Patent Document

BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention generally relates to a bicycle hub dynamo assembly is configured with a hub and a releasable electrical connector. 
   2. Background Information 
   Bicycling is becoming an increasingly more popular form of recreation as well as a means of transportation. Moreover, bicycling has become a very popular competitive sport for both amateurs and professionals. Whether the bicycle is used for recreation, transportation or competition, the bicycle industry is constantly improving the various components of the bicycle as well as the frame of the bicycle. 
   Recently, bicycles have been equipped with more and more electrical components requiring electrical power. Thus, some bicycles have been equipped with a hub dynamo for generating and supplying electrical power to the various electrical components such as lamps, cycle computers, electronic shifting units, etc. Two examples of hub dynamos are disclosed in U.S. Pat. Nos. 6,409,197 and 6,559,564, which are assigned to Shimano, Inc. 
   The dynamo hub typically has an electrical cord that supplies the power to the various components mounted on the bicycle that require electrical power. This electrical cord must be attached to the bicycle frame in a manner such that it does not interfere with the normal operation of the bicycle and its components. For example, when the dynamo hub is part of a front hub, the electrical cord must be mounted in a manner such that it does not interfere with the turning of the front fork and front bicycle wheel relative to the main frame. Moreover, if a dynamo hub were to be mounted on a bicycle having a front suspension fork, then the electrical cord must be mounted in a manner to provide for the contraction and expansion of the front suspension fork. 
   Also, when a dynamo hub is integrated with a hub that has a quick release axle, the connection between the electrical cord and the dynamo hub sometimes gets damaged due to the fragile connection therebetween. In other words, when the wheel with the dynamo hub is detach from the main frame, it is usually necessary to detach the electrical cord from the dynamo hub to remove the wheel. This often results in the connection between the electrical cord and the dynamo hub being damaged over a period of time in which the connection is repeatedly connected and disconnected. 
   In view of the above, it will be apparent to those skilled in the art from this disclosure that there exists a need for an improved hub dynamo assembly. This invention addresses this need in the art as well as other needs, which will become apparent to those skilled in the art from this disclosure. 
   SUMMARY OF THE INVENTION 
   One object of the present invention is to provide an electrical connector for use with a hub dynamo assembly that can be repeatedly disconnected and reconnected to a dynamo hub without being damaged. 
   Another object of the present invention is to provide an electrical connector for use with a hub dynamo assembly that is relatively inexpensive to manufacture. 
   The foregoing objects can basically be attained by providing a bicycle hub dynamo assembly that basically comprises a hub axle, a hub shell, a bearing unit, a generator mechanism and an electrical cord. The hub axle has a first axle end and a second axle end with a center axis extending between the first and second axle ends. The hub shell has a first shell end and a second shell end with an inner tubular surface forming a central passage extending between the first and second shell ends, the hub axle being disposed within the central passage of the hub shell. The bearing unit is disposed between the hub axle and the hub shell to rotatably support the first shell end of the hub shell on the first axle end of the hub axle. The generator mechanism is housed in the hub shell and adapted to generate electricity by rotation of the hub shell relative to the hub axle. The generator mechanism includes a first electrical connector with first electrical contacts. The electrical cord includes a second electrical connector with second electrical contacts configured to mate with the first electrical contacts of the first electrical connector, the second electrical connector includes an inner housing part and an outer housing part with a fixing portion of the second electrical contacts retained between the inner and outer housing parts. 
