Abstract:
A cable connecting apparatus for a control cable having an inner wire that slides within an outer casing includes a cable sleeve adapted to receive the outer casing of the control cable; a guide having a first end portion and a second end portion, wherein the guide supports the cable sleeve so that the cable sleeve moves toward the first end portion and the second end portion; and a biasing device for biasing the cable sleeve toward the second end portion of the guide. A connecting apparatus for a first control cable having a first inner wire that slides within a first outer casing and a second outer casing and a second control cable having a second inner wire that slides within a third outer casing and a fourth outer casing includes a bracket including a first support for supporting the first outer casing; a second support for supporting the second outer casing spaced apart from the first outer casing; a third support for supporting the third outer casing; and a fourth support for supporting the fourth outer casing spaced apart from the third outer casing. A connecting member is provided for connecting a portion of the first inner wire located between the first outer casing and the second outer casing to a portion of the second inner wire disposed between the third outer casing and the fourth outer casing, wherein the connector moves together with the first inner wire and the second inner wire. A position confirmation means is provided that allows the position of at least one of the first outer casing, the second outer casing, the third outer casing and the fourth outer casing to be visually confirmed.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention is directed to bicycle brake devices and, more particularly, to a bicycle brake cable retainer, a bicycle brake lever assembly, a bicycle brake cable connector, and a bicycle brake system.  
           [0002]    A bicycle brake system commonly comprises front and rear braking devices for applying braking forces to the front and rear wheels, front and rear brake levers mounted on the handlebar and designed to operate the front and rear braking devices, and brake cables secured to the front and rear braking devices and to the front and rear brake levers. Each brake cable comprises an inner wire that slides within an outer casing, wherein the inner wire is connected at one end to the brake lever and at the other end to the braking device. The outer casing ordinarily has one end mounted to a bracket for the brake lever and another end mounted to a bracket for the braking device.  
           [0003]    The braking device comprises a braked member that rotates with the wheel and a braking member capable of coming into contact with the braked member. The braked member usually is the rim or hub of the wheel. The braking device for applying the braking force to a wheel rim may be a caliper brake or a cantilever brake, whereas the braking device for applying the braking force to a wheel hub may be an internal expanding brake in the form of a band brake, disk brake, roller brake, or the like. The braking device usually includes a play adjusting mechanism for adjusting the gap between the braked member and the braking member (that is, the play of the braking device) when the brake lever is not being operated. In a typical mechanism, an outer retainer for securing the outer casing is screwed into the braking device, the retention position of the outer casing is shifted in the axial direction of the cable by the rotation of the outer retainer, and the play is thus adjusted. This operation also sets the brake timing of the braking device.  
           [0004]    A cable connector that allows the front and rear braking devices to be operated simultaneously with a single brake lever is disclosed in JP (Kokai)  4-2588,  for example. In that device, the cable connector is disposed in the middle of the front and rear brake cables. The cable connector has a connection member for connecting exposed portions of the inner wires of the front and rear brake cables together and a bracket that allows the connection member to move. Outer retainers for securing the portions of the outer casings extending toward the braking devices and the portions of the outer casings extending toward the brake levers are disposed at opposite ends of the bracket. In a brake system having such a cable connector, both inner cables are pulled when a single brake lever is actuated, thus making it possible to obtain enhanced frame stability and stabilized braking characteristics. In addition, braking can be accomplished by operating either the left or right brake lever, thus making it possible to operate the brake levers with ease and to increase the service life of the braking devices by dispersing the braking force.  
           [0005]    Since both inner cables are pulled when a single brake lever is actuated in such a system, the inner cable secured to the unactuated brake lever extends further from the outer casing, sags, and causes the brake lever to become loose. Furthermore, since the front and rear inner cables move simultaneously, the front and rear brake timing may vary considerably if the play is markedly different for each braking device. Since the inner cable connected to the rear braking device is longer than the one connected to the front braking device, it tends to stretch more during use. As a result, the rear brake timing gradually shifts away from the initial timing during use, thus making it necessary to readjust the amounts of play for the front and rear braking devices.  
