Patent Description:
To address the issue of weight with respect to the spokes in a wheel, <CIT> describes extremely lightweight braided fiber spokes. An additional benefit of braided fiber spokes is reduced vibration transmission from the cycling surface to the rider when compared to traditional metal spokes. These spokes contain a loop or eye splice formed on one end of the spoke which is produced by feeding the braided fiber back through itself. Methods by which these looped spokes can be made to interface with traditional bicycle rims and hubs are also provided.

Traditional hubs can be used with the braided fiber spokes described above, although an additional object, such as a non-integral rod, must be used to retain the spoke in the hub, or the spoke must be manipulated around itself in such a way as to risk damaging the spoke during installation. Further, traditional hubs contain sharp edges that can damage braided fiber spoke loops. Additionally, the process for building wheels with traditional hubs and spokes with loops is time-consuming and requires specialty tools. Therefore, traditional bicycle hubs do not provide an ideal interface for braided fiber spokes with loops. Because looped spokes are a relatively new invention, no previous hubs have been conceived specifically for the purpose of, and therefore are unable to adequately perform the function of, retaining the looped ends of spokes during installation and operation of the bicycle wheel.

<CIT>, <CIT>, <CIT> and <CIT> are noted.

This Summary and the Abstract herein are provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description.

A first aspect of the invention is a hub and spoke assembly that includes a hub body that is symmetric about a rotational axis having a first end and a second end. A first plurality of projections is disposed on the hub body at the first end and a second plurality of projections disposed on the hub body at the second end. The projections of each of the first plurality projections and the second plurality projections are spaced apart from each adjacent projection about the rotational axis on the first and second ends, respectively. Each projection of the first plurality of projections and the second plurality of projections comprises a base portion joined to the hub body and a support extending from the base portion to a free end. A first plurality of spokes and a second plurality of spokes are provided. Each spoke of the first plurality of spokes and the second plurality of spokes comprises an elongated braided fiber having a loop at a first end and a second end configured for attachment to a rim. At least one spoke of the first plurality of spokes is joined to each support of the first plurality of projections with the loop disposed about the support, and at least one spoke of the second plurality of spokes is joined to each support of the second plurality of projections with the loop disposed about the support.

According to the invention, each support of each projection of the first plurality of projections and the second plurality of projections extends from the base portion to the free end in a direction about the rotational axis, while the supports in each of the first plurality of projections and the second plurality of projections extend in opposite directions about the rotational axis. In such an embodiment, a single base portion may be used with supports extending in opposite directions. This configuration balances the load upon the base portion.

In some embodiments, each base portion of each projection of the first plurality of projections and the second plurality of projections extends radially away from a surface of the hub body with respect to the rotational axis, while in other embodiments, each base portion and associated support of each projection of the first plurality of projections and the second plurality of projections are disposed longitudinally inwardly from a perimeter edge of the first end and a perimeter edge of the second end, respectively. Although the projections can be separate pieces that are secured to the hub body, in a preferred embodiment, each base portion and associated support of each projection of the first plurality of projections and the second plurality of projections are integral with the hub body being formed from a single unitary body.

In some embodiments, the supports in each of the first plurality of projections and the second plurality of projections are curved so that portions of the support from the base portion to the free end are at a fixed radial distance from the rotational axis, which can make the hub more compact; however, in other embodiments, the supports in each of the first plurality of projections and the second plurality of projections are shaped so that portions of the support from the base portion to the free end are at different radial distances from the rotational axis. When the free end of each support is at a greater radial distance than the associated base portion, assembly of the spokes on the hub may be easier.

If desired, each of the first end and second end can comprise a flange with a flange body extending radially away from the hub body to an outer perimeter edge, and wherein the first plurality of projections are located on the flange of the first end and the second plurality of projections are located on the flange of the second end. Preferably in such an embodiment, each base portion and associated support of each projection of the first plurality of projections and the second plurality of projections are integral with the flange body being formed from a single unitary body.

In some embodiments, the outer perimeter edge of each of the first end and the second end is continuous about the rotational axis at a radial distance from the rotational axis greater than each of the associated base portions.

