Abstract:
A method of supporting a hose on a cable stopper of a bicycle involves providing a cable harness assembly including a hose hanger and a stopper bushing; inserting the stopper bushing within an inner space of the cable stopper; radially expanding the stopper bushing within the inner space of the cable stopper such that the stopper bushing at least partially contacts an interior wall of the cable stopper to couple the hose hanger to the cable stopper; and supporting the hose on a cable portion of the hose hanger. The hose hanger includes a body portion and the cable portion that is sized and configured to support the hose. The stopper bushing has an unexpanded outer width that is sized and configured to be received within the inner space of the cable stopper.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. patent application Ser. No. 09/488,711 filed on Jan. 21, 2000. The entire disclosure of U.S. patent application Ser. No. 09/488,711 is hereby incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention generally relates to a cable harness assembly for a bicycle. More specifically, the present invention relates to a cable harness assembly for guiding a disk brake control hose, a control cable or the like in accompaniment with a conventional cable stopper brazed on a bicycle frame. 
     2. Background Information 
     An arrangement of a generic cable harness is described in the ROC (Taiwan) Patent Publication No. 361417, such as that in FIG.  10 . This type of cable harness A includes a cable gripper  33 , a connector  30  and a connecting screw  31 . The cable harness A is mounted to a bicycle by being mounted to a conventional cable stopper  11  brazed on the bicycle frame. 
     However, in such a type of cable harness A, the connector screw  31  must be detached from the connector  30  and then removed from the cable gripper  33  prior to being mounted to a cable stopper  11  of the bicycle frame. This arrangement is thus tedious to use and may easily result in losing small parts after dismantling. 
     The necessity arises of mounting a cable harness to the cable stopper without having to dismantle the cable harness in order to carry out mounting operations. 
     In view of the above, there exists a need for a cable harness assembly which overcomes the above mentioned problems in the prior art. This invention addresses this need in the prior art as well as other needs, which will become apparent to those skilled in the art from this disclosure. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide a cable harness assembly that is easy to install. 
     More specifically, an object of the invention to design an arrangement for holding hoses, cables, or hydraulic lines in such a way that easy mounting is possible without the necessity to dismantle the cable harness assembly. As a result, losing of small parts can also be prevented and mounting can be easily accomplished without involving extraneous work. 
     To achieve the intended object, this invention discloses a cable harness assembly comprising a hose hanger, a hanger stopper, a stopper bushing and a hanger fixing bolt, wherein the stopper bushing expands when the fixing bolt is fastened to the hanger stopper forcing the hose hanger and the hanger stopper to press against the stopper bushing. 
     A further embodiment including a hose hanger and a stopper bushing is disclosed where the stopper bushing will rotate and skew with respect to the hose hanger while performing the fastening operation. 
     These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring now to the attached drawings which form a part of this original disclosure: 
     FIG. 1 is an exploded view illustrating the cable harness assembly in accordance with one embodiment of this invention; 
     FIG. 2 is a cross-sectional view illustrating the cable harness assembly of FIG. 1 before being mounted to a cable stopper brazed on a bicycle frame; 
     FIG. 3 is a cross-sectional view illustrating the cable harness assembly of FIG. 1 after being mounted to a cable stopper brazed on a bicycle frame; 
     FIG. 4 is an exploded view illustrating a second embodiment of a cable harness assembly of this invention; 
     FIG. 5 is a cross-sectional view illustrating the cable harness assembly of FIG. 4 before being mounted to a cable stopper brazed on a bicycle frame; 
     FIG. 6 is an exploded view illustrating a third embodiment of a cable harness assembly of this invention; 
     FIG. 7 is a cross-sectional view illustrating the cable harness assembly of FIG. 6 before being mounted to a cable stopper brazed on a bicycle frame; 
     FIG. 8 is a cross-sectional view illustrating a fourth embodiment of a cable harness assembly of this invention; 
     FIG. 9 illustrates a hose or a hydraulic line being guided through a cable harness assembly of this invention; and 
     FIG. 10 illustrates a conventional prior art cable harness that is attached to a cable stopper brazed on a bicycle frame. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in FIG. 1, a cable harness assembly  100   a  is illustrated in accordance with one embodiment of the present invention. The cable harness assembly  100   a  basically comprises a hose hanger  1   a , a hanger stopper  2   a , a stopper bushing  3   a  and a hanger fixing bolt  4 . The hose hanger  1   a  includes a body portion  12 , a cable portion  16 , and opposite ends  15  and  17 . The body portion  12  has a first outer diameter or width that has a first axial bore  14  extending between opposite ends  15  and  17 . The cable portion  16  extends outwardly from the body portion  12  for receiving a control cable or hose. 
