Patent Publication Number: US-6669603-B1

Title: Stationary exercise bicycle

Description:
This is a continuation of application Ser. No. 09/263,858, filed Mar. 8, 1999 now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of The Invention 
     The present invention relates to the field of exercise equipment, in general, and to an improved stationary exercise bicycle, in particular. 
     2. Prior Art 
     Relatively recent trends towards physical fitness awareness have led to an increase in the number of individuals exercising on a regular basis in order to keep physically fit. Several types of exercise equipment are currently in use to provide exercise to persons who wish to keep physically fit without venturing outdoors. One of the most popular of such indoor exercise devices is the stationary exercise bicycle. 
     A number of present day gymnasiums and exercise clubs have some type of stationary exercise bicycle apparatus whereby a person pedals a simulated bicycle as a form of exercise. Early exercise bicycles included apparatus designed to support a conventional bicycle so that the rear wheel thereof can rotate against a frictional load. These types of devices fall into several general categories, the first of which connects the front axle and the bottom bracket of the bicycle to a frame in order to support the bicycle. The rear wheel drives against a roller, which in turn is connected to a loading mechanism. Typically, the rear wheel drives a flywheel and a variable resistance load. A second type of apparatus used with a conventional bicycle supports the rear wheel, either on a pair of rollers or by a fixed support at the rear axle. Each of the above devices has numerous drawbacks for use as an exercise device. 
     The devices using a bottom bracket support allow the use of a real bicycle frame but fail to provide a realistic resistance and ride simulation. This type of equipment usually has one roller contacting the rear wheel. The devices using one or more rollers to support the rear wheel have stability and slippage problems. If the roller is behind the rear axle, the roller must be relatively long because the wheel wobbles and moves sideways and frequently falls off the roller. Conversely, if the roller is in front of the axle, the wheel stays centered but does not maintain adequate contact during periods of maximum torque on the rear wheel. In both cases, if a realistic resistance is applied, the rear tire slips on the roller. 
     For example, during maximum performance periods, the bicycle rider is not on the saddle, but is leaning over the handlebar and, essentially, standing on the pedals. As the weight of the rider shifts forward, the force on the rear wheel decreases and the weight on the front wheel increases, causing slippage of the rear wheel. Further, in this position with a bicycle on the bottom bracket support, the bicycle frequently pivots about the bottom bracket, effectively removing the rear wheel from contact with the supporting roller or rollers. Thus, just when the maximum resistance is needed to prevent slippage at the rear wheel, the rear wheel is at minimum friction contact with the resistance rollers and, therefore, slips. 
     More sophisticated bicycle simulating equipment has been developed through the years leading to current stationary bicycle designs which sometimes do not resemble standard bicycles at all. These devices consist primarily of bicycle cranks driven by the feet of the exerciser and are drivingly coupled, usually by a chain drive, to a flywheel to provide resistance to the pedal motion thereby providing the exerciser with a force to work against. Both the appearance and the functional features of the exercise bicycle are continuously undergoing change and improvement. However, they still suffer from several drawbacks 
     The drawbacks associated with more sophisticated stationary bicycle devices include relatively complex load providing components thus inherently increasing the overall production cost of the bicycle and the need for maintenance and repair. Also, most prior art stationary bicycles use weighted flywheels that eventually create a balancing problem preventing the user from obtaining a smooth ride potentially leading to injury by micro-trauma to various body structures. 
     Also, most prior art stationary bicycles allow for size and configuration adjustment only by incremental units which are in the range of 1′. Consequently, optimal customization to an individual&#39;s characteristics is virtually impossible thus, again, potentially leading to injury to various body structures such as joints and ligaments. In addition, the adjustment providing mechanisms of most prior art stationary bicycles are either mechanically complex or unreliable thereby leading to high production cost, susceptibility to break down, or both. 
     Still further, most prior art stationary bicycles include frames made of standard forged steel which are assembled by a welding process. Typically, the frame is painted with a powder coat baked at approximately 400 degrees. This type of frame and associated paint covering may potentially lead to frame warping and reduced longevity because of rust or other deteriorating process. 