In embodiments which do not form part of the claimed invention, each support of each projection can extend away from the associated flange body in a direction parallel to the rotational axis, preferably where adjacent supports in each of the first plurality of projections and the second plurality of projections extend in opposite longitudinal directions with respect to the rotational axis. In other embodiments, the outer perimeter edge of each of the first end and the second end is discontinuous about the rotational axis wherein a radial slot is disposed between adjacent projections about the rotational axis in the flange body on each of the first and second ends.

In yet another embodiment, which does not form part of the claimed invention, each support of each projection is egg or tear-drop shaped with the widest portion of the support being furthest from the rim such that it supports the loop of each spoke. This configuration spreads the tension load of the spoke over a longer portion of the loop since this longer portion is being supported by the widest portion of the support.

Another embodiment which does not form part of the claimed invention defines a hub comprising a hub body being symmetric about a rotational axis having a first end and a second end. Each of the first and second ends comprises a pair of longitudinally spaced apart flanges. Each flange has a flange body extending radially away from the hub body to an outer perimeter edge encircling the rotational axis, wherein each flange body includes apertures, and wherein the apertures of each flange are disposed about the rotational axis. A plurality of supports is provided. Each support is removably mounted in a pair of apertures in the flanges on each of the first and second ends.

In another embodiment which does not form part of the claimed invention, each support is mounted in each corresponding pair of apertures extends in a direction parallel to the rotational axis. A plurality of spokes is joined to the hub. Each spoke includes an elongated braided fiber having a loop at a first end and a second end configured for attachment to a rim. At least one spoke is joined to each support and the loop is disposed about the support with the support being mounted in the associated apertures; however in a preferred embodiment, two spokes are joined to each support.

Another aspect of the invention is a hub comprising a hub body being symmetric about a rotational axis having a first end and a second end. A first plurality of projections is disposed on the hub body at the first end and a second plurality of projections is disposed on the hub body at the second end. Each projection is spaced apart from each adjacent projection about the rotational axis on the first and second ends, respectively. Each projection comprises a base portion joined to the hub body and a support extending from the base portion to a free end. Each support of each projection of the first plurality of projections and the second plurality of projections extends from the base portion to the free end in a direction about the rotational axis.

According to the invention, the supports in each of the first plurality of projections and the second plurality of projections extend in opposite directions about the rotational axis, and preferably adjacent supports in each of the first plurality of projections and the second plurality of projections extend in opposite directions about the rotational axis. Each base portion of each projection of the first plurality of projections and the second plurality of projections can be configured to extend radially away from a surface of the hub body with respect to the rotational axis.

Referring to <FIG>, a first embodiment of a hub and spoke assembly <NUM> is illustrated whereby spokes <NUM> connect a hub <NUM> to a rim <NUM> to make a complete wheel <NUM>. Generally, the hubs and spoke assemblies described herein are particularly well-suited for human-powered bicycle wheels due to the low weight and durability. However, other applications can benefit from these embodiments such as but not limited to wheelchairs, automobiles, electric bicycles, and other motor vehicles.

The hub <NUM> includes a hub body <NUM> which is symmetric about a rotational axis <NUM> having a first end <NUM> and a second end <NUM>. Projections <NUM> on the first end <NUM> and projections <NUM> on the second end <NUM> are spaced apart from each adjacent projection about the rotational axis <NUM>. By being spaced apart, the projections <NUM>,<NUM> allow for a laterally stiff wheel <NUM> when the wheel <NUM> is subject to sideways load. Each projection in projections <NUM>, <NUM> comprises a base portion <NUM> and a support <NUM>.

As used herein the "base portion" is the portion of the projection joined to the hub body (which may include end flanges in embodiments described below), while the "support" functionally is that portion of the projection joined to the base portion that is in contact with a loop of a spoke. The support has a length longer than a width of the loop of the spoke. Each support extends from the base portion to a free end (e.g. <NUM>).

Spokes <NUM> preferably comprise braided fibers with a loop <NUM> on a first end. Braided fiber spokes are disclosed in <CIT>.

The loop <NUM> is disposed about the support <NUM> of the projection <NUM>, while a second end is attached to the rim <NUM>, for example as described in <CIT>.

In this embodiment, each projection comprises two supports <NUM> with associated free ends <NUM>. An outer perimeter edge <NUM> is discontinuous about the rotational axis wherein a radial slot <NUM> is disposed between adjacent free ends <NUM>. <FIG> and <FIG> also illustrate an undercut slot <NUM> beneath the free ends <NUM>. An undercut slot <NUM> may be desirable to better retain spokes with loops when no tensile load is applied to the spokes.