   These and other objects, features, aspects and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring now to the attached drawings which form a part of this original disclosure: 
       FIG. 1  is a partial, side elevational view of a bicycle with a front bicycle suspension assembly and a front bicycle hub dynamo assembly that utilize a bicycle electrical cord for powering a bicycle lamp in accordance with a preferred embodiment of the present invention; 
       FIG. 2  is a front elevational view of the front suspension fork which includes the front bicycle suspension assembly and the front bicycle hub dynamo assembly for powering the bicycle lamp via the bicycle electrical cord having the bicycle electrical cord connector in accordance with the present invention; 
       FIG. 3  is a first side elevational view of the front suspension fork in accordance with the present invention with the bicycle lamp and other parts removed for purposes of illustration; 
       FIG. 4  is a second side elevational view of the front suspension fork in accordance with the present invention with the bicycle lamp and other parts removed for purposes of illustration; 
       FIG. 5  is a rear elevational view of the front suspension fork in accordance with the present invention with the bicycle lamp and other parts removed for purposes of illustration; 
       FIG. 6  is a partial side elevational view of a bottom portion of the front suspension fork with the electrical connector of the electrical cord disconnected in accordance with the present invention; 
       FIG. 7  is a partial enlarged side elevational view of a bottom portion of the front suspension fork in accordance with the present invention; 
       FIG. 8  is a partial top plan view of a top portion of the front suspension fork in accordance with the present invention; 
       FIG. 9  is a partial top plan view of the top portion of the front suspension fork in accordance with the present invention with the top cover removed; 
       FIG. 10  is an inside plan view of the top cover of the front suspension fork with the switch unit mounted thereto in accordance with the present invention; 
       FIG. 11  is a partial cross-sectional view of the top portion of the top cover, the upper crown and one of the inner tubes in accordance with the present invention; 
       FIG. 12  is a partial perspective view of the bottom of the outer tube with the electrical extending outwardly therefrom; 
       FIG. 13  is a rear elevational view of the front hub with the top half shown in cross section in accordance with the present invention; 
       FIG. 14  is a partial perspective view of the lower or bottom end of the electrical cord with the electrical cord connector in accordance with the present invention; 
       FIG. 15  is an end elevational view of the electrical cord connector of the electrical cord in accordance with the present invention; 
       FIG. 16  is a partial exploded perspective view of the electrical cord connector with the outer housing part disconnected from the inner housing part in accordance with the present invention; 
       FIG. 17  is a cross sectional view of the electrical connector as seen along section line  17 — 17  of  FIG. 15  in accordance with the present invention; 
       FIG. 18  is a cross sectional view of the electrical connector as seen along section line  18 — 18  of  FIG. 15  in accordance with the present invention; 
       FIG. 19  is a cross sectional view of the electrical connector, similar to  FIG. 18 , but coupled to the electrical connector of the hub dynamo in accordance with the present invention; 
       FIG. 20  is a top plan view of the outer housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 21  is a first edge elevational view of the outer housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 22  is a side elevational view of the outer housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 23  is a second edge elevational view of the outer housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 24  is a bottom plan view of the outer housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 25  is a first cross-sectional view of the outer housing part of the electrical cord connector as seen along section line  25 — 25  of  FIG. 22  in accordance with the present invention; 
       FIG. 26  is a second cross-sectional view of the outer housing part of the electrical cord connector as seen along section line  26 — 26  of  FIG. 21  in accordance with the present invention; 
       FIG. 27  is a third cross-sectional view of the outer housing part of the electrical cord connector as seen along section line  27 — 27  of  FIG. 21  in accordance with the present invention; 
       FIG. 28  is a top plan view of the inner housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 29  is a first edge elevational view of the inner housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 30  is a first side elevational view of the inner housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 31  is a second edge elevational view of the inner housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 32  is a bottom plan view of the inner housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 33  is a second side elevational view of the inner housing part of the electrical cord connector in accordance with the present invention; 
       FIG. 34  is a first cross-sectional view of the inner housing part of the electrical cord connector as seen along section line  34 — 34  of  FIG. 31  in accordance with the present invention; 
       FIG. 35  is a second cross-sectional view of the inner housing part of the electrical cord connector as seen along section line  35 — 35  of  FIG. 29  in accordance with the present invention; 
       FIG. 36  is a third cross-sectional view of the inner housing part of the electrical cord connector as seen along section line  36 — 36  of  FIG. 30  in accordance with the present invention; 
       FIG. 37  is first side elevational view of one of the electrical contacts for the electrical cord connector in accordance with the present invention; 
       FIG. 38  is an edge elevational view of one of the electrical contacts of the electrical cord connector in accordance with the present invention; and 
       FIG. 39  is a second side elevational view of one of the electrical contacts of the electrical cord connector in accordance with the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Selected embodiments of the present invention will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments of the present invention are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. 
   Referring initially to  FIGS. 1–7 , a front portion of a bicycle  10  is illustrated that is equipped with a front suspension fork  12  and a front dynamo hub  14  in accordance with a first embodiment of the present invention. A bicycle electrical cord  16  is installed in the front suspension fork  12  for interconnecting at least two electrical components. Preferably, the bicycle electrical cord  16  is connected to the front dynamo hub  14  (one electrical component) by an electrical cord connector  18  for powering a bicycle lamp  20  (another electrical component) in accordance with a first embodiment of the present invention. 