     Most prior art stationary bicycle devices have tried to provide a realistic simulation of a smooth ride and load resistance experience when riding a bicycle. 
     However, the previous attempts to accurately replicate or simulate these various load effects have all had their drawbacks. Typical load variables can include wind resistance, whether the rider is going up hill or down hill, the inertia of the rider and bicycle, the friction inherent in the bicycle itself and the frictional resistance between the bicycle tires and riding surface. Proper simulation of realistic load resistance involved providing the intended ride with the ability to fine-tune by relatively small increments the load applied to the pedals of the stationary bicycle. 
     For example, the effective wind resistance has been simulated by rotating fan blades, which are mechanically coupled to the rotational speed of the bicycle wheel. While the rotating fan blades can provide a force that increase as the square of the rotational speed of the fan blades, these fans are noisy, inaccurate, not readily adjustable and cannot be adjusted to account for variation in wind resistance that will occur with riders of different size and weight. 
     Similar prior devices have attempted to simulate the amount of load to be applied by either a mechanical or electronic brake system. A typical mechanical brake involves a friction belt that wraps around a moving surface to cause a frictional drag on that rotating surface depending upon the tension of the belt. Typically, the friction belt is positioned within a grooved formed on the peripheral surface of a flywheel. These mechanical systems, however, cannot be accurately calibrated, have a slow response time and are subject to load variations over time as the elements of the mechanical system go out of adjustment and alignment. Further, the frictional load varies with the environmental temperature and with the temperature of the frictionally engaging parts. 
     The prior art mechanical systems, thus, have poor repeatability, high variation in drag and are difficult or impossible to accurately calibrate to a given load. Further, a large force is typically required to be exerted on the friction belt in order to adequately vary the frictional loads. Still further, prior art mechanical systems are not provided with emergency braking functions allowing a given rider to quickly immobilize the flywheel or other mechanisms linked to the pedal in the event that an emergency situation arises. 
     Electronic prior art braking systems have some advantages over the mechanical systems, but the accuracy of the simulated ride depends upon several factors, including how accurately the system can be calibrated and the realism of the program with which the electronic brake is varied. Furthermore, these systems are typically much more complex than mechanical systems and, hence, considerably more expensive. Furthermore, they often require costly maintenance and repair. Accordingly, there exists a need for an improved stationary bicycle. 
     SUMMARY OF THE INSTANT INVENTION 
     The invention is directed to a stationary bicycle which has load-providing components allowing for fine-tuned adjustment of the selected load. The load providing components are made of relatively simple mechanical components so as to increase the reliability, reduce the maintenance and provide a relatively smooth cycling feel. 
     In addition, the stationary bicycle is manufactured using specific materials and processes so as to provide for a reliable product having a relatively long life cycle characterized by reliable functioning. 
     Furthermore, the stationary bicycle described herein comprises a design which allows for ergonomic fine tuning of the relative positioning between the various components thereof so as to provide ergonomic adjustments which can reduce the risk of injury to the body of the individual using the device and, thereby, allowing for a more efficient workout. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevation view of one embodiment of a stationary exercise bicycle in accordance with the present invention. 
     FIG. 2 is an enlarged, partially sectional view of a horizontal seat adjustment mechanism which forms a part of the stationary bicycle shown in FIG.  1 . 
     FIG. 3 is an enlarged, partially exploded view of a the horizontal seat adjustment mechanism which forms a part of the stationary bicycle shown in FIG.  1 . 
     FIG. 4 is an enlarged, partially sectional view of a vertical adjustment mechanism for the seat or the handle bars each of which form a part of the stationary bicycle shown in FIG.  1 . 
     FIG. 5 is an exploded view of the vertical adjustment mechanism for the handle bars portion of the stationary bicycle shown in FIGS. 1 and 4. 
     FIG. 6 is an enlarged, partially sectional view of the horizontal bar adjustment mechanism which forms a part of the stationary bicycle shown in FIG.  1 . 
