Bicycle sprocket assembly

The present invention relates to a bicycle sprocket assembly.

Discussion of the Background

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. One bicycle component that has been extensively redesigned is a sprocket assembly.

In accordance with a first aspect of the present invention, a bicycle sprocket assembly comprises a sprocket support member and a reinforcement member. The sprocket support member is configured to support a sprocket. The sprocket support member includes a central cylindrical portion and at least one sprocket support portion extending radially outwardly from the central cylindrical portion with respect to a rotational center axis of the bicycle sprocket assembly. The sprocket support member is made of a non-metallic material. The reinforcement member is provided in the central cylindrical portion to reinforce the central cylindrical portion in a circumferential direction about the rotational center axis.

With the bicycle sprocket assembly according to the first aspect, the reinforcement member improves strength of the central cylindrical portion in the circumferential direction.

In accordance with a second aspect of the present invention, the bicycle sprocket assembly according to the first aspect is configured so that the reinforcement member has an annular shape defined about the rotational center axis.

With the bicycle sprocket assembly according to the second aspect, the reinforcement member further improves the strength of the sprocket support member.

In accordance with a third aspect of the present invention, the bicycle sprocket assembly according to the first or second aspect is configured so that the non-metallic material includes a resin material.

With the bicycle sprocket assembly according to the third aspect, it is possible to improve the strength of the sprocket support member with saving weight of the sprocket support member.

In accordance with a fourth aspect of the present invention, the bicycle sprocket assembly according to any one of the first to third aspects is configured so that the non-metallic material comprises a fiber composite material.

With the bicycle sprocket assembly according to the fourth aspect, it is possible to improve the strength of the sprocket support member with saving weight of the sprocket support member.

In accordance with a fifth aspect of the present invention, the bicycle sprocket assembly according to the fourth aspect is configured so that the reinforcement member is made of a fiber composite material. The fiber composite material of the reinforcement member has a fiber direction defined at least along the circumferential direction.

With the bicycle sprocket assembly according to the fifth aspect, it is possible to effectively improve the strength of the sprocket support member with saving weight of the sprocket support member.

In accordance with a sixth aspect of the present invention, the bicycle sprocket assembly according to the fifth aspect is configured so that the fiber composite material of the reinforcement member includes a reinforcement fiber provided in the central cylindrical portion to be wound about the rotational center axis by more than one turn.

With the bicycle sprocket assembly according to the sixth aspect, it is possible to more effectively improve the strength of the sprocket support member with saving weight of the sprocket support member.

In accordance with a seventh aspect of the present invention, the bicycle sprocket assembly according to any one of the fourth to sixth aspects is configured so that the fiber composite material includes a fiber reinforced plastic.

With the bicycle sprocket assembly according to the seventh aspect, it is possible to effectively improve the strength of the sprocket support member with saving weight of the sprocket support member.

In accordance with an eighth aspect of the present invention, the bicycle sprocket assembly according to the seventh aspect is configured so that the fiber reinforced plastic includes a carbon fiber reinforced plastic.

With the bicycle sprocket assembly according to the eighth aspect, it is possible to more effectively improve the strength of the sprocket support member with saving weight of the sprocket support member.

In accordance with a ninth aspect of the present invention, the bicycle sprocket assembly according to any one of the first to seventh aspects is configured so that the central cylindrical portion of the sprocket support member comprises a hub engagement profile to engage with a bicycle hub assembly.

With the bicycle sprocket assembly according to the ninth aspect, it is possible to utilize the bicycle sprocket assembly as a rear sprocket assembly.

In accordance with a tenth aspect of the present invention, the bicycle sprocket assembly according to any one of the first to eighth aspects is configured so that the sprocket support member includes a plurality of sprocket support portions extending radially outwardly from the central cylindrical portion.

With the bicycle sprocket assembly according to the tenth aspect, it is possible to improve the strength of the sprocket support member with saving weight of the sprocket support member.

In accordance with an eleventh aspect of the present invention, the bicycle sprocket assembly according to any one of the first to tenth aspects is configured so that the reinforcement member is embedded in the central cylindrical portion.

With the bicycle sprocket assembly according to the eleventh aspect, the reinforcement member effectively improves the strength of the sprocket support member.

In accordance with a twelfth aspect of the present invention, the bicycle sprocket assembly according to the eleventh aspect is configured so that the reinforcement member is partly exposed from the central cylindrical portion.

