Patent Publication Number: US-2019176782-A1

Title: Emergency Break Cable Tension Adjustment Devices and Methods

Description:
REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Application No. 62/595,239 entitled “Emergency Break Cable Tension Adjustment Devices and Methods” filed Dec. 7, 2017, which is entirely incorporated by reference. 
    
    
     BACKGROUND 
     1. Field of the Invention 
     This invention is directed to devices and methods for tensioning emergency break cables. Specifically, the invention is directed to devices and methods for tensioning loose emergency break cables without replacing the cable. 
     2. Description of the Background 
     In road vehicles, the emergency brake, also called hand brake, parking brake, or e-brake, is used to keep the vehicle stationary and in many cases also perform an emergency stop. Emergency brakes on older vehicles often consist of a cable connected to two-wheel brakes at one end and the other end to a pulling mechanism which is operated by the driver&#39;s hand or foot. The mechanism may be a hand-operated lever, at floor level beside the driver, or a straight pull handle located near the steering column, or a (foot-operated) pedal located beside the driver&#39;s leg. In most automobiles the emergency brake operates only on the rear wheels, which have reduced traction while braking. However, some automobiles have the emergency brake operate on the front wheels. 
     The most common use for an emergency brake is to keep a vehicle motionless when it is parked. The emergency brake may have a ratchet or other locking mechanism that will keep it engaged until manually released. On vehicles with automatic transmissions, this is usually used in concert with a parking pawl in the transmission. 
     Over time, the emergency break cable may stretch out and loose tension. Once stretched, the cable may not perform correctly or be able to properly lock the wheels. Typically, a mechanic or owner of the car will have to replace the cable which can be a costly and time-consuming endeavor. Therefore, there is a desire to re-tension the cable without replacing the cable. 
     SUMMARY 
     The present invention overcomes the problems and disadvantages associated with current strategies and designs and provides new tools and methods for tensioning emergency break cables. 
     One embodiment of the invention is directed to a device for tensioning a cable. The device comprises a nut having two open ends, two bolts, each bolt having a central bore and adapted to mate with one open end of the nut, and two cable securement devices. The cable securement devices are smaller than an inner diameter of the nut and larger than a diameter of the central bores of the bolts. 
     Preferably, the device further comprises at least two spring washers, each spring washer adapted to be placed between a head of a bolt and the nut. The cable is preferably divided into two portions and the central bore of each bolt is adapted to receive an end of one portion of the cable and a cable securement device is adapted to secure the bolt to the portion of the cable. In a preferred embodiment, as the bolts are tightened into the nut, the two portions of the cable are drawn together, thereby tensioning the cable. Preferably, the cable securement device is a c-washer. The cable is preferably an emergency break cable. The device is preferably adapted to tension an existing emergency break cable. 
     Another embodiment of the invention is directed to a method of tensioning a cable with two free ends. The method comprises the steps of threading each free end through a bolt having a borehole, securing each free end of the cable to the bolt with a cable securement device, and inserting both bolts into a single nut, wherein as the bolts a tightened, the free ends of the cable are drawn together, thereby tensioning the cable. 
     Preferably, the method further comprises the step of placing a spring washer between a head of a bolt and the nut prior to assembly. The cable securement device is preferably a c-washer. Preferably, the cable is an emergency break cable. In a preferred embodiment, the device is adapted to tension an existing emergency break cable. The method preferably further comprises the step of removing a factory installed cable joiner/crimp. Preferably, the cable securement devices are smaller than an inner diameter of the nut and larger than a diameter of the central bores of the bolts. 
     Other embodiments and advantages of the invention are set forth in part in the description, which follows, and in part, may be obvious from this description, or may be learned from the practice of the invention. 
    
    
     
       DESCRIPTION OF THE FIGURES 
         FIG. 1  An exploded view of an embodiment of the emergency break tensioning device. 
         FIG. 2  A translucent assembled view of an embodiment of the emergency break tensioning device. 
         FIGS. 3A-D  Views of the individual components of the emergency break tensioning device. 
         FIG. 4  A view of a disassembled emergency break cable. 
         FIG. 5  An embodiment of the emergency break tensioning device being installed on the emergency break cable. 
         FIG. 6  An embodiment of the emergency break tensioning device being installed on the emergency break cable. 
         FIG. 7  An embodiment of the emergency break tensioning device being installed on the emergency break cable. 
         FIGS. 8A-B  An embodiment of the emergency break tensioning device being installed on the emergency break cable. 
         FIG. 9  An embodiment of the emergency break tensioning device installed on the emergency break cable. 
     
