Bicycle hub

[0002] This application is a continuation-in-part application of U.S. patent application Ser. No. 09/494,544, filed on Jan. 31, 2000. The entire disclosure of U.S. patent application Ser. No. 09/494,544 is hereby incorporated herein by reference.

[0003] 1. Field of the Invention

[0004] This invention generally relates to a bicycle hub with spoke openings in the tubular portion of the hub body. More specifically, the present invention relates to a bicycle hub with a seal that isolates the spoke openings from the remainder of the interior of the hub body.

[0005] 2. Background Information

[0006] Bicycling is becoming an increasingly popular form of recreation as well as a means of transportation. Moreover, bicycling has become a very popular competitive sport. Whether the bicycle is used for recreation, transportation or competition, the bicycle industry is constantly improving their components. Recently, the braking systems for bicycles have included the use of disc brakes. The use of disc brakes has resulted in modifications to the bicycle hub of the bicycle wheel so that a brake rotor can be mounted thereon.

[0007] The most basic bicycle wheels have a hub, a plurality of spokes and an annular rim. The hub is attached to a part of the frame of the bicycle for relative rotation. The inner ends of the spokes are coupled to the hub and extend outwardly from the hub. The annular rim is coupled to the outer ends of the spokes and has an outer portion for supporting a pneumatic tire thereon. Typically, the spokes of the bicycle wheel are thin metal wire spokes. The ends of the hub are provided with a flange that is used to couple the spokes to the hub. In particular, holes are provided in the hub flanges. The wire spokes are usually bent on their inner end and provided with an enlarged head or flange that is formed in the shape of a nail head. The inner end is supported in one of the holes in one of the hub flanges. The outer ends of the spokes typically are provided with threads for engaging spoke nipples, which secure the outer ends of the wire spokes to the rim. In particular, the spoke nipples have flanges, which engage the interior surface of the rim.

[0008] With a spoke constructed in this manner, the nipples are installed in nipple holes formed in the rim. The spokes are inserted sideways through the holes in the hub flange until the enlarged head or flanges of the spokes engaging the areas surrounding the holes in the hub flange. The male threads on the ends of the spokes are threaded into the female threads of the spoke nipples installed in the openings of the rim.

[0009] When the hub is a brake disc hub or is a rear hub, installation and/or replacement of the spokes can be difficult. In the case of a disk brake hub, one end of the hub usually has a rotor mounting portion. Often, the rotor mounting portion is a plurality of blind bores that receive bolts to directly mount the brake disc rotor to the end of the hub. Thus, the brake disc rotor makes it difficult to insert the spokes in a sideways direction. Likewise, if the hub is a rear hub, the sprockets can be obstacles to install or replace spokes.

[0010] One problem with spoke openings in the tubular portion of the hub body is that contaminants can enter the hub body through the spoke openings. When dirt gets into the hub body, the rotation of the hub body relative to the hub axle can be significantly impair.

[0011] In view of the above, there exists a need for a bicycle hub with a spoke seal which overcomes the above mentioned problems in the prior art. This invention addresses this need in the prior art as well as other needs, which will become apparent to those skilled in the art from this disclosure.

[0012] One object of the present invention is to provide a bicycle hub having a seal with a seal support for isolating the spoke openings form the interior of the hub body.

[0013] Another object of the present invention is to provide a bicycle hub having a seal with a seal support that aids in the installation of the spokes.

[0014] Another object of the present invention is to provide a bicycle hub that has first spoke openings with an insertion portion and a retaining portion, and a spoke opening cover located along a first annular groove intersecting the insertion portions.

[0015] Another object of the present invention is to provide a bicycle hub that is relatively lightweight in that no spoke flanges are needed.

[0016] The foregoing objects can be attained by providing a bicycle hub for use with bicycle spokes. The bicycle hub comprising a hub axle, a hub body, a first flexible seal arranged in the hub body and a first rigid seal support. The hub axle has a center axis extending between a first end and a second end. The hub body has an interior passageway with the hub axle being rotatably supported therein. The hub body has a set of first spoke openings circumferentially arranged around the hub body. The first flexible seal is arranged in the interior passageway of the hub body and adjacent the first spoke openings to isolate the first spoke openings from the hub axle. The first rigid seal support is located beneath the first flexible seal to radially support the first flexible seal.

[0017] The foregoing objects can further be attained by providing a bicycle hub for use with bicycle spokes. The