With the bicycle sprocket assembly according to the twelfth aspect, it is possible to easily embed the reinforcement member in the central cylindrical portion in a case where the sprocket support member is formed with an injection molding.

In accordance with a thirteenth aspect of the present invention, the bicycle sprocket assembly according to any one of the first to twelfth aspect is configured so that the central cylindrical portion includes a first axial surface and a second axial surface provided on a reverse side of the first axial surface in an axial direction parallel to the rotational center axis. The reinforcement member is closer to the second axial surface than to the first axial surface in the axial direction.

With the bicycle sprocket assembly according to the thirteenth aspect, it is possible to easily provide a gate of the injection molding away from the reinforcement member. This smoothens flow of a molten material during the injection molding.

In accordance with a fourteenth aspect of the present invention, the bicycle sprocket assembly according to any one of the first to thirteenth aspects is configured so that the central cylindrical portion includes an inner peripheral surface and an outer peripheral surface provided radially outwardly of the inner peripheral surface. The reinforcement member is provided between the inner peripheral surface and the outer peripheral surface without being exposed from the inner peripheral surface and the outer peripheral surface.

With the bicycle sprocket assembly according to the fourteenth aspect, the reinforcement member effectively improves the strength of the sprocket support member.

In accordance with a fifteenth aspect of the present invention, the bicycle sprocket assembly according to any one of the first to fourteenth aspects is configured so that the reinforcement member is provided at a radial center between the outer peripheral surface and the inner peripheral surface.

With the bicycle sprocket assembly according to the fifteenth aspect, the reinforcement member effectively improves the strength of the sprocket support member.

A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

FIG. 1 is a perspective view of a bicycle sprocket assembly in accordance with an embodiment.

FIG. 2 is another perspective view of the bicycle sprocket assembly illustrated in FIG. 1 .

FIG. 3 is a side elevational view of the bicycle sprocket assembly illustrated in FIG. 1 .

FIG. 4 is an exploded perspective view of the bicycle sprocket assembly illustrated in FIG. 1 .

FIG. 5 is another side elevational view of the bicycle sprocket assembly illustrated in FIG. 1 .

FIG. 6 is a cross-sectional view of the bicycle sprocket assembly taken along line VI-VI of FIG. 5 .

FIG. 7 is a cross-sectional view of the bicycle sprocket assembly taken along line VII-VII of FIG. 5 .

FIG. 8 is an enlarged partial view of the bicycle sprocket assembly illustrated in FIG. 1 .

FIG. 9 is a cross-sectional view of an injection molding apparatus for the bicycle sprocket assembly taken along line IX-IX of FIG. 10 .

FIG. 10 is a plan view of the injection molding apparatus for the bicycle sprocket assembly illustrated in FIG. 1 .

FIG. 11 is a flow chart of an injection molding using the injection molding apparatus illustrated in FIG. 10 .

The embodiment(s) will now be described with reference to the accompanying drawings, wherein like reference numerals designate corresponding or identical elements throughout the various drawings.

Referring initially to FIGS. 1 and 2 , a bicycle sprocket assembly 10 in accordance with an embodiment comprises a sprocket support member 12 configured to support a sprocket. The bicycle sprocket assembly 10 comprises sprockets SP 1 , SP 2 , SP 3 , SP 4 , and SP 5 . The sprocket support member 12 is configured to support the sprockets SP 1 to SP 5 . The sprockets SP 1 to SP 5 are attached to the sprocket support member 12 . The sprocket support member 12 is a separate member from the sprockets SP 1 to SP 5 . The sprockets SP 1 to SP 5 are separate members from each other. However, at least one of the sprockets SP 1 to SP 5 can be at least partly provided integrally with another of the sprockets SP 1 to SP 5 . A total number of sprockets of the bicycle sprocket assembly 10 is not limited to this embodiment. In this embodiment, the bicycle sprocket assembly 10 is a rear sprocket assembly. However, structures of the bicycle sprocket assembly 10 can be applied to a front sprocket assembly.

In the present application, the following directional terms “front,” “rear,” “forward,” “rearward,” “left,” “right,” “transverse,” “upward” and “downward” as well as any other similar directional terms refer to those directions which are determined on the basis of a user (e.g., a rider) who sits on a saddle (not shown) of a bicycle with facing a handlebar (not shown). Accordingly, these terms, as utilized to describe the bicycle sprocket assembly 10 , should be interpreted relative to the bicycle equipped with the bicycle sprocket assembly 10 as used in an upright riding position on a horizontal surface.