     To enhance the flexibility of the hose hanger  1   a , the body portion  12  and the cable portion  16  of the hose hanger  1   a  can be joined by a neck portion  18 . The hose hanger  1   a  is preferably integrally formed as a one-piece, unitary member by injection molding. The cable portion  16  of the hose hanger  1   a  is formed with a longitudinal opening or slot  162 , preferably be configured to have a C-shaped cross-section. The C-shaped configuration of slot  162  has an inner diameter or width that is proximate to the outer diameter or width of a hose or hydraulic line  60 , to be held in the cable portion  16  as seen in FIG.  3 . 
     The hanger stopper  2   a  has opposite ends  21  and  23  and a second outer diameter or width, that is preferably slightly smaller than the first outer diameter or width of the body portion  12 . The hanger stopper  2   a  is formed with a second axial bore  22  extending between opposite ends  21  and  23 . A halting piece  24  further extends from the hanger stopper  2   a , preferably in an outwardly radial direction. The halting piece  24  has a rectangular configuration. The function of the halting piece  24  will be described later. 
     The stopper bushing  3   a  has opposite ends  37  and  38 . The stopper bushing  3   a  is sandwiched between the hose hanger  1   a  and the hanger stopper  2   a , and formed with a third axial bore  32  therethrough. The stopper bushing  3   a  is made of a radially expandable material, that has a third outer diameter or width being normally approximate to the second outer diameter or width of the hanger stopper  2   a . In the embodiment shown in FIGS. 1-3, the radially expandable material for making the stopper bushing  3   a  is a resilient material, such as rubber. 
     To assemble the hose hanger  1   a , the hanger stopper  2   a  and the stopper bushing  3   a  together, the hanger fixing bolt  4  is inserted through the first axial bore  14  of the hose hanger  1   a , the third axial bore  32  of the stopper bushing  3   a  and the second axial bore  22  of the hanger stopper  2   a . Prior to mounting of the cable harness assembly  100   a  to a bicycle frame, a tip end of the hanger fixing bolt  4  is inserted and threaded into the second axial bore  22  of the hanger stopper  2   a  by a short distance sufficient to hold the hose hanger  1   a , the stopper bushing  3   a  and the hanger stopper  2   a  together, but without providing external forces on the stopper bushing  3   a , as shown in FIG.  2 . 
     In use, the cable harness assembly  100   a  is inserted into a cable stopper  42  that is formed with an inner wall  44  and is conventionally brazed to a bicycle frame  40 . The lateral end  15  of the hose hanger  1   a  next to the stopper bushing  3   a  then urges against a lateral end of the cable stopper  42 . The halting piece  24  extending from the hanger stopper  2   a  is inserted through a slit (not shown) of the cable stopper  42  to halt the hanger stopper  2   a  from further rotation driven by the hanger fixing bolt  4 . A tool (not shown) is then implemented to drive the hanger fixing bolt  4  such that the fixing bolt  4  is fastened to the second axial bore  22  of the hanger stopper  2   a . The second axial bore  22  of the hanger stopper  2   a  may be formed with threads (not shown) therein so as to facilitate the fastening operation. The fixing bolt  4  may also be fastened to the second axial bore  22  in a self-tapping manner so as to reduce manufacturing cost of the hanger stopper  2   a.    
     In the embodiments as shown in FIGS. 1-3, the third diameter or width of the stopper bushing  3   a  will expand in one way or another as a result of the fastening operation of the hanger fixing bolt  4 , so as to attain the desired mounting effect to the bicycle frame  40 . Afterwards, a hose or hydraulic line  60  can be inserted into the cable portion  16  of the hose hanger  1   a  by being pressed through the longitudinal opening  162  so as to be secured to the bicycle frame  40 , as shown in FIG.  9 . 
     In a further embodiment shown in FIGS. 4 and 5, the lateral ends  21  of the hanger stopper  2   b  next to the stopper bushing  3   b  tapers radially inwards. The radially expandable material for making the stopper bushing  3   b  is a deformable, rigid material, such as metal or plastic. The stopper bushing  3   b  is further formed with at least one blind slit  34  along a longitudinal direction thereof. The cooperation between the tapering lateral end  21  and the slits  34  will be described later. 