The projections <NUM>,<NUM> in this embodiment are ideally suited for braided fiber spokes <NUM> with loops <NUM> because two loops <NUM> of two separate spokes <NUM> can be connected to the same projection <NUM>,<NUM>. In a preferred case, the spokes <NUM> may pull roughly opposite of each other to balance the tension load and reduce the stress on the base portion <NUM>. The base portion <NUM> is designed such that it can withstand the forces (in both static and fatigue) involved with a wheel under load, whether that be derived from a drive or brake mechanism, or the weight of an object supported by a wheel.

Referring back to <FIG>, multiple projections <NUM> and <NUM> are ideally spaced apart from each adjacent projection at the first and second ends <NUM>,<NUM> of the hub body <NUM>, respectively, to provide many distributed locations for spokes <NUM> to connect to. In the embodiment depicted in <FIG>, a total of <NUM> projections provide attachment locations for <NUM> spokes, whereby two spokes <NUM> are connected to each projection <NUM>,<NUM>; however in other embodiments more or less projections may be used. Alternatively, each projection <NUM>,<NUM> could attach just one spoke <NUM> such that the number of projections <NUM>,<NUM> and the number of spokes <NUM> are equal. It should be noted, the projections <NUM>,<NUM> need not be equally spaced around the hub body <NUM> as illustrated in <FIG> nor do the attachment points in the rim <NUM> need to be distributed equally around the rotational axis of the rim.

<FIG> illustrate various other hub and spoke assemblies each having a projection comprising a base portion and at least one support with a free end. illustrates an embodiment a hub and spoke assembly <NUM> where again one end <NUM> of a hub, not shown, is illustrated. The hub is generally of the same form as hub <NUM> having two ends and a center hub body. A second end would be similar to end <NUM>. Projections <NUM> are joined to the end <NUM> where each projection <NUM> includes a base portion <NUM>, a support <NUM> and free end <NUM>. An outer perimeter edge <NUM> is continuous about the rotational axis. Rounded edges <NUM> on the projections <NUM> are ideally suited to prevent braided fibers from becoming cut or abraded when subject to tensile loads. While not specifically shown in other embodiments, similar rounded edges on bearing surfaces may be present to promote long-term durability of the braided fiber loops which contact those surfaces.

<FIG> illustrates a hub and spoke assembly <NUM> having one end <NUM> of a hub, not shown, but generally of the same form as hub <NUM> having two ends and a center hub body. A second end would be similar to end <NUM>. Projections <NUM> are joined to the end <NUM>, preferably on opposite sides as shown. Each projection <NUM> includes a base portion <NUM>, a support <NUM> and free end <NUM>. An outer perimeter edge <NUM> is continuous about the rotational axis.

<FIG> illustrates another embodiment of a hub and spoke assembly <NUM> similar to the embodiment of <FIG>. One end <NUM> of a hub, not shown, is provided. Generally the hub is of the same form as hub <NUM> in that a second end would be similar to end <NUM> with a hub body provided between the ends. Projections <NUM> are joined to the end <NUM>, preferably on opposite sides as shown. Each projection <NUM> includes a base portion <NUM>, a support <NUM> and free end <NUM>. Each support <NUM> further includes an end portion <NUM>. End portions <NUM> are not axially aligned with each associated portion of the support <NUM> used to receive the loops, such portion extending directly from the base portion <NUM>. The end portion <NUM> can help retain the loops on the projection <NUM> since the loops cannot be placed adjacent the free ends <NUM>, where such is possible in the embodiment of <FIG>. An outer perimeter edge <NUM> is continuous about the rotational axis.

<FIG> illustrates a hub and spoke assembly <NUM> having one end <NUM> of a hub, not shown, but generally of the same form as hub <NUM> having two ends and a center hub body. A second end would be similar to end <NUM>. Projections <NUM> are joined to the end <NUM>, preferably on opposite sides as shown. Each projection <NUM> includes a base portion <NUM>, a support <NUM> and free end <NUM>. Like the embodiment of <FIG>, an outer perimeter edge <NUM> is discontinuous about the rotational axis wherein a radial slot <NUM> is disposed between adjacent free ends <NUM>. <FIG> also illustrates an undercut slot <NUM> beneath the free ends <NUM>.