     FIG. 7 is an exploded view of the handle bar horizontal adjustment mechanism shown in FIG.  6 . 
     FIG. 8 is an enlarged, partially sectioned view of the load creating mechanism which forms a part of the stationary bicycle shown in FIG.  1 . 
    
    
     DESCRIPTION OF A PREFERRED EMBODIMENT 
     Referring now to FIG. 1, there is shown, in an elevation view, a stationary exercise bicycle  10  in accordance with a preferred embodiment of the present invention. The bicycle  10  has a frame which includes a base section  12  which includes a base longitudinal tube  14  and a pair of base transversal tubes  16 . The transversal tubes  16  are rigidly attached to the base longitudinal tube  14 , typically, at opposed ends thereof. A front support tube  18  extends upwardly from the base longitudinal tube  14  adjacent the first end thereof. The front support tube  18  is, preferably, angled relative to the base longitudinal tube  14  so as to extend slightly towards the rear portion of the bicycle  10 . 
     A structurally strong main support tube  20  is joined to and extends upwardly from the rearward portion (or end) of the base longitudinal tube  14 . The support tube  20  intersects with and is joined to an upper portion of the front support tube  18 . 
     A rear support tube  22  is joined to and extends upwardly from an intermediate section of the main support tube  20 . Preferably, the rear support tube  22  extends upwardly from the base longitudinal support  14  in a direction generally parallel to the front support tube  18 . An optional auxiliary support tube  24  extends between the rear support tube  22  and the main support tube  20  to provide additional structural strength, if desired. It should be understood, of course, that the configuration of the frame of the present embodiment could vary without departing from the scope of the present invention but that the herein above disclosed configuration is considered as a preferred embodiment of the invention. 
     At least the upper end segment of the rear support tube  22  is, typically, hollow so as to slidably receive a correspondingly shaped seat tube (or Bar)  28  therein. In a preferred embodiment of the present invention, a seat height adjustment device  146  permits the complete adjustability of tube  28  relative to tube  22  for fine-tuning of the height positioning between the seat  34  and the base  12 . The height adjustment device  46  is described in greater detail relative to FIGS. 4 and 5. 
     A suitable bicycle seat  34  is mounted on the horizontal seat adjustment plate  30  which is rigidly mounted to an upper end segment of the seat tube  28 . The horizontal seat adjustment plate  30  and mechanism  136  is described in greater detail infra relative to FIGS. 2 and 3. 
     The stationary bicycle  10  also includes a handle bar tube  60  slidably inserted within a corresponding hollow section of the front support tube  18 . A handle bar  62  is mounted to the handle bar tube  60 . A feature of the present invention is the handle bar vertical height adjustment device or apparatus  64  using components similar to the seat height adjustment and described in greater detail infra relative to FIGS. 4 and 5. Likewise, the handle bar mechanism includes a horizontal adjustment mechanism  166  shown in greater detail in FIGS. 6 and 7. 
     A drive mechanism  68  is mounted on the frame of the exercise bicycle  10  preferably adjacent the intersection between the rear support tube  22  and the main transversal support  20 . The drive mechanism  68  includes pedals  70  mounted to respective pedal cranks  72 . The cranks  72  are, in turn, mechanically coupled to a drive mechanism gear  81  which is partially hidden from view by a guard plate  76 . The pedal cranks  72  are mechanically coupled to a bottom bracket  78 , which is joined within the walls of the mounting structure, as is well known in the art. Thus, the drive gear  81  turns in response to the pedaling action exerted on the pedal cranks  72 . 
     A flywheel  80  is rotationally mounted to the frame. preferably through the use of a flywheel axle  182 . The flywheel  80  is designed to -provide the rider with the feel of riding a real bicycle. Preferably, the flywheel  80 . is precision machined instead of being, die-cast, as is often the case with prior art devices. Likewise, the flywheel  80  is precision balanced instead of being weighted, as is often the case with prior art devices. Typically, the flywheel has an outer diameter substantially in the range of 14′ and a weight approximately in the range of 44 lb. The precision flywheel approximates the momentum of the moving bicycle and rider to provide smooth performance of the drive system and to prevent jerky motion between the high torque pedal position, i.e., when the pedals are horizontally level with one another, and low torque pedal position, i.e., when one pedal is in its uppermost position and the other pedal is in its lowermost position. 