     Accordingly, in the embodiment as shown in FIGS. 1-3, the fastening operation will force the hanger stopper  2   a  to move towards the stopper bushing  3   a  so as to press against the stopper bushing  3   a , such that the third outer diameter or width of the stopper bushing  3   a  increases due to radial deformation to a point to urge against the inner wall  44  of the cable stopper  42  so as to secure the cable harness  100   a  to the bicycle frame  40  due to radial expansion of the stopper bushing  3   a.    
     The second embodiment is assembled in substantially the same manner as the first embodiment. The hose hanger  1   b , the hanger stopper  2   b  and the stopper bushing  3   b  are coupled together by inserting the hanger fixing bolt  4  through the first axial bore  14  of the hose hanger  1   b , the third axial bore  32  of the stopper bushing  3   b  and the second axial bore  22  of the hanger stopper  2   b . Prior to mounting of the cable harness assembly  100   b  to a bicycle frame, a tip end of the hanger fixing bolt  4  is inserted and threaded into the second axial bore  22  of the hanger stopper  2   b  by a distance sufficient to hold the hose hanger  1   b , the stopper bushing  3   b  and the hanger stopper  2   b  together, but without providing external forces on the stopper bushing  3   b , as shown in FIG.  5 . 
     In use, the cable harness assembly  100   b  is inserted into a cable stopper  42  that is formed with an inner wall  44  and is conventionally brazed to a bicycle frame  40 . The lateral end  15  of the hose hanger  1   b  next to the stopper bushing  3   b  then urges against a lateral end of the cable stopper  42 . The halting piece  24  extending from the hanger stopper  2   b  is inserted through a slit (not shown) of the cable stopper  42  to halt the hanger stopper  2   b  from further rotation driven by the hanger fixing bolt  4 . A tool (not shown) is then implemented to drive the hanger fixing bolt  4  such that the fixing bolt  4  is fastened to the second axial bore  22  of the hanger stopper  2   b . The second axial bore  22  of the hanger stopper  2   b  may be formed with threads (not shown) therein so as to facilitate the fastening operation. The fixing bolt  4  may also be fastened to the second axial bore  22  in a self-tapping manner so as to reduce manufacturing cost of the hanger stopper  2   b.    
     In the embodiment as shown in FIGS. 4 and 5, the fastening operation will force the hanger stopper  2   b  to move towards the stopper bushing  3   b  subjecting the tapering lateral end  21  of the hanger stopper  2   b  to tuck into the third axial bore  32  of the stopper bushing  3   b  and causing the stopper bushing  3   b  to expand and flare open due to the slits  34  provided on the stopper bushing  3   b , so as to secure the cable harness assembly  100   b  to the bicycle frame  40  due to radial expansion of the stopper bushing  3   b  at the flared portion. 
     In the embodiments as shown in FIGS. 4 and 5, the third diameter or width of the stopper bushing  3   b  will expand in one way or another as a result of the fastening operation of the hanger fixing bolt  4 , so as to attain the desired mounting effect to the bicycle frame  40 . Afterwards, a hose or hydraulic line  60  can be inserted into the cable portion  16  of the hose hanger  1   b  by being pressed through the longitudinal opening  162  to be secured to the bicycle frame  40 , as shown in FIG.  9 . 
     In still a further embodiment shown in FIGS. 6 and 7, a portion of the lateral end  15  of the hose hanger  1   c  next to the stopper bushing  3   c  also tapers radially inwards, preferably from a radial location that is approximate to the second outer diameter or width of the hanger stopper  2   c . In this particular embodiment, the stopper bushing  3   c  is a C-shaped member  36 , preferably made of metal or plastic, with a third axial bore  32  as shown. The cooperation between the tapering lateral ends  21 , the portion of the lateral end  15  and the C-shaped member  36  will be described later. 
     The third embodiment is assembled in substantially the same manner as the first embodiment. To assemble the hose hanger  1   c , the hanger stopper or and the stopper bushing  3   c  together, the hanger fixing bolt  4  is inserted through the first axial bore  14  of the hose hanger  1   c , the third axial bore  32  of the stopper bushing  3   c , and the second axial bore  22  of the hanger stopper  2   c . Prior to mounting of the cable harness assembly  100   c  to a bicycle frame, a tip end of the hanger fixing bolt  4  is inserted and threaded into the second axial bore  22  of the hanger stopper  2   c  by a short distance sufficient enough to hold the hose hanger  1   c , the stopper bushing  3   c , and the hanger stopper  2   c  together, but without providing external forces on the stopper bushing  3   c , such as those shown in FIG.  7 . 