           [0006]    Optimally, the play of the front and rear braking devices should be kept the same or be limited to a specific difference. In a conventional braking device in which braking force is applied to the rim, the play can be kept constant by equalizing the gap between the brake shoe and the rim for the front and back wheels. In practice, however, this is difficult to do. In systems in which braking force is applied to the wheel hub, the braking member brought into contact with the drum is disposed inside the braking device, thus making it impossible to see the gap formed between the braking member and the hub. This makes it even more difficult to provide the front and back braking devices with the desired amounts of play.  
         SUMMARY OF THE INVENTION  
         [0007]    The present invention is directed to an apparatus that can be used to simplify the adjustment of brake play and/or minimize looseness of the brake cable. In one embodiment of an invention directed to a cable connecting apparatus for a control cable having an inner wire that slides within an outer casing, the cable connecting apparatus includes a cable sleeve adapted to receive the outer casing of the control cable; a guide having a first end portion and a second end portion, wherein the guide supports the cable sleeve so that the cable sleeve moves toward the first end portion and the second end portion; and a biasing device for biasing the cable sleeve toward the second end portion of the guide. This allows slack to be taken up in a brake cable attached, for example, to a brake lever in a system wherein the front and rear cables are connected together for simultaneous operation.  
           [0008]    In an embodiment of an invention directed to an indicating apparatus for a control cable having an inner wire that slides within an outer casing, the indicating apparatus includes a guide adapted to receive the outer casing of the control cable, an indicator adapted to be retained to the outer casing of the control cable, and a window for viewing the indicator. In another embodiment of an invention directed to an indicating apparatus for a control cable having an inner wire that slides within an outer casing, the indicating apparatus includes a guide adapted to receive the outer casing of the control cable, an indicator adapted to be retained to the outer casing of the control cable, and indicia supported by the guide for cooperating with the indicator to indicate a position of the outer casing of the control cable.  
           [0009]    In an embodiment of an invention directed to a connecting apparatus for a first control cable having a first inner wire that slides within a first outer casing and a second outer casing and a second control cable having a second inner wire that slides within a third outer casing and a fourth outer casing, the apparatus includes a bracket including a first support for supporting the first outer casing, a second support for supporting the second outer casing, a third support for supporting the third outer casing, and a fourth support for supporting the fourth outer casing. A connecting member is provided for connecting a portion of the first inner wire located between the first outer casing and the second outer casing to a portion of the second inner wire disposed between the third outer casing and the fourth outer casing, wherein the connector moves together with the first inner wire and the second inner wire. A position confirmation means is provided that allows the position of at least one of the first outer casing, the second outer casing, the third outer casing and the fourth outer casing to be visually confirmed. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    [0010]FIG. 1 is a side view of a bicycle that incorporates a particular embodiment of a braking apparatus according to the present invention;  
         [0011]    FIG. 2  is a detailed view of the braking apparatus;  
         [0012]    FIGS.  3 ( a ) and  3 ( b ) are views illustrating the operation of a braking device shown in FIG. 2;  
         [0013]    [0013]FIG. 4 shows partial cross sectional views of the outer retainers and cable connector shown in FIG. 2;  
         [0014]    [0014]FIG. 5 is an exploded view of the cable connector shown in FIG. 2;  
         [0015]    [0015]FIG. 6 is a detailed cross sectional view of the cable connector shown in FIG. 2;  
         [0016]    FIGS.  7 ( a ) and  7 ( b ) are a schematic views illustrating how play in the braking devices is confirmed;  
         [0017]    [0017]FIG. 8 is a partial cross sectional view of another embodiment of a cable connector according to the present invention;  
         [0018]    [0018]FIG. 9 is a partial cross sectional view of another embodiment of a cable connector according to the present invention; and  
         [0019]    [0019]FIG. 10 is a cross sectional view of a braking device that includes a particular embodiment of a braking force modulator.  