   As seen in  FIG. 1 , the front portion of the bicycle  10  has an upper end of the front suspension fork  12  movably coupled to a main bicycle frame  22  and a lower end of the front suspension fork  12  coupled to the front dynamo hub  14 . The front dynamo hub  14  is part of a front wheel  26 , which is rotatably mounted to the front suspension fork  12  by the front dynamo hub  14  in conventional manner. A handlebar  28  is fixed to the front suspension fork  12  in a conventional manner to turn the front suspension fork  12  relative to the main bicycle frame  22 . The bicycle electrical cord  16  is arranged to extend through an internal area of the front suspension fork  12  as explained below. 
   In the illustrated embodiment, as best seen in FIGS.  2  and  6 – 7 , the bicycle electrical cord  16  has a first cord portion  16   a  and a second cord portion  16   b  with a switch unit  30  electrically coupled between the first and second cord portions  16   a  and  16   b . The first cord portion  16   a  has a lower end electrically coupled to the front dynamo hub  14  via the electrical cord connector  18  and an upper end electrically coupled to the switch unit  30 . The second cord portion  16   b  has one end electrically coupled to the lamp  20  and the other end electrically coupled to the switch unit  30 . The switch unit  30  is mounted on the top of a portion of the front suspension fork  12  as discussed below. The switch unit  30  is used to connect and disconnect electrical power electrically from the front dynamo hub  14  to the bicycle lamp  20 . 
   The front suspension fork  12  basically includes a pair of telescoping struts  31  and  32  that are interconnected by an upper crown  33  which is coupled to a steerer tube  34 . The steerer tube  34  is coupled to the main bicycle frame  22  in a conventional manner and has the handlebar  28  coupled to its upper end in a conventional manner. As explained below, the basic constructions of the struts  31  and  32  are identical, except that the strut  31  is configured and arranged to act as a shock absorber and the strut  32  is configured and arranged to act as a protective conduit for protecting the first cord portion of the electrical cord  16 . 
   As best seen in  FIGS. 2 ,  4  and  5 , the strut  31  includes an inner (upper) telescoping member or tube  36  and an outer (lower) telescoping member or tube  38  telescopically coupled to the inner telescoping tube  36 . The inner and outer telescoping tubes  36  and  38  are constructed of hard rigid materials that are conventionally used for struts. The inner and outer telescoping tubes  36  and  38  of the strut  31  are configured and arranged to form a variable volume chamber having a dampening unit  40  located therein. The dampening unit  40  is configured and arranged to absorb impacts on the front suspension fork  12  due to engagement with a rock, a hole, a bump or a like. The dampening unit  40  can be any conventional dampening unit such as one or more compression springs, a combination of dampening elements and/or the like. Accordingly, the dampening unit  40  will not be discussed or illustrated in detail herein. 
   Basically, the inner telescoping tube  36  includes an upper end portion  36   a  and a lower end portion  36   b  with an upper internal passage  36   c  located between the upper and lower end portions  36   a  and  36   b . The outer telescoping tube  38  includes an upper end portion  38   a , a lower end portion  38   b  and a lower internal passage  38   c  located between the upper and lower end portions  38   a  and  38   b . The internal passages  36   c  and  38   c  form the variable volume chamber with the dampening unit  40  located therein. 
   The upper end portion  36   a  of the inner telescoping tube  36  is fixedly coupled to the upper crown  33 , while the lower end portion  36   b  of the inner telescoping tube  36  is slideably coupled within the upper end portion  38   a  of the outer telescoping tube  38 . A seal (not shown) is configured and arranged in a conventional manner between the lower end portion  36   b  of the inner telescoping tube  36  and the upper end portion  38   a  of the outer telescoping tube  38  to allow for the relative sliding movement of the inner and outer telescoping tubes  36  and  38 . The upper end portion  36   a  of the inner telescoping tube  36  also has internal treads that adjustably secures an adjustment member  49 . The adjustment member seals the opening of the upper end portion  36   a  of the inner telescoping tube  36 . Thus, the variable volume chamber of the strut  31  is a closed chamber. 