As seen in FIG. 3 , the bicycle sprocket assembly 10 has a rotational center axis A 1 and is rotatably supported by a bicycle hub assembly H relative to a bicycle frame (not shown) about the rotational center axis A 1 . The bicycle sprocket assembly 10 is configured to be engaged with a bicycle chain C to transmit a driving rotational force F 1 between the bicycle chain C and the bicycle sprocket assembly 10 . The bicycle sprocket assembly 10 is rotated about the rotational center axis A 1 in a driving rotational direction D 11 during pedaling. The driving rotational direction D 11 is defined along a circumferential direction D 1 of the bicycle sprocket assembly 10 .

The sprocket SP 1 has a pitch-circle diameter PCD 1 . The sprocket SP 2 has a pitch-circle diameter PCD 2 . The sprocket SP 3 has a pitch-circle diameter PCD 3 . The sprocket SP 4 has a pitch-circle diameter PCD 4 . The sprocket SP 5 has a pitch-circle diameter PCD 5 . The pitch-circle diameter PCD 1 is the largest among the pitch-circle diameters PCD 1 to PCD 5 . The pitch-circle diameter PCD 5 is the smallest among the pitch-circle diameters PCD 1 to PCD 5 . The sprocket SP 1 corresponds to low gear. The sprocket SP 5 corresponds to top gear. The pitch-circle diameter PCD 1 is defined by centers of pins (not shown) of the bicycle chain C engaged with the sprocket SP 1 . The pitch-circle diameter PCD 2 is defined by the centers of the pins (not shown) of the bicycle chain C engaged with the sprocket SP 2 . The pitch-circle diameter PCD 3 is defined by the centers of the pins (not shown) of the bicycle chain C engaged with the sprocket SP 3 . The pitch-circle diameter PCD 4 is defined by the centers of the pins (not shown) of the bicycle chain C engaged with the sprocket SP 4 . The pitch-circle diameter PCD 5 is defined by the centers of the pins (not shown) of the bicycle chain C engaged with the sprocket SP 5 .

As seen in FIG. 4 , the sprocket SP 1 includes a sprocket body SP 11 and a plurality of sprocket teeth SP 12 extending radially outwardly from the sprocket body SP 11 . The sprocket SP 2 includes a sprocket body SP 21 and a plurality of sprocket teeth SP 22 extending radially outwardly from the sprocket body SP 21 . The sprocket SP 3 includes a sprocket body SP 31 and a plurality of sprocket teeth SP 32 extending radially outwardly from the sprocket body SP 31 . The sprocket SP 4 includes a sprocket body SP 41 and a plurality of sprocket teeth SP 42 extending radially outwardly from the sprocket body SP 41 . The sprocket SP 5 includes a sprocket body SP 51 and a plurality of sprocket teeth SP 52 extending radially outwardly from the sprocket body SP 51 .

In this embodiment, a total number of the sprocket teeth SP 12 is 45. A total number of the sprocket teeth SP 22 is 40. A total number of the sprocket teeth SP 32 is 36. A total number of the sprocket teeth SP 42 is 32. A total number of the sprocket teeth SP 52 is 28. However, the total number of the sprocket teeth SP 12 is not limited to this embodiment. The total number of the sprocket teeth SP 22 is not limited to this embodiment. The total number of the sprocket teeth SP 32 is not limited to this embodiment. The total number of the sprocket teeth SP 42 is not limited to this embodiment. The total number of the sprocket teeth SP 52 is not limited to this embodiment.

As seen in FIG. 4 , the sprocket body SP 11 includes projections SP 13 . The sprocket body SP 21 includes projections SP 23 . The sprocket body SP 31 includes projections SP 33 . The sprocket body SP 41 includes projections SP 43 . The sprocket body SP 51 includes projections SP 53 .

As seen in FIG. 5 , the sprocket support member 12 includes a central cylindrical portion 14 and at least one sprocket support portion 16 . The central cylindrical portion 14 of the sprocket support member 12 comprises a hub engagement profile 14 A to engage with the bicycle hub assembly H. The at least one sprocket support portion 16 extends radially outwardly from the central cylindrical portion 14 with respect to the rotational center axis A 1 of the bicycle sprocket assembly 10 . In this embodiment, the sprocket support member 12 includes a plurality of sprocket support portions 16 extending radially outwardly from the central cylindrical portion 14 . The sprocket support portions 16 are spaced apart from each other in the circumferential direction D 1 . However, the at least one sprocket support portion 16 can have other shapes such as an annular shape. A total number of the sprocket support portions 16 is not limited to this embodiment.

