for retaining the second cable and a tubular portion defining a first connector opening for receiving the first connector therein and having a side wall extending along a second connector axis. The side wall includes a first passage for passing the locking member in the direction of the second connector axis away from the first connector opening, a second passage extending in a circumferential direction, and a recess communicating with the second passage and extending in the direction of the first connector opening for receiving the locking member therein. The first and second passages and the recess may be formed entirely within the inner peripheral surface of the side wall or may be formed by openings that extend through the side wall.

BACKGROUND OF THE INVENTION

The present invention is directed to control cables for bicycle transmissions and, more particularly, to a cable connector for splicing two cables in series for use with a bicycle transmission.

Internal hub transmissions are often used on bicycles because the gear shifting mechanism is housed inside the wheel hub and is protected from elements such as rain, mud, etc. The transmission typically is controlled by a control cable of the type having an inner wire that slides within an outer casing (e.g., a Bowden cable), wherein the inner wire is connected to a clutch actuating mechanism disposed on the side of the hub. Gear shifting is accomplished by selectively pulling and releasing the inner wire.

When installing or removing the hub transmission, or when changing the control cable, the control cable must be connected to and disconnected from the clutch actuating mechanism. However, the clutch actuating mechanism is usually disposed in close proximity to the hub axle which, in turn, is coupled to the rear fork ends of the bicycle. As a result, there is very little space to access the cable coupling mechanism, and sometimes the entire wheel must be removed from the bicycle before the cable can be disconnected. When the wheel is removed, the cable is still attached to the hub, thus making wheel removal very awkward. Also, some clutch actuating mechanisms have the form of an annular ring disposed around the hub axle. Thus, changing the control cable inevitably requires removal of the rear wheel. This is very inconvenient for the bicycle mechanic.

SUMMARY OF THE INVENTION

The present invention is directed to a bicycle cable connector for splicing two cables together in series so that the cable may be quickly uncoupled from the transmission, thus making it very easy to remove the hub from the bicycle or replace the control cable. In one embodiment of the present invention, a bicycle cable connector for connecting a first cable to a second cable includes a first connector and a second connector. The first connector includes a first cable retaining portion for retaining the first cable and a projection extending along a first connector axis, wherein the projection includes a radially outwardly extending locking member. The second connector includes a second cable retaining portion for retaining the second cable and a tubular portion defining a first connector opening for receiving the first connector therein and having a side wall extending along a second connector axis. The side wall includes a first passage for passing the locking member in the direction of the second connector axis away from the first connector opening, a second passage extending in a circumferential direction, and a recess communicating with the second passage and extending in the direction of the first connector opening for receiving the locking member therein. The first and second passages and the recess may be formed entirely within the inner peripheral surface of the side wall or may be formed by openings that extend through the side wall.

In another embodiment of the present invention, a bicycle cable connector for connecting a first cable to a second cable includes a first connector and a second connector. The first connector includes a first cable retaining portion for retaining the first cable and a projection extending along a first connector axis, wherein the projection includes a threaded outer peripheral surface extending completely around the projection. The second connector includes a second cable retaining portion for retaining the second cable and a tubular portion having a threaded inner peripheral surface extending completely around the inner peripheral surface for engaging the threaded outer peripheral surface of the projection.

As applied to a clutch actuator member for a bicycle hub transmission, the clutch actuator may include a frame having a first end and a second end, a casing support disposed at the first end of the frame for supporting the outer casing of a control cable assembly which includes a first cable therein, an annular clutch actuating member rotatably mounted at the second end of the frame, and a second cable retained to the clutch actuating member for rotating the clutch actuating member. First and second connectors constructed as above may be provided for connecting the first cable to the second cable.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1is a plan view of a bicycle hub clutch actuator10which incorporates a particular embodiment of a cable coupling device14according to the present invention. Clutch actuator10includes a frame18having a first end22and a second end26. A casing support30is disposed at the first end22of frame18for supporting a second outer casing34of a second control cable assembly38, and an annular clutch actuating member42is rotatably mounted at the second end26of the frame. A second inner cable46is retained to the clutch actuating member42for rotating clutch actuating member42which, in turn, actuates a clutch in a hub transmission (not shown) in a conventional manner. Inner cable46slides within outer casing34of control cable assembly38and terminates at cable coupling device14. Cable coupling device14couples inner cable46to a first inner cable50within a first outer casing54of a first control cable assembly58.

FIG. 2is a detailed oblique view of the cable coupling device14shown inFIG. 1, andFIG. 3is an exploded view of cable coupling device14. As shown in those Figures, cable connecting device14includes a bracket60, a first connector64and a second connector68.FIG. 4is an oblique partial cross sectional view of first connector64and second connector68in a connected state.