     
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS  
       [0020]    [0020]FIG. 1 is a side view of a bicycle that incorporates a particular embodiment of a braking apparatus according to the present invention. In this embodiment, the bicycle is a touring bicycle comprising a frame  1  with a double-loop frame body  2  and a front fork  3 , a handle assembly  4  for steering, a drive unit  5  for transmitting the rotation of pedals  5   a  to a rear wheel  7 , a front wheel  6 , and a brake system  8  for braking the front and rear wheels  6  and  7 . The handle assembly  4  comprises a handle stem  10  fixedly mounted in the upper portion of the front fork  3  and a handlebar  11  fixedly mounted on the handle stem  10 . The handle assembly  4 , drive unit  5 , front wheel  6 , rear wheel  7 , and brake system  8  are mounted together with a saddle  9  and other components on the frame  1 .  
         [0021]    As shown in FIG. 2, the brake system  8  comprises front and rear brake levers  12   f  and  12   r,  braking devices  13   f  and  13   r  actuated by the front and rear brake levers  12   f  and  12   r,  front and rear brake cables  14   f  and  14   r  connected between the front and rear brake levers  12   f  and  12   r  and the front and rear braking devices  13   f  and  13   r,  and a cable connector  15  for connecting the front and rear brake cables  14   f  and  14   r  in a manner described below. The brake cables  14   f  and  14   r  comprise inner cables  16   f  and  16   r  connected at both ends to the brake levers  12   f  and  12   r  and to the braking devices  13   f  and  13   r  , and outer casings  17   f  and  17   r  for covering the inner cables  16   f  and  16   r.  The outer casings  17   f  and  17   r  are divided by the cable connector  15  into the outer casings  17   fa  and  17   ra  extending from cable connector  15  toward the brake levers  12   f  and  12   r,  and the outer casings  17   fb  and  17   rb  extending from cable connector  15  toward the braking devices  13   f  and  13   r.    
         [0022]    The front brake lever  12   f  is mounted inwardly from a grip  18   a  attached to the left end of the handlebar  11 , and the rear brake lever  12   r  is mounted inwardly from a grip  18   b  attached to the right end of the handlebar  11 . The brake levers  12   f  and  12   r  are mirror images of each other. The brake levers  12   f  and  12   r  each comprise a lever bracket  20  mounted on the handlebar  11 , a lever member  21  pivotably supported by the lever bracket  20 , and an outer retainer  22  fixedly screwed into the lever bracket  20 .  
         [0023]    Each lever bracket  20  comprises a rocking shaft  20   a  for pivotably supporting the lever member  21 , a mounting component  20   b  detachably mountable on the handlebar  11 , and an internally threaded component  20   c  capable of threadably accepting the outer retainer  22  and receiving the inner cables  16   f  and  16   r  therethrough. Each lever member  21  is biased by a biasing member (not shown) in the direction of brake release, and each lever member  21  has an inner retainer  21   a  for securing the inner cables  16   f  and  16   r  of the brake cables  14   f  and  14   r.    