     In use, the cable harness assembly  100   c  is inserted into a cable stopper  42  that is formed with an inner wall  44  and is conventionally brazed to a bicycle frame  40 . The lateral end  15  of the hose hanger  1   c  next to the stopper bushing  3   c  then urges against a lateral end of the cable stopper  42 . The halting piece  24  extending from the hanger stopper  2   c  is inserted through a slit (not shown) of the cable stopper  42  to halt the hanger stopper  2   c  from further rotation driven by the hanger fixing bolt  4 . A tool (not shown) is then implemented to drive the hanger fixing bolt  4  such that the fixing bolt  4  is fastened to the second axial bore  22  of the hanger stopper  2   c . The second axial bore  22  of the hanger stopper  2   c  may be formed with threads (not shown) therein so as to facilitate the fastening operation. The fixing bolt  4  may also be fastened to the second axial bore  22  in a self-tapping manner so as to reduce manufacturing cost of the hanger stopper  2   c.    
     In the embodiment as shown in FIGS. 6 and 7, the fastening operation will force the hanger stopper  2   c  to move towards the C-shaped member  36 , subjecting the tapering lateral end  21  of the hanger stopper  2   c  to tuck into the axial bore  32  of the C-shaped member  36  and further causing the expanded C-shaped member  36  to slide towards the tapering lateral end  15  of the hose hanger  1   c , to secure the cable harness assembly  100   c  to the bicycle frame  40  due to expansion of the C-shaped member  36 . 
     In the embodiments as shown in FIGS. 6 and 7, the third diameter or width of the stopper bushing  3   c  will expand in one way or another as a result of the fastening operation of the hanger fixing bolt  4 , so as to attain the desired mounting effect to the bicycle frame  40 . Afterwards, a hose or hydraulic line  60  can be inserted into the cable portion  16  of the hose hanger  1   c  by being pressed through the longitudinal opening  162  to be secured to the bicycle frame  40 , as shown in FIG.  9 . 
     Another embodiment of this invention as shown in FIG. 8, it is disclosed a cable harness assembly  200  comprising a hose hanger  1   d , a stopper bushing  3   d  and a hanger fixing bolt  4 . The hose hanger  1   d , in this embodiment, includes a body portion  12  of a first outer diameter or width, a cable portion  16  extending from the body portion  12 , and opposite ends  15  and  17 . The body portion  12  has a first outer diameter or width and is formed with a first axial bore  14  of a first inner diameter or width therethrough. The body portion  12  of this embodiment is provided at one of the lateral ends  15  with a head  13  having a fourth outer diameter or width, preferably being smaller than the first outer diameter or width of the body portion  12 , having a lateral end  131 . The hose hanger  1   d , in this embodiment, may be optionally, a two-piece structure, where the head  13  is independent from the body portion  12 , or a one-piece structure, where the head  13  is integrally formed with the hose hanger  1   d.    
     The stopper bushing  3   d  is placed next to the hose hanger  1   d  and formed with a threaded axial bore  35  of a second inner diameter or width therethrough. The stopper bushing  3   d  is made of a rigid material, such as metal or plastic, that has a third outer diameter or width being approximate to the fourth outer diameter or width of the head  13  of the hose hanger  1   d.    
     In this embodiment, the lateral end  131  of the head  13  of the hose hanger  1   d  and the lateral end  37  of the stopper bushing  3   d  next to each other are both skewed, such that the fastening operation as described previously, will force the stopper bushing  3   d  to rotate and skew with respect to the head  13  of the hose hanger  1   d  due the skewed interface therebetween, to a point that interfacing tip of the head  13  urges against the inner wall  44  of the cable stopper  42  so as to secure the cable harness  200  to the bicycle frame  40 . The first inner diameter or width of the first axial bore  14  of the hose hanger  1   d  may be, optionally, slightly bigger than the second inner diameter or width of the threaded axial bore  35  of the stopper bushing  3   d , to facilitate the skewing of the stopper bushing  3   d  when the fixing bolt  4  is fastened to the threaded axial bore  35  of the stopper bushing  3   d.    
     In this embodiment, the disposition between the stopper bushing  3   d  and the hose hanger  1   d  changes as a result of the fastening operation of the hanger fixing bolt  4 , to attain the desired mounting effect to the bicycle frame  40 . 
     Apparently, the various embodiments of cable harness assembly  100   a ,  100   b ,  100   c  and  200  as described can be easily mounted to a conventional cable stopper  42  without the necessity to dismantle the cable harness assembly  100   a ,  100   b ,  100   c  and  200  or involve extraneous work. 
     While only selected embodiments have been chosen to illustrate the invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made without departing from the scope of the invention as defined in the appended claims. Also, the foregoing description of the embodiments according to the invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.