Bracket60includes an elongated brace member72; a first casing support collar76disposed at a first end78of brace member72and defining a first outer casing opening80for supporting outer casing54of control cable assembly58therein; and a second casing support collar84disposed at a second end88of brace member72and defining a second outer casing opening92for supporting outer casing34of control cable assembly38therein. First casing support collar76defines a first slit96opposite brace member72for receiving outer casing54of control cable assembly58therethrough, and second casing support collar84defines a second slit100opposite brace member72for receiving outer casing34of control cable assembly38therethrough.

First connector64includes a first cable retaining portion110having a cable opening112for retaining inner cable50by a threaded fastener such as a fixing bolt114that screws into a threaded opening118and abuts against cable50. The outer peripheral surface126of first cable retaining portion110is knurled to facilitate manipulation during assembly and disassembly of cable coupling device14. First connector64also includes first connector locking portion in the form of a generally cylindrical projection119extending along a first connector axis X, wherein projection119includes a pair of diametrically opposed and radially outwardly extending locking members122.

Second connector68includes a second cable retaining portion130for retaining a cable end bead146of inner cable46of control cable assembly38by a fastener such as a rivet134that extends through an opening138in second cable retaining portion130and through an opening142in a cable end bead146attached to the end of inner cable46. The outer peripheral surface147of second cable retaining portion130is knurled to facilitate manipulation during assembly and disassembly of cable coupling device14. Second connector68also includes a tubular portion150defining a first connector opening154for receiving projection119of first connector64therein. Tubular portion150includes a side wall158extending along a second connector axis Y, wherein side wall158includes a second connector locking portion in the form of a locking wall162extending radially inwardly from an inner peripheral surface of side wall158and having a front side164and a rear side166. Locking wall162extends in a circumferential direction of the tubular portion and includes diametrically opposed recesses170(only one recess is shown inFIG. 3) extending in the direction of the second connector axis Y toward first connector opening154for receiving the pair of locking members122of first connector64therein. Side wall158defines diametrically opposed first passages174(only one such passage is shown inFIG. 3) for passing the locking members122in a direction of second connector axis Y away from first connector opening154from the front side164of locking wall162to the rear side of locking wall162, and diametrically opposed second passages178(only one such passage is shown inFIG. 3) extending in a circumferential direction for passing the locking members122along the rear side166of locking wall162to the recesses170. In this embodiment, the first passages174, the second passages178and the recesses170do not extend through side wall158so that projection119is covered by tubular portion150.

Second connector68also includes an abutment member180in the form of a round washer slidingly disposed in tubular portion150and a biasing member in the form of a spring184for biasing abutment member180toward first connector opening154. Spring184is disposed between abutment member180and an abutment188formed on cable end bead146. Thus, abutment member180and spring184cause cable terminating bead146and projection119to be biased away from each other so that locking projections122are firmly seated in recesses170.

In use, inner cable46is coupled to inner cable50by inserting locking members122through first passages174until locking members122are located at the rear side166of locking wall162. Thereafter, first connector64is rotated clockwise inFIG. 3relative to second connector68so that locking members122move in the circumferential direction within second connector130until locking members122reach recesses170. Locking members122then are seated in recesses170and held firmly in place by spring184and abutment member180. Inner cable46is disconnected from inner cable50by reversing this procedure.

FIG. 5is a detailed oblique view of an alternative embodiment of a cable coupling device214according to the present invention, andFIG. 6is an exploded view of cable coupling device214. As with the first embodiment described above, cable connecting device214includes a bracket260, a first connector264and a second connector268.FIG. 7is an oblique partial cross sectional view of first connector264and second connector268in a connected state.

Bracket260includes an elongated brace member272; a first casing support collar276disposed at a first end278of brace member272and defining a first outer casing opening280for supporting outer casing54of control cable assembly58therein; and a second casing support collar284disposed at a second end288of brace member272and defining a second outer casing opening292for supporting outer casing34of control cable assembly38therein. First casing support collar276defines a first slit296opposite brace member272for receiving outer casing54of control cable assembly58therethrough, and second casing support collar284defines a second slit300opposite brace member272for receiving outer casing34of control cable assembly38therethrough.

First connector264includes a first cable retaining portion310having a cable opening312for retaining inner cable50by a threaded fastener such as a fixing bolt314that screws into a threaded opening318and abuts against inner cable50. The outer peripheral surface326of first cable retaining portion310is knurled to facilitate manipulation during assembly and disassembly of cable coupling device214. First connector264also includes a first connector locking portion in the form of a generally cylindrical projection319extending along a first connector axis X, wherein projection319includes a pair of diametrically opposed and radially outwardly extending locking members322.