<FIG> illustrates an embodiment of a hub and spoke assembly <NUM> similar to the embodiment of <FIG>. Again, one end <NUM> of a hub, not shown, is illustrated but the hub is generally of the same form as hub <NUM> having two ends and a center hub body. A second end would be similar to end <NUM>. Projections <NUM> are joined to the end <NUM>, preferably on opposite sides as shown. Each projection <NUM> includes a base portion <NUM>, a support <NUM> and free end <NUM>. Like the embodiment of <FIG>, an outer perimeter edge <NUM> is discontinuous about the rotational axis wherein a radial slot <NUM> is disposed between adjacent free ends <NUM>. However, this embodiment does not include an undercut slot as in the embodiment of <FIG>.

<FIG> illustrates an embodiment of a hub and spoke assembly <NUM> having functional features similar to the embodiment of <FIG>. One end <NUM> of a hub is illustrated. The other end of the hub, which has the same form as hub <NUM> having two ends and a center hub body is not shown. The other end would be similar to end <NUM>. Projections <NUM> are joined to the end <NUM>, preferably on opposite sides although the projections on the opposite side are not shown. Each projection <NUM> includes a base portion <NUM>, a support <NUM> and free end <NUM>. An outer perimeter edge <NUM> is continuous about the rotational axis.

<FIG> illustrates a hub and spoke assembly <NUM> having ends <NUM>,<NUM> of a hub body <NUM>. Each projection <NUM> includes a base portion <NUM>, a support <NUM> and free end <NUM>. Projections <NUM> are similar to projections <NUM> of <FIG> but base portions <NUM> clearly are joined to and extend from the hub body <NUM> without any form of end flange.

<FIG> illustrates a hub and spoke assembly <NUM> having ends <NUM>,<NUM> of a hub body <NUM>. Each projection <NUM> includes a base portion <NUM>, a support <NUM> and free end <NUM>. Projections <NUM> are similar to projections <NUM> of <FIG> but the projections <NUM> are formed on the hub body <NUM>, disposed longitudinally inwardly from perimeter edges <NUM> of ends <NUM>, <NUM>, rather than being formed on an end flange body. This embodiment may be preferred not only because of its aesthetic simplicity but also because it is more aerodynamic, lighter in weight, and/or easier to manufacture. The projections <NUM> might be separate bodies or formed integral with the hub body <NUM> from a single unitary body. Advantages of a single unitary body can be strength, durability, and resistance to corrosion.

The following paragraphs highlight some common features found between the embodiments described above. Referring to <FIG>, the free end <NUM> of each support <NUM> of each projection <NUM> of extends from the base portion <NUM> to the free end <NUM> in a direction about the rotational axis of the hub. With the supports <NUM> extending in a direction about the rotational axis of the hub, this may reduce the risk of the spokes coming loose because the loop must travel backwards to become dislodged. This embodiment may also be preferred because of favorable aerodynamics or manufacturability compared to other embodiments. The embodiments of <FIG>, <FIG>, <FIG>, and <FIG> have similar projections to that shown in <FIG>, i.e., where the free end of each support of each projection extends from the base portion to the free end in a direction about the rotation axis.

Referring again back to <FIG>, two supports <NUM> are present in each of the projections <NUM>,<NUM>. However, it should be noted that the supports <NUM> of each projection <NUM> extend in opposite directions about the rotational axis. One advantage of this design is that is allows two spokes to be attached to one projection, or hook, in a manner that is symmetric, and ideally with a low stress on the base portion of the projections. In addition, adjacent supports <NUM> extend in opposite directions about the rotational axis allowing for potentially many connection points radially distributed around the hub. These features are also apparent in the embodiments illustrated in <FIG>, <FIG>, <FIG>, and <FIG>.

It should also be noted the supports in each of the embodiments of <FIG>, <FIG>, and <FIG> are curved so that portions of the support from the base portion to the free end are at a fixed radial distance from the rotational axis. Such a design may reduce the cost to manufacture. Another advantage of curved supports is to reduce the likelihood of a spoke detaching from a projection or a support unintentionally. Alternatively, the supports could be shaped so that portions of the support from the base portion to the free end are at different radial distances from the rotational axis. This is illustrated in <FIG> where support <NUM>' extends upwardly such that a free end <NUM>' is further radially from the rotational axis than the end of the support nearest the base portion <NUM>. With the supports <NUM>' shaped in this manner, it may be easier to attach the loops.