   The outer telescoping tube  38  includes an upper end portion  38   a , a lower end portion  38   b  and a lower internal passage  38   c  located between the upper and lower end portions  38   a  and  38   b . The lower end portion  38   b  has a wheel mount or dropout  38   d  for attaching one end of the front dynamo hub  14  thereto. 
   As best seen in  FIGS. 2 ,  3  and  5 , the strut  31  contract and expand together with the dampening unit  40  to act as a shock absorber for the entire structure of the front suspension fork  12 . More specifically, a telescoping motion occurs between the inner and outer tubes  36  and  38  to compress the dampening unit  40 , which is configured and arranged within the inner and outer tubes  36  and  38  to absorb impacts on the front suspension fork  12  due to engagement with a rock, a hole, a bump or a like. In other words, as the telescoping strut  31  is compressed to absorb a shock, the lower end portion  36   b  of the inner telescoping tube  36  travels towards the lower end portion  38   b  of the outer telescoping tube  38 , thus reducing the volume of the variable volume chamber formed between the inner and outer telescoping tubes  36  and  38 . Similarly, when the telescoping strut  31  expands to return to its neutral position, the lower end portion  36   a  of the inner telescoping tube  36  travels away from the lower end portion  38   b  of the outer telescoping tube  38  to increase the volume of the variable volume chamber formed by the inner and outer telescoping tubes  36  and  38 . 
   Preferably, the strut  32  does not include a dampening unit, but rather has the first cord portion  16   a  of the electrical cord  16  running therethrough. Of course, if needed and/or desired, a second dampening unit can be installed in the strut  32  that does not interfere with the electrical cord  16 . The strut  32  basically includes an inner (upper) telescoping member or tube  46  and an outer (lower) telescoping member or tube  48  telescopically coupled to the inner telescoping tube  46 . The inner and outer telescoping tubes  46  and  48  are constructed of hard rigid materials that are conventionally used for struts. The inner and outer telescoping tubes  46  and  48  of the strut  32  are configured and arranged to form a variable volume chamber having a majority of the first cord portion  16   a  of the electrical cord  16  located therein. 
   The outer telescoping tubes  38  and  48  are interconnected by a bridge member  50  that is integrally formed with the outer telescoping tubes  38  and  48 . Of course, it will be apparent to those skilled in the art that the bridge member  50  can be a separate member that is fixed to the outer telescoping tubes  38  and  48 . Thus, the bridge member  50  interconnects the struts  31  and  32  together such that they act as a single unit. In other words, the struts  31  and  32  contract and expand together with the dampening unit  40  acting as a shock absorber for the entire structure of the front suspension fork  12 . More specifically, a telescoping motion occurs between the inner tubes  36  and  46  and the outer tubes  38  and  48  to compress the dampening unit  40 . Accordingly, the dampening unit  40  is configured and arranged to absorb impacts on the front suspension fork  12  due to engagement with a rock, a hole, a bump or a like. 
   Basically, the inner telescoping tube  46  includes an open upper end portion  46   a  and an open lower end portion  46   b  with an upper internal passage  46   c  located between the upper and lower end portions  46   a  and  46   b . The outer telescoping tube  48  includes an upper end portion  48   a , a lower end portion  48   b  and a lower internal passage  48   c  located between the upper and lower end portions  48   a  and  48   b . The internal passages  46   c  and  48   c  form an enclosed chamber with the first cord portion  16   a  of the electrical cord  16  extending therethrough. The first cord portion  16   a  of the electrical cord  16  is configured and arranged within the internal passages  46   c  and  48   c  of the telescoping tubes  46  and  48  such that sufficient slack is provided in the first cord portion  16   a  to accommodate expansion and contraction of the inner and outer telescoping tubes  46  and  48 . 
   The upper end portion  46   a  of the inner telescoping tube  46  is fixedly coupled to the upper crown  33 , while the lower end portion  46   b  of the inner telescoping tube  46  is slideably coupled within the upper end portion  48   a  of the outer telescoping tube  48 . The inner telescoping tube  46  is open at its upper end such that an upper end portion of the first cord portion  16   a  of the electrical cord  16  extends outwardly therefrom for connection with the switch unit  30  as seen in  FIG. 11 . A seal (not shown) is provided between the lower end portion  46   b  of the inner telescoping tube  46  and the upper end portion  48   a  of the outer telescoping tube  48  in a conventional manner to allow the relative sliding movement of the inner and outer telescoping tubes  46  and  48 . 