Second connector268includes a second cable retaining portion330for retaining a cable end bead346of inner cable46of control cable assembly38. The outer peripheral surface347of second cable retaining portion330is knurled to facilitate manipulation during assembly and disassembly of cable coupling device214. Second connector268also includes a tubular portion350defining a first connector opening354for receiving projection319of first connector264therein. Tubular portion350includes a second connector locking portion in the form of a side wall358extending along a second connector axis Y. Side wall358includes diametrically opposed first passages374for passing the locking members322in a direction of second connector axis Y away from first connector opening354, diametrically opposed second passages378extending in a circumferential direction, and recesses370extending in a direction of the second connector axis Y toward first connector opening354for forming seats for locking members322. In this embodiment, the first passages374, the second passages378and the recesses370extend through side wall358so that projections322are exposed.

Second connector268also includes an abutment member380slidingly disposed in tubular portion350, an abutment member381press fit into tubular portion350as shown more clearly inFIG. 8, and a biasing member in the form of a spring384for biasing abutment member380toward first connector opening354. As shown inFIGS. 6 and 8, spring384is disposed between abutment member380and an abutment388formed on cable end bead346. Thus, abutment member380and spring384cause cable terminating bead346and projection319to be biased away from each other so that locking projections322are firmly seated in recesses370. To ensure stability of movement of abutment member380and cable end bead346within tubular portion350, abutment member380includes diametrically opposed guide projections392which slide within a complementary pair of guide grooves396formed in the inner peripheral surface of tubular portion350, wherein guide grooves396extend in a direction of the second connector axis Y. Cable end bead346has similar diametrically opposed guide projections393which slide within guide grooves396.

In use, inner cable46is coupled to inner cable50by inserting locking members322through first passages374until locking members322are located at the position of second passages378. Thereafter, first connector264is rotated clockwise inFIG. 6relative to second connector268so that locking members322move in the circumferential direction within second connector268until locking members322reach recesses370. Locking members322then are seated in recesses370and are held firmly in place by spring384and abutment member380. Inner cable46is disconnected from inner cable50by reversing this procedure.

FIG. 9is a detailed oblique view of another alternative embodiment of a cable coupling device414according to the present invention, andFIG. 10is an exploded view of cable coupling device414. As with the first two embodiments, cable connecting device414includes a bracket460, a first connector464and a second connector468.FIG. 11is an oblique partial cross sectional view of first connector464and second connector468in a connected state.

Bracket460includes an elongated brace member472; a first casing support collar476disposed at a first end478of brace member472and defining a first outer casing opening480for supporting outer casing54of control cable assembly58therein; and a second casing support collar484disposed at a second end488of brace member472and defining a second outer casing opening492for supporting outer casing34of control cable assembly38therein. First casing support collar476defines a first slit496opposite brace member472for receiving outer casing54of control cable assembly58therethrough, and second casing support collar484defines a second slit500opposite brace member472for receiving outer casing34of control cable assembly38therethrough.

First connector464includes a first cable retaining portion510having a cable opening512for retaining inner cable50by a threaded fastener such as a fixing bolt514that screws into a threaded opening518and abuts against inner cable50. The outer peripheral surface526of first cable retaining portion510is knurled to facilitate manipulation during assembly and disassembly of cable coupling device414. First connector464also includes a first connector locking portion in the form of a generally cylindrical projection519extending along a first connector axis X, wherein projection519includes a threaded outer peripheral surface522extending completely around projection519.

Second connector468includes a second cable retaining portion530for retaining a generally cylindrical cable end bead532of inner cable46of control cable assembly38. Second connector468also includes a tubular portion550defining a first connector opening554for receiving projection519of first connector464therein. Tubular portion550includes a side wall558extending along a second connector axis Y, wherein an inner peripheral surface560of side wall558is threaded completely in the circumferential direction to form a second connector locking portion. Thus, in this embodiment inner cable46is coupled to inner cable50by screwing first connector464to second connector468.

FIG. 12is a plan view of an alternative embodiment of a bicycle hub clutch actuator610which incorporates an embodiment of a cable coupling device614according to the present invention. In this embodiment, clutch actuator610includes a frame618having a first end622and a second end626. A casing support630is disposed at the first end622of frame618for supporting an outer casing654of a first control cable assembly658, wherein first control cable assembly658includes a first cable650that slides within a first outer casing654. An annular clutch actuating member642is rotatably mounted at the second end626of frame618, and a second cable646is retained to clutch actuating member642for rotating clutch actuating member642. Cable coupling device614includes a first connector664and a second connector668that may be constructed according to any of the embodiments described above. In this embodiment, frame618has an opening670for exposing first connector664and second connector668to facilitate assembly and disassembly of cables646and650. A flexible cover in the form of a bellows674having a first end678mounted to first end622of frame618and a second end680mounted to first cable650is provided to prevent contaminants from entering between outer casing654and first cable650and thereby adversely affect the operation of first control cable assembly658.

While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. For example, the size, shape, location or orientation of the various components may be changed as desired. The functions of one element may be performed by two, and vice versa. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the scope of the invention should not be limited by the specific structures disclosed or the apparent initial focus on a particular structure or feature.