         [0024]    As shown in FIG. 4 , each outer retainer  22  comprises a cable sleeve  23 , a guide  24 , a coil spring  25 , and a cable cover  26 . The guide  24  is a cylindrical member whose tip is provided with an externally threaded portion  24   a  for detachable threaded engagement with the internally threaded component  20   c  of a conventional lever bracket  20 . Such a structure makes it easy to remove and/or repair outer retainer  22 . The cable sleeve  23  is a perforated cup-shaped member capable of securing the tips of the outer casings  17   fa  or  17   ra,  and it has on the external periphery thereof a spring sleeve  23   a  that is folded near the opening. Guide  24  is designed to support the cable sleeve  23  on the internal peripheral surface thereof while allowing cable sleeve  23  to move a predetermined distance along the axis of the brake cables  14   f  and  14   r.  The coil spring  25 , disposed in compressed form between the tip of guide  24  and the spring sleeve  23   a  of cable sleeve  23 , biases the cable sleeve  23  toward the base end (cable insertion side) of guide  24 . The base end of guide  24  opens to allow the passage of the cable sleeve  23 , and an annular lid member  27  made of metal and capable of accommodating the outer casings  17   fa  and  17   ra  therein is fixedly mounted in the opening by press fitting. The cable sleeve  23  is thus retained inside guide  24  against the biasing force of the coil spring  25 . Cable sleeve  23  is moved toward the tip of guide  24  (toward the brake lever) against the biasing force of the coil spring  25  when the inner cables  16   f  and  16   r  of the brake cables  14   f  and  14   r  are pulled, and the cable sleeve  23  is moved toward the base end of guide  24  (toward the lid member  27 ) by the coil spring  25  when the inner cables  16   f  and  16   r  are released from tension, as shown by the chain line in FIG. 4. The cable cover  26 , which is a contractible bellows member made of an elastic material, sealingly covers the external peripheral surfaces of the guide  24  and the outer casings  17   fa  and  17   ra  to prevent the entry of water or other contaminants to prevent freezing or corrosion of the components.  
         [0025]    As shown in FIGS.  2 ,  3 ( a ) and  3 ( b ), the front and rear braking devices  13   f  and  13   r  are roller-type internal expanding brakes. The braking devices  13   f  and  13   r  comprise fixed brackets  30   f  and  30   r  fixedly mounted to the back portions of the bicycle front fork  3  and frame body  2 , play adjusting components  31   f  and  31   r  for securing the outer casings  17   fb  and  17   rb  and adjusting the play of the braking devices  13   f  and  13   r,  brake bodies  32   f  and  32   r,  and brake operating arms  33   f  and  33   r  that can pivot relative to the brake bodies  32   f  and  32   r.  The play adjusting components  31   f  and  31   r  are provided with outer retainers screwed into the fixed brackets  30   f  and  30   r,  thus allowing the play of the braking devices  13   f  and  13   r  to be adjusted by moving the end positions of the outer casings  17   fb  and  17   rb  back and forth in the axial direction.  
         [0026]    The brake bodies  32   f  and  32   r  have substantially the same structure, so the rear brake body  32   r  alone will be described herein. As shown in FIGS.  3 ( a ) and  3 ( b ), the rear brake body  32   r  comprises a rotary component  40  that rotates integrally with the hub shell of the rear wheel  7 , a brake drum (braked member)  41  fixedly mounted on the internal peripheral surface of the rotary component  40 , and brake shoes (braking members)  42  capable of coming into contact with and disengaging from the brake drum  41 . The brake shoes  42  are brought into contact with the brake drum  41  for applying a braking force to the rear wheel  7  when a plurality of rollers  44  supported by a roller case  43  are moved radially outward by the rotation of a rotary cam  45 . The rotary cam  45  rotates in conjunction with the brake operating arm  33   r,  wherein the inner cable  16   r  is secured to the brake operating arm  33   r.  Thus, pulling the inner cable  16   r  by gripping the brake lever  12   r  will cause the brake operating arm  33   r  to rotate clockwise from the brake release position shown in FIG. 3( a ) to the braking position shown in FIG. 3( b ). This, in turn, causes the brake shoes  42  to come into contact with the brake drum  41  and apply a braking force to the rear wheel  7 . The gap formed between the brake shoes  42  and the brake drum  41  during brake release constitutes the play of the braking device  13   r.    
         [0027]    The cable connector  15  is a device for connecting the front and rear brake cables  14   f  and  14   r  together so that both the front and rear braking devices  13   f  and  13   r  may be actuated by operating either one of the front and rear brake levers  12   f  and  12   r.  As shown in FIGS.  4 - 6 , the cable connector  15  comprises a connection member  45  for connecting the inner cables  16   f  and  16   r  of the front and rear brake cables  14   f  and  14   r  together, a bracket  46  for housing the connection member  45 , a play confirmation component  47  that allows the play of the front and rear braking devices  13   f  and  13   r  to be confirmed visually, and a casing  48  for covering the bracket  46 .  