The projections on which spokes are attached may extend radially away from the hub surface with respect to the rotation axis. Examples of those type of projections are depicted in <FIG>, <FIG>, and <FIG>. Those projections which extend radially in <FIG>, <FIG>, and <FIG> may be formed from a single unitary body. One advantage of forming the projections from a single body versus multiple bodies is to reduce the cost to manufacture. For example, a hub might be machined from a single piece of aluminum or an aluminum alloy.

Alternatively, and specifically referring to <FIG>, the projections <NUM> on which spokes attach to may be embodied within a flange <NUM> that extends radially from the associated hub body.

Hubs with flanges can be advantageous because they provide a larger diameter for transmitting torque to the rim, thereby reducing the tensile stress on spokes when a hub is subject to torque.

<FIG>, <FIG>, and <FIG> illustrate assemblies in which the projections are joined to or formed from a flange body that extends radially from the associated hub body. Projections located on the flanges are the attachment locations for one or more spokes. Referring to <FIG>, projections <NUM> in this embodiment extend approximately straight away from the flange <NUM>. In another embodiment illustrated in <FIG>, the projections <NUM> extend in an "L" shape away from the flange <NUM>. In yet another embodiment of projections, supports <NUM> extending from a flange <NUM> are teardrop or egg shape and have an end portion cap <NUM> that helps ensure that the loops of the spokes are disposed and retained on the supports <NUM>.

The projections illustrated by <FIG>, <FIG>, and <FIG> might be integral with the flange body being formed from a single unitary body, to increase the strength or the manufacturability of the assembly. Different from that assembly illustrated in <FIG>, those of <FIG>, and <FIG> have an outer perimeter edge that is continuous about the rotational axis at a radial distance from the rotational axis greater than each of the associated base portions. In addition, the projections within these three assemblies extend in a direction parallel to the rotation axis and adjacent supports on either side of each flange extend in opposite longitudinal directions. This has the advantage of providing an attachment point for two separate spokes on either side of the flange.

Alternatively, <FIG> depicts a hub body <NUM> without a distinct flange. Instead, the projections <NUM> attach directly to the hub body <NUM>. Advantages of this type of design can be lower weight, smaller hub diameter, or ease of manufacturing.

Claim 1:
A hub (<NUM>) suitable to be assembled with a first plurality of spokes (<NUM>) and a second plurality of spokes (<NUM>), each spoke of the first plurality of spokes and the second plurality of spokes comprises an elongated braided fiber having a loop (<NUM>) at a first end and a second end configured for attachment to a rim (<NUM>), wherein at least one spoke (<NUM>) of the first plurality of spokes can be joined to each support (<NUM>) of the first plurality of projections (<NUM>) with the loop (<NUM>) disposed about the support (<NUM>), and wherein at least one spoke (<NUM>) of the second plurality of spokes can be joined to each support (<NUM>) of the second plurality of projections (<NUM>) with the loop (<NUM>) disposed about the support (<NUM>), the hub comprising:
a hub body (<NUM>, <NUM>, <NUM>) being symmetric about a rotational axis having a first end (<NUM>, <NUM>) and a second end; and
a first plurality of projections (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) disposed on the hub body (<NUM>) at the first end and a second plurality of projections (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) disposed on the hub body at the second end, wherein the projections of each of the first plurality projections and the second plurality projections are spaced apart from each adjacent projection about the rotational axis on the first and second ends, respectively, wherein each projection of the first plurality of projections and the second plurality of projections comprises a base portion (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) joined to the hub body and a support (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) extending from the base portion to a free end (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>), and
wherein each support (<NUM>, <NUM>, <NUM>, <NUM>) of each projection (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) of the first plurality of projections and the second plurality of projections extends from the base portion (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) to the free end (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) in a direction about the rotational axis (<NUM>),
wherein the supports in each of the first plurality of projections and the second plurality of projections extend in opposite directions about the rotational axis,
wherein adjacent supports in each of the first plurality of projections and the second plurality of projections extend in opposite directions about the rotational axis.