   The outer telescoping tube  48  includes an upper end portion  48   a , a lower end portion  48   b  and a lower internal passage  48   c  located between the upper and lower end portions  48   a  and  48   b . The lower end portion  48   b  has a wheel mount or dropout  48   d  for attaching one end of the front dynamo hub  14  thereto. Also as best seen in  FIG. 12 , the outer telescoping tube  48  is provided with a cord opening  48   e  at its lower end such that a lower end portion of the first cord portion  16   a  of the electrical cord  16  extends outwardly from the lower internal passage  48   c  of the outer telescoping tube  48 . 
   Referring now to  FIGS. 8–11 , the upper crown  33  includes a top cover  52  that is fixedly coupled thereto for covering the upper open end of the inner telescoping tube  46 . Preferably, the top cover  52  is secured to the upper crown  33  by a fastener such as a screw  53  that threads into an internally threaded hole  54  formed in the upper crown  33 . Thus, the top cover  52  is configured and arranged to be selectively removed from a position covering the upper end opening of the inner telescoping tube  46  for accessing the switch unit  30 . 
   The switch unit  30  is preferably fixedly coupled to the top cover  52 . The switch unit  30  includes a push button switch  55  that projects outwardly from an upper surface of the top cover  52  and an electrical connector  56  protruding downwardly from an inner surface of the top cover  52 . Preferably, the electrical connector  56  of the switch unit  30  projects into partially into the upper end portion  46   a  of the inner telescoping tube  46 . The electrical connector  56  is electrically coupled to the electrical cord  16  that is connected between the front dynamo hub  14  and the bicycle lamp  20 . The push button switch  55  is a conventional switch that is selectively pushed to connect and disconnect a pair of electrical contacts (not shown) in the electrical connector  56 . In other words, electrical power to the lamp  20  is interrupted by pushing the push button switch  55  when the push button switch  55  is in the contact closed position that supplies electrical power to the lamp  20 . The push button switch  55  is pushed again to disconnect electrical power to the lamp  20  when the push button switch  55  is in the contact open position that interrupts electrical power to the lamp  20 . 
   Referring now to  FIGS. 1–3 ,  5 ,  6 ,  7 ,  10 – 12  and  16 – 19 , the electrical cord  16  is a conventional electrical cord with a pair of insulated conductor wires W 1  and W 2  having an outer elastomeric cover or sheath C. In the area of the switch unit  30 , the elastomeric cover or sheath C of the electrical cord  16  is split into two pieces that define the first and second cord portions  16   a  and  16   b.    
   As best seen in  FIGS. 1–3 , the first cord portion  16   a  of the electrical cord  16  is located in the internal passages  46   c  and  48   c  of the inner and outer telescoping tubes  46  and  48 , and is arranged with sufficient slack to accommodate expansion and contraction of the inner and outer telescoping tubes  46  and  48 . Thus, the first cord portion  16   a  of the electrical cord  16  is protected and does not interfere with the normal operation of the bicycle  10  and its components. 
   As seen in  FIGS. 5–7  and  16 – 19 , the lower ends of the conductor wires W 1  and W 2  are electrically coupled to the electrical connector  18  as discussed below. The upper ends of the conductor wires W 1  and W 2  are electrically coupled to the lamp  20  using conventional push clips (not shown). The conductor wire W 1  is split into two pieces with the switch unit  30  electrically coupling the two pieces of conductor wire W 1  together. In particular, the electrical contacts (not shown) in the electrical connector  56  are connected to the two pieces of the conductor wire W 1 . 
   Referring now to  FIG. 13 , the front dynamo hub  14  is preferably a substantially conventional member, except for its electrical connector  60 . Thus, the front dynamo hub  14  will not be discussed or illustrated in detail herein. 
   As seen in  FIGS. 6 ,  7  and  19 , the electrical connector  60  has an insulating body portion  60   a  and a pair of electrical contacts  60   b  that are electrically coupled to a dynamo portion of the front dynamo hub  14  in a conventional manner. The insulating body portion  60   a  supports the electrical contacts  60   b  in a protected manner for coupling with the electrical connector  18  as seen in  FIG. 19 . The electrical connector  60  is configured and arranged as a male connector. 
   Basically, the front dynamo hub  14  comprises an internal stator assembly  61  and an external rotor assembly  62  that form the dynamo portion of the front dynamo hub  14 . The internal stator assembly  61  comprises a hub axle  63 , a pair of stator yokes  64 , a bobbin  65  with a wound coil  66 , a cylindrical core yoke  67  and two separate disks  68 . 