In this embodiment, the central cylindrical portion 14 is integrally provided with the plurality of sprocket support portions 16 as a one-piece unitary member. However, the central cylindrical portion 14 can be a separate member from the plurality of sprocket support portions 16 . For example, the sprocket support member 12 is formed with an injection molding such as an insert molding. As seen in FIG. 6 , the sprockets SP 1 to SP 5 are partly embedded in the sprocket support member 12 . As seen in FIGS. 2 and 6 , the sprockets SP 1 to SP 5 are partly embedded in each of the sprocket support portions 16 .

As seen in FIG. 6 , the bicycle sprocket assembly 10 comprises a reinforcement member 18 provided in the central cylindrical portion 14 to reinforce the central cylindrical portion 14 in the circumferential direction about the rotational center axis A 1 . The reinforcement member 18 is embedded in the central cylindrical portion 14 . The reinforcement member 18 is partly exposed from the central cylindrical portion 14 . As seen in FIG. 5 , the reinforcement member 18 has an annular shape defined about the rotational center axis A 1 .

As seen in FIG. 7 , the central cylindrical portion 14 includes a first axial surface 14 B and a second axial surface 14 C. The second axial surface 14 C is provided on a reverse side of the first axial surface 14 B in an axial direction D 2 parallel to the rotational center axis A 1 . The reinforcement member 18 is closer to the second axial surface 14 C than to the first axial surface 14 B in the axial direction D 2 . The first axial surface 14 B is closer to the sprocket SP 5 than the second axial surface 14 C in the axial direction D 2 . The second axial surface 14 C is closer to the sprocket SP 1 than the first axial surface 14 B in the axial direction D 2 . The reinforcement member 18 is partly exposed from the second axial surface 14 C of the central cylindrical portion 14 . However, the reinforcement member 18 can be closer to the first axial surface 14 B than to the second axial surface 14 C in the axial direction D 2 . The reinforcement member 18 can be provided at an axial center between the first axial surface 14 B and the second axial surface 14 C in the axial direction D 2 .

The central cylindrical portion 14 includes an inner peripheral surface 14 D and an outer peripheral surface 14 E provided radially outwardly of the inner peripheral surface 14 D. The hub engagement profile 14 A is provided on the inner peripheral surface 14 D. The reinforcement member 18 is provided between the inner peripheral surface 14 D and the outer peripheral surface 14 E without being exposed from the inner peripheral surface 14 D and the outer peripheral surface 14 E. The reinforcement member 18 is provided at a radial center of the outer peripheral surface 14 E and the inner peripheral surface 14 D. However, the reinforcement member 18 can be provided between the inner peripheral surface 14 D and the outer peripheral surface 14 E to be exposed from at least one of the inner peripheral surface 14 D and the outer peripheral surface 14 E. The reinforcement member 18 can be closer to one of the inner peripheral surface 14 D and the outer peripheral surface 14 E than to the other of the inner peripheral surface 14 D and the outer peripheral surface 14 E.

As seen in FIG. 7 , the sprocket support member 12 is made of a non-metallic material. The non-metallic material includes a resin material 18 B. The non-metallic material comprises a fiber composite material. The projections SP 13 , SP 23 , SP 33 , SP 43 , and SP 53 are embedded in the sprocket support portion 16 .

The reinforcement member 18 is made of a fiber composite material. The fiber composite material of the reinforcement member 18 has a fiber direction D 3 defined at least along the circumferential direction D 1 . The fiber composite material includes a fiber reinforced plastic. The fiber reinforced plastic includes a carbon fiber reinforced plastic.

As seen in FIG. 8 , the fiber composite material of the reinforcement member 18 includes a reinforcement fiber 18 A provided in the central cylindrical portion 14 to be wound about the rotational center axis A 1 by more than one turn. In this embodiment, the fiber composite material of the reinforcement member 18 includes a plurality of reinforcement fibers 18 A provided in the central cylindrical portion 14 to be wound about the rotational center axis A 1 by more than one turn. The reinforcement fiber 18 A is provided in the central cylindrical portion 14 to be wounded about the rotational center axis A 1 by a plurality of turns. The reinforcement fiber 18 A is coiled about the rotational center axis A 1 . The reinforcement fiber 18 A includes a carbon fiber. However, the reinforcement fiber 18 A can include other fibers such as a glass fiber. As seen in FIGS. 7 and 8 , for example, the reinforcement member 18 further includes a resin material 18 B such as plastic.