         [0028]    The connection member  45  is movably mounted inside the bracket  46  and comprises a first connector  45   a  connected by screws  45   c  to a second connector  45   b.  The front and rear inner cables  16   f  and  16   r  are connected together by the insertion of the two cables  16   f  and  16   r  between the two connectors  45   a  and  45   b.  The connection member  45  is biased by two coil springs  49  in the direction of the braking devices  13   f  and  13   r.  Such biasing aids the initial setting of connection member  45 .  
         [0029]    The bracket  46  comprises a bracket body  46   a  formed of metal and press-molded into a substantial U shape, and a bottom plate component  46   b  mounted over the open portion of the bracket body  46   a.  The central portion of the bracket body  46   a  is provided with outer retainers  46   c  for securing the outer casings  17   fa  and  17   ra  on the side of the brake levers  12   f  and  12   r.  The bottom plate component  46   b,  which is disposed opposite the central portion, is provided with outer retainers  46   d  designed to secure the outer casings  17   fb  and  17   rb  on the side of the braking devices  13   f  and  13   r.  A guide  50  is disposed in contact with the lower surface of the bottom plate component  46   b.  Guide  50  allows confirmation knobs  51   f  and  51   r  to be supported while allowing movement of confirmation knobs  51   f  and  51   r  in the axial direction. A casing  48  is mounted to cover the bracket  46  and the guide  50 , and a transparent indicator window  52  with the graduation marks  52   f  and  52   r  is provided to the casing  48 . The upper end of the casing  48  is closed while the lower end is blocked by the guide  50 . The upper end of the casing  48  is provided with through holes  48   f  and  48   r  for accommodating the outer casings  17   fa  and  17   ra.  The outer casings  17   fa  and  17   ra  are sealed with an O-ring  55  (FIG. 6) around the through holes  48   f  and  48   r  to prevent liquids from penetrating inside.  
         [0030]    The confirmation knobs  51   f  and  51   r  comprise cup-shaped indicators  53   f  and  53   r  and knob components  54   f  and  54   r.  The inner cables  16   f  and  16   r  are sealed with a seal ring  56  mounted inside the indicators  53   f  and  53   r.  Indicators  53   f  and  53   r  are made readily visible by being colored, for example, red or yellow, and they are fixed by crimping to the tips of the outer casings  17   fb  and  17   rb.  Guide  50  movably guides the indicators  53   f  and  53   r.  Thus, the play of the braking devices  13   f  and  13   r  can be visually confirmed by determining the position occupied by the end portions  57   f  and  57   r  of the indicators  53   f  and  53   r  in relation to the graduation marks  52   f  and  52   r  when the outer casings  17   fb  and  17   rb are pulled toward the braking devices  13   f  and  13   r.    
         [0031]    When the brake cables  14   f  and  14   r  are set, the inner cables  16   f  and  16   r  are in a retracted state, so the cable sleeves  23  are moved by the outer casings  17   fa  and  17   ra  toward the brake lever against the biasing force of the corresponding coil springs  25 . When one of the front and rear brake levers  12   f  and  12   r  (for example, the rear brake lever  12   r ) is operated, the inner cable  16   r  is pulled, and the rear braking device  13   r  experiences a braking force. The inner cable  16   f,  which is connected to the inner cable  16   r  by connection member  45 , also is pulled, thus causing the braking device  13   f  to experience a braking force as well. However, at this time no tension is applied to the portion of inner cable  16   f  between the connection member  45  and the brake lever  12   f,  thus causing slack in the inner wire  16   f.  When this happens, the cable sleeve  23  is biased and moved by the coil spring  25  toward the base end (cable insertion side) of outer retainer  22  as shown by the chain line in FIG.4. Consequently, the lever member  21  remains taut.  