   The internal stator assembly  61  is fixed to the front suspension fork  12  by the hub axle  63 . The hub axle  63  is preferably a quick release hub axle having an adjustment nut  63   a  coupled to one end and a cam lever  63   b  coupled to the other end. The electrical connector  60 , the stator yokes  64 , the cylindrical core yoke  67  and the separation disks  68  are all fixed to this hub axle  63  so they do not rotate with the wheel  26 . 
   The external rotor assembly  62  comprises a pair of frame portions  69  and a cap  70  integrated as shown in  FIG. 13 . The external rotor assembly  62  is rotatably fixed to the hub axle  63  with the aid of bearings B. The flanges formed on the outer peripheral portion of the frame portions  69  are attached to a plurality of spokes  26   a  of the front wheel  26 . A permanent magnet M comprising four magnets spaced at equal intervals in the circumferential direction is fixed to the cap  70 . In this permanent magnet M, the north (N) and south (S) poles are intermittently formed at equally spaced intervals. A total of twenty-eight poles of each type face the stator yokes  64 . The operation of the front dynamo hub  14  is explained in more detail in U.S. Pat. No. 6,409,197 (assigned to Shimano, Inc.). 
   Referring now to  FIGS. 14–19 , the electrical connector  18  is configured and arranged as a female connector. The electrical cord connector  18  includes an outer housing part  71 , an inner housing part  72  and a pair of electrical contacts  73 . Preferably, each of the inner and outer housing parts  71  and  72  is constructed as a one-piece, unitary member from an insulating plastic material such that the outer and inner housing parts  71  and  72  insulate the contacts  73  from each other. Preferably, the material of the inner and outer housing parts  71  and  72  is a rigid insulating material with limited flexibility. The inner and outer housing parts  71  and  72  are connected together by a snap fit as explained below with the electrical contacts retained between abutting surfaces of the inner and outer housing parts  71  and  72 . 
   Referring now to  FIGS. 20–27 , the outer housing part  71  is preferably a one piece, unitary member that has a main body section  74  and a cord receiving section  75  that are integrally formed as a one piece, unitary member. The main body section  74  has a substantially rectangular outer cross-sectional shape with an internal space or cavity  76  that is sized to retain the inner housing part  72  therein. Thus, the main body section  74  has first end wall  81 , a first side wall  82 , a second end wall  83  and a second side wall  84  that define the rectangular cavity  76  that receives and retains the inner housing part  72 . The end wall  81  is provided with a gripping tab  81   a  and a retaining opening  81   b . The end wall  83  is provided with a gripping tab  83   a  and a retaining opening  83   b . Also, the interior surfaces of the end walls  81  and  83  are preferably step shaped to form two abutments  81   c  and  83   c , respectively, which limit the movement of the inner housing part  72  when the inner housing part  72  is being snap fitted into the outer housing part  71 . 
   The cord receiving section  75  has a substantially cylindrical cord receiving bore  85  that is in communication with the interior cavity  76  of the main body section  71 . The cord receiving bore  85  has a lower portion of the electrical cord  16  located therein. Preferably, the interface between the cover C of time electrical cord  16  and cord receiving bore  85  is watertight. A cord retaining ring  86  is located on the lower portion of the electrical cord  16  that is located in the interior cavity  76  of the main body section  74  to prevent the electrical cord  16  from being pulled out of the electrical connector  18 . 
   Referring now to  FIGS. 28–36 , the inner housing part  72  has a substantially rectangular overall exterior shape in cross-section that is dimensioned to be press-fitted into the interior cavity  76  of the outer housing part  71  by a snap fit. In particular, the inner housing part  72  has a first end wall  91 , a first side wall  92 , a second end wall  93  and a second side wall  94  that are sized slightly smaller than the interior cavity  76  of the outer housing part  71 . Theses walls define a connector receiving recess or cavity  90  that is dimensioned to frictionally retain the connector  60  of the front dynamo hub  14  therein. 