The method of manufacturing of the bicycle sprocket assembly 10 will be described in detail below referring to FIGS. 9 to 11 .

As seen in FIG. 9 , the sprockets SP 1 to SP 5 and the reinforcement member 18 are put on a first mold M 1 (step S 1 of FIG. 11 ). A second mold M 2 is put on the first mold M 1 (step S 2 of FIG. 11 ) and is secured to the first mold M 1 . The second mold M 2 and the first mold M 1 provide a mold cavity M 3 corresponding to the sprocket support member 12 ( FIG. 6 ). The second mold M 2 includes a sprue bushing BS to supply a molten material. The molten material includes a molten plastic and fibers such as carbon fibers. As seen in FIGS. 9 and 10 , the second mold M 2 further includes a runner M 21 . The runner M 21 includes a plurality of gates M 22 . The runner M 21 connects the sprue bushing BS to the mold cavity M 3 . The runner M 21 defines a passageway to conduct the molten material from the sprue bushing BS to the mold cavity M 3 . In FIGS. 9 and 10 , each of the first mold M 1 and the second mold M 2 is illustrated as a single part. However, the first mold M 1 can include a plurality of parts. The second mold M 2 can include a plurality of parts. A core can be put between the first mold M 1 and the second mold M 2 to define the mold cavity M 3 .

In this embodiment, the gates M 22 are located at positions corresponding to the first axial surface 14 B ( FIG. 7 ) of the central cylindrical portion 14 in the axial direction D 2 . As seen in FIG. 10 , the gates M 22 are equally circumferentially spaced and are located at circumferential positions respectively corresponding to the sprocket support portions 16 .

As seen in FIGS. 9 and 10 , the molten material is supplied from the sprue bushing BS into the mold cavity M 3 through the runner M 21 and the gates M 22 (step S 3 of FIG. 11 ). The molten material flows in the mold cavity M 3 , and the mold cavity M 3 is filled with the molten material. Thus, the central cylindrical portion 14 and the sprocket support portions 16 are formed with the molten material.

As seen in FIG. 10 , the molten material is fused together at intermediate areas IA in the mold cavity M 3 when the central cylindrical portion 14 is formed. The intermediate areas IA are located between the sprocket support portions 16 in the circumferential direction D 1 . The reinforcement member 18 is provided continuously at the intermediate areas IA. This reinforces the central cylindrical portion 14 in the circumferential direction D 1 even if a seam of the fibers being included the molten material is formed at the intermediate area IA. Lines of the seams are left on the central cylindrical portion 14 at the intermediate areas IA, for example.

The resin material 18 B of the reinforcement member 18 includes plastic which is the same as the plastic of the molten material supplied in the mold cavity M 3 . Heat of the molten material can at least partly melt the resin material 18 B of the reinforcement member 18 . For example, the resin material 18 B of the reinforcement member 18 is at least partly fused together with the molten material. The first and second molds M 1 and M 2 are cooled (step S 4 of FIG. 11 ). The first and second molds M 1 and M 2 are removed (step S 5 of FIG. 11 ). An extra part formed by the runner M 21 is removed from the central cylindrical portion 14 (step S 6 of FIG. 11 ). For example, the extra part is cut off from the central cylindrical portion 14 at the gates M 22 . Gate scars are left on the central cylindrical portion 14 at positions corresponding to the gates M 22 . The gate scars are eliminated from the central cylindrical portion 14 with a machine processing (step S 7 of FIG. 11 ). Thus, the sprocket support member 12 is integrally formed with the sprockets SP 1 to SP 5 and the reinforcement member 18 , and the bicycle sprocket assembly 10 ( FIG. 1 ) is manufactured.

The term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. This concept also applies to words of similar meaning, for example, the terms “have,” “include” and their derivatives.

The terms “member,” “section,” “portion,” “part,” “element,” “body” and “structure” when used in the singular can have the dual meaning of a single part or a plurality of parts.

The ordinal numbers such as “first” and “second” recited in the present application are merely identifiers, but do not have any other meanings, for example, a particular order and the like. Moreover, for example, the term “first element” itself does not imply an existence of “second element,” and the term “second element” itself does not imply an existence of “first element.”

The term “pair of,” as used herein, can encompass the configuration in which the pair of elements have different shapes or structures from each other in addition to the configuration in which the pair of elements have the same shapes or structures as each other.

The terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

Finally, 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. All of numerical values described in the present application can be construed as including the terms such as “substantially,” “about” and “approximately.”

Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.