         [0032]    To adjust the play of braking devices  13   f  and  13   r  during manufacture or during routine brake adjustment, the knob components  54   f  and  54   r  of the confirmation knobs  51   f  and  51   r  are grasped, and the outer casings  17   fb  and  17   rb  are pulled toward the braking devices  13   f  and  13   r.  At that time, the play of the braking devices  13   f  and  13   r  can be visually confirmed by determining the position occupied by the bottom portions  57   f  and  57   r  of the indicators  53   f  and  53   r  on the graduation marks  52   f  and  52   r.  The play of the rear braking device  13   r  should be slightly reduced if the goal is to provide the front braking device  13   f  with a slower response than the one possessed by the rear braking device  13   r.  In this case, the play should be adjusted using play adjusting components  31   f  and  31   r  so that the bottom portion  57   f  of the indicator  53   f  for the front braking device  13   f  is aligned with the graduation mark  52   fb  shown by the broken line in FIG. 7, and so that the bottom portion  57   r  of the indicator for the rear braking device  13   r  is aligned with the graduation mark  52   ra  shown by the solid line in FIG. 7.  
         [0033]    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. Components that are shown directly connected or contacting each other may have intermediate structures disposed between them. 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. Although the original embodiment was described with reference to a case in which roller-type internal expanding brakes for exerting a braking force on wheel hubs were used as the braking devices, such brakes may include band or disk brakes for exerting a braking force on hubs, or caliper or cantilever brakes for exerting a braking force on rims.  
         [0034]    Although the original embodiment was described with reference to a case in which coil springs  49  and  25  were mounted on the cable connector  15  and outer retainer  22 , respectively, it is also possible to adopt an arrangement in which a coil spring is provided to either of the components, and the inner cable or the outer casing is biased in the direction in which the inner cable is exposed. FIG. 8 is a partial cross sectional view of another embodiment of a cable connector according to the present invention. The cable connector  65  shown in FIG. 8 is devoid of a coil spring for biasing a connection member  75 . The rest of the structure is the same as in the above embodiment. In this structure, the gap between the brake cables  14   f  and  14   r  can be reduced in proportion to the absence of springs. A more compact cable connector  65  can therefore be designed.  
         [0035]    Although the original embodiment was described with reference to a case in which separate brackets and casings were used, it is also possible to integrate the casings and brackets together. FIG. 9 is a partial cross sectional view of such an embodiment. In the cable connector  80  shown in FIG. 9, the cylindrical bracket  84  doubles as a casing, and the connection member  85  is mounted while allowed to move in the axial direction. In this case, the entire connection member  85  is biased by a single coil spring  86 . In this embodiment, the outer casings  17   fb  and  17   rb  are provided with annular markings 87 . Play should be adjusted such that the markings  87  reach a position beyond the bottom portion  84   a  of the bracket  84  when the outer casings  17   fb  and  17   rb  are pulled toward the braking device during play adjustment.  
         [0036]    It is also possible to mount a modulator (brake force adjusting mechanism) capable of varying the braking force of one of the two front and rear braking devices  13   f  and  13   r  during braking. In FIG. 10, a modulator  95  is mounted inside a hub  94  connected to a front braking device  93   f.  The modulator  95  comprises washers  96  with retaining holes nonrotatably secured in the hub  94 , and lugged washers  97  disposed between the washers  96  with retaining holes. The lugged washers  97  are secured in an annular cup  99  that rotates in conjunction with the rotary component  98  of the braking device  93   f,  and are caused to rotate in conjunction with the rotary component  98 . The modulator  95  allows the rate at which the braking force increases with the operating force during braking to be reduced in accordance with the contact pressure of the two types of washers  96  and  97 .  
         [0037]    Although the original embodiment was described with reference to an arrangement in which the casing  48  was not fixedly mounted on the frame  1 , it is also possible immovably mount the casing on the frame  1 . Furthermore, although the above embodiment was described with reference to an arrangement in which the play confirmation mechanism was provided to the cable connector  15 , it is also possible to provide the gauge to the front and rear braking devices  13   f  and  13   r.    
         [0038]    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.