   The end wall  91  includes a retaining protrusion  95  that is a generally triangularly shaped member that include an abutment surface  95   a  extending perpendicular to the end wall  91  and a ramp surface  95   b  that is inclined to the end wall  91 . The end wall  93  includes a retaining protrusion  96  that is a generally triangularly shaped member that include an abutment surface  96   a  extending perpendicular to the end wall  91  and a ramp surface  96   b  that is inclined to the end wall  93 . The ramp surfaces  95   b  and  96   b  are designed to allow easier insertion of the inner housing part  72  into the internal cavity  76  of the outer housing part  71 . When the inner housing part  72  is inserted into the outer housing part  71 , the protrusions  95  and  96  are received in the retaining openings  81   b  and  83   b  of the outer housing part  71 . Preferably, the protrusions  95  and  96  are attached in a cantilevered fashion to the end walls  91  and  93  such that the protrusions  95  and  96  are resiliently coupled to the end walls  91  and  93  to flex inwardly relative to the longitudinal axis of the inner housing part  72  when the inner housing part  72  is inserted into the interior cavity  76  of the outer housing part  71 . 
   The side wall  92  has a pair of contact receiving grooves  97  and a pair of through openings  98 . The contact receiving grooves  97  are configured and arranged to tightly receive the electrical contacts  73  therein. The through openings  98  are configured and arranged in the side wall  92  along center portions of the contact receiving grooves  97 . These openings  98  allow the electrical contacts  73  to be deformed for fixedly securing the electrical contacts  72  to the inner housing barn  72  as discussed below. 
   Referring now to  FIGS. 16–19  and  37 – 39 , the electrical contacts  73  are preferably identical. Thus, each of the contacts  73  has a wire connection end  73   a  and an electrical contact end  73   b  with a center section or fixing portion  73   c  extending between the wire connection end  73   a  and the electrical contact end  73   b . Preferably, the electrical contacts  73  are constructed as a one-piece, unitary member from a metallic sheet material having good electrical conductive characteristics. 
   The wire connection end  73   a  is provided with a hole for receiving one of the conductors of the conductor wires W 1  and W 2  that is preferably soldered thereto. The connection end  73   a  is also preferably provided with a reduced section so that the connection end  73   a  can be deformed or bent out of the initial plane of a center section  73   c  of the contact  73  of as shown in  FIG. 17 . The contact end  73   b  is preferably part-shaped such that the free end of the contact end  73   b  is cantilevered to be resiliently deflected towards the center section  73   c  of the contact  73  when the electrical connector  18  is connected to the electrical connector  60  of the front dynamo hub  14  as seen in  FIG. 19 . In particular, when the contacts  73  are slide into the contact receiving grooves  97  of the inner housing part  72 , the contact ends  73   b  extend around a front edge of the side wall  92  and then the free end of the contact ends  73   b  extend rearwardly into the interior cavity  76  of the inner housing part  72 . The portions of the contact ends  73   b  located in the interior cavity  76  of the inner housing part  72  are spaced from the interior surface of the side wall  92  of the inner housing part  72 . This arrangement allows the contact ends  73   b  to be resiliently deflected towards the interior surface of the side wall  92  of the inner housing part  72  when the electrical connector  18  is connected to the electrical connector  60  of the front dynamo hub  14  as seen in  FIG. 19 . 
   Each electrical contact  73  is also provided with a cutout  73   d  in the center section or fixing portion  73   c  to form a retaining tab  73   e . The retaining tabs  73   e  are designed to be bent or deformed into the openings  98  of the side wall  92  of the inner housing part  72  to secure the contacts  73  to the inner housing part  72  prior to the inner housing part  72  being coupled to the outer housing part  71 . 
   The bicycle lamp  18  is a conventional bicycle lamp. Thus, bicycle lamp  18  will not be discussed or illustrated in detail herein. However, the bicycle lamp  18  is powered by the electrical energy generated by the front dynamo hub  14 . 
   The bicycle  10  and its various components are well known in the prior art, except for those components that relate to the present invention. Thus, the bicycle  10  and its various components will not be discussed or illustrated in detail herein, except for those components that relate to the present invention. 
   As used herein, the following directional terms “forward, rearward, above, downward, vertical, horizontal, below and transverse” as well as any other similar directional terms refer to those directions of a bicycle equipped with the present invention. Accordingly, these terms, as utilized to describe the present invention should be interpreted relative to a bicycle equipped with the present invention. 
   The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms should be construed as including a deviation of at least ±5% of the modified term if this deviation would not negate the meaning of the word it modifies. 
   While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. Furthermore, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Technology Category: 4