    
    
     DESCRIPTION OF THE INVENTION 
       FIG. 1  depicts an exploded view of a preferred embodiment of the emergency break tensioning device  100 . Device  100  is preferably comprised of a central long nut  101  (see  FIG. 3A ). Preferably nut  101  has a standard hexagonal outer surface. For example, the outer surface of nut  101  may be ⅝″, 9/16″, ½″, ¾″, or another dimension. Furthermore, the outer surface of nut  101  may be a standard metric size. Preferably, nut  101  is 3″ long, however nut  101  may have another length. For example, nut  101  may be 2″, 2.5″, 3.5″, or 4″ long. The interior surface of nut  101  is preferably threaded. For example, nut  101  may have 11 tpi (teeth-per-inch), 10 tpi, 12 tpi, or another number of teeth-per-inch. 
     Bolts  102  (see  FIG. 3B ) area preferably adapted to be threaded into nut  101 . Bolts  102  preferably have standard hexagonal heads. For example, the heads of bolts  102  may be ⅝″, 9/16″, ½″, ¾″, or another dimension. Furthermore, the heads of bolts  102  may be a standard metric size. Preferably, bolts  102  are 1″ long, however bolts may have another length. For example, bolts may be ½″, ¾″, 1¼″, or 1½″ long. The shanks of bolts  102  are preferably threaded. For example, bolts  102  may have 11 tpi (teeth-per-inch), 10 tpi, 12 tpi, or another number of teeth-per-inch. Preferably, the threading of nut  101  matches the threading of bolts  102 . Preferably, nut  101  and bolts  102  are standard US sized nuts and bolts of ⅝″ with 11 tpi. Preferably, bolts  102  have a central bore drill through the head and shank of each bolt. The bore may have a 11/32″ diameter 5/16″ diameter, ⅜″ diameter or another diameter. 
     Device  100  may also have two or more spring washers  103  (see  FIG. 3C ) and two or more c-washers  104  (see  FIG. 3D ). Preferably, when assembled, each side of device  100  has an equal number of spring washers  103  and an equal number of c-washer  104 . Spring washers  103  preferably are standard sized spring washers that match the size of nut  101  and bolts  102 . For example, spring washers  103  may be ⅝″, 9/16″, ½″, ¾″, or another dimension. C-washers  104  preferably have a larger outer diameter than the bore hole in bolts  102  and a smaller diameter than the inner diameter of nut  101 , such that c-washers  104  fit inside nut  101  but cannot fit through bolts  102 . For example, c-washers  104  may have an outer diameter of ½″, 7/16″, or 9/16″. Additionally, c-washers  104  preferably have an inner diameter slightly larger than the diameter of an emergency break cable, such that the emergency break cable can sit within c-washer  104 . For example, the inner diameter of c-washer  104  may be 11/64″, 3/16″, or 13/64″. Preferably, c-washers  104  are made from 16-gauge material, however another thickness material can be used. 
     Preferably the components of device  100  are rust resistant, able to withstand conditions faced by automobiles (e.g. rain, snow, salt, chemicals, wind, dirt, sand, and hot and cold temperatures). The components of device  100  are preferably made of zinc coated steel, stainless steel, brass, galvanized steel, still with other anti-wear or anti-rust coatings, aluminum, silicone bronze, plastic, nylon, rubber, carbon fiber, another high strength anti-corrosion materials, or combinations thereof. Preferably, all of the components are made of the same material, however different components may be made of different materials. The components may be custom or off the shelf and hand-made or machine-made. 
     In order to retrofit device  100  onto an existing break line, the factory installed cable joiner/crimp is removed where the emergency break cable sections meet. As shown in  FIG. 4 , the ends of the two sections of the existing break line  410  are exposed and free. Each end of existing break line  410  is preferably inserted into the hole of a bolt  102  and a spring washer  103  is placed over the threads of bolt  102 , as shown in  FIG. 5 . Alternatively, spring washers  103  can be added after c-washers  104 . Preferably, at least one c-washer  104  is placed over each existing break line  410 , between bolt  102  and the lug end of the existing break line  410 , as show in  FIG. 6 . The c-washers  104  may be pinched between the lug end of the existing break line  410  and bolt  102  to prevent c-washers  104  from falling off during assembly. Nut  101  is preferably then screwed onto each bolt  102  as shown in  FIG. 7 . As shown in  FIGS. 8A and 8B , nut  101  and bolts  102  are tightened (preferably to 60 ft-lbs torque) to complete the assembly of device  100 , as shown in  FIG. 9 . As nut  101  and bolts  102  are tightened, existing break line  410  ends are pulled together, thereby tensioning the break line. While the assembly is described in a certain order, other orders of assembling are envisioned. For example, one side of device  100  can be assembled prior to the second side of device  100  being assembled. 
     Other embodiments and uses of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. All references cited herein, including all publications, U.S. and foreign patents and patent applications, are specifically and entirely incorporated by reference. The term comprising, where ever used, is intended to include the terms consisting and consisting essentially of. Furthermore, the terms comprising, including, and containing are not intended to be limiting. It is intended that the specification and examples be considered exemplary only with the true scope and spirit of the invention indicated by the following claims.