     In a preferred embodiment of the present invention, the drive mechanism link between the driving gear  81  and the flywheel  80  preferably takes the form of a reinforced, steel-belted, kevlar belt  82  instead of the chain found on most conventional prior art exercise bicycles. The reinforced steel-belted kevlar belt  82  is provided with a plurality of notches  82 A formed integrally therein for mechanically engaging corresponding mechanical components on both the driving gear  81  and the hub of the flywheel  80 . The use of a reinforced steel-belted kevlar belt  82  provides longer lasting, stretch resistant characteristics. Moreover, belt  82  is more resistant to wear, is rust proof and is relatively unbreakable, thus, reducing the required amount of maintenance and repairs associated with conventional chains of prior art devices. 
     Another feature of the present invention resides in the use of a specifically designed load varying means  84  for varying the load or the amount of force necessary to turn the flywheel  80 . The load varying means  84  is shown in greater details in FIG.  8 . 
     In a preferred construction, the overall frame  10  is made out of stainless steel and cold forged, semi-tempered, seamless steel instead of the standard forged steel with welds used for the frame of most conventional stationary bicycles. Furthermore, the frame is adapted to be coated with an electronic paint instead of the conventional coating with powder coat paint. This technique provides for a stronger, sweat resistant and chip resistant finish. Typically, the width of the base transversal beam  16  is in the range of about 22′ and a length of base  14  is in the range of about 42′. Also, the height of the seat  34  and handlebar  62  in the retracted configuration is in the range of about 35′. These dimensions are suggested but are not limitative. 
     Referring concurrently now to FIGS. 2 and 3, there is shown in great detail one of the features of the present invention, i.e., a seat horizontal adjustment mechanism  136 . The mechanism shown in FIG. 2 permits adjustment of the horizontal relationship of the seat  34  relative to the vertical seat tube  28 . The horizontal seat adjustment mechanism  136  preferably includes a seat adjustment plate or support  30  having an adjustment plate slot  32  extending therethrough. The seat  34  is attached to a seat shoe  36  which is configured and sized so as to be slidably mounted within a guiding slot  38  formed on the upper surface of the plate  30 . Typically, one end of the seat shoe  36  includes at least one flat side  36 A to properly position the shoe in the guiding slot  38 . This arrangement provides for horizontal (fore and aft) adjustment of seat position. A quick release mechanism or handle  40  having a locking pin  42  extending through the slot  32  is adapted to be used for locking the shoe  36  in a predetermined position within the slot  38 . That is, the pin  42  is, typically, threadedly attached to seat shoe  36 . A washer  39  may be used for spanning the slot  32 , if desirable. The quick release mechanism  40 , thus, allows for fine tuned horizontal positioning of the seat  34  relative to the seat tube  28 . A conventional hinge  44  comprising an adjustable screw and nut combination allows for tilt adjustments of the seat  34 , as is well known in the art. 
     Referring concurrently now to FIGS. 4 and 5, there is shown a preferred embodiment, respectively, of the seat height adjustment device or apparatus  46  or the handle bar vertical adjustment means or apparatus  64  in greater detail. The respective seat and handle bar height adjustment devices  46  preferably includes an aperture  48  formed in the rear support tube  22  (or support tube  60  in the case of the handle bar adjustment) for receiving a frictional abutment component such as a bushing  50  adapted to frictionally engage the outer surface of the seat tube  28  or front support tube  18 . The bushing  50  is preferably made out of a relatively ductile material such as brass while the support component  52  is preferably made out of stainless steel or the like. The adjustment support component  52  which has an aperture  54  formed therein is mounted on the rear support tube  28  or on the front support tube  18 . A quick release handle  56  having an abutment pin  58  connected to the abutment bushing  50 , for example by threads, is mounted on the adjustment support component  52 . The quick release handle  56  is, thus, adapted to permit, by rotation thereof, for fine tuned, releasable locking of the seat tube  28  within the rear support tube  22 . The same type of adjustment mechanism can be used to adjust the height of the handle bars  62 . In this case, the quick release mechanism  64  permits adjustment of tube (or bar)  60  in the upright tube  18 . 
     Referring concurrently now to FIGS. 6 and 7, there is shown in greater detail the handle bar horizontal adjustment means  66  for fine adjustment of the relative horizontal positioning between the handle bar  62  and the handle bar tube  60 . The handle bar horizontal adjustment mechanism  66  is somewhat similar to the seat horizontal adjustment means  136  (See FIGS. 1-3) except that it is used for releasable locking of the handle bar tube  60  inserted within the front support tube  18  in a finely tuneable (or adjustable) predetermined relationship relative to each other. The main difference between the handle bar horizontal adjustment means  66  and the seat adjustment means  136  is that the handle bar  62  is mounted to the handlebar component  138  instead of a seat component. Similarly, the handle bar horizontal adjustment means  66  allows for precision fine-tuned horizontal adjustment of the positioning of components relative to each other. 
     A horizontal handlebar support  130  is attached to the handlebar tube  60  as shown in FIG.  7 . The handle bar horizontal support  130  has a longitudinal groove  132  cut therein. The handlebar component  138  has a threaded hole therein adapted to receive threaded shaft  142  of the quick release handle  140 . A quick-release handle  140  has a threaded shaft  142  for threadedly engaging the handlebar component  138 . The handlebar component  138  has lower parallel beveled edges corresponding to the upper parallel beveled edges of the handlebar horizontal support  130  as shown in FIG.  7 . 
     Support for this language can be found in the Original Specification, Drawing FIGS. 4 and 5. 
     Referring now to FIG. 8, there is shown in greater detail, in a partially sectioned view, one embodiment of the load varying unit  84 . In this embodiment, the tensioning rod  86  is preferably made out of relatively rigid material such as stainless steel. The tensioning rod  86  has a tension knob  90  threadedly mounted at the proximal end thereof. The distal end of rod  86  is pivotally mounted in a groove or cavity  103  in the upper surface of the pad  102 . A distal section  94  of the tension rod  86  passes through and is in a proximal relationship with the resilient washer  96 . The wheel abutment pad  102  is mounted to the frame  10 , typically to a segment of the main support tube  20 , by a pad mounting device such as a flexible rod  104 . The abutment pad  102  is preferably made out of a relatively light, rigid material such as anodized aluminum. An abutment surface of the abutment pad  102  is provided with a layer  105  of high coefficient of friction such as patent leather. The layer  105  is preferably mounted to the interior surface of pad  102  using conventional fastening means such as screws  106 , thus, allowing for easy replacement of the lining layer  105  when needed. Similarly, the pad  102  is preferably mounted to the strap  104 - using conventional fastening components such as screws  108  for ease of replacement. 
     In use, rotation of the knob  90  allows for adjustment of a surface pressure and, thus, of the surface coefficient of friction between the layer  105  and the circumferential edge surface of flywheel  80 . Furthermore, the specific construction of the load creating means allows for an emergency braking function merely requiring that the user press downwardly on the knob  90 . To release the braking action the user merely needs to pull upwardly on the knob  90 . The resilient washer  96  provides a resilient biasing force tending to bias the lining  105  against the flywheel  80  thus further enhancing the provision for a smooth ride. 
     Thus, there is shown and described a unique design and concept of stationary exercise bicycle. While this description is directed to a particular embodiment, it is understood that those skilled in the art may conceive modifications and/or variations to the specific embodiments shown and described herein. Any such modifications or variations which fall within the purview of this description are intended to be included therein as well. It is understood that the description herein is intended to be illustrative only and is not intended to be limitative. Rather, the scope of the invention described herein is limited only by the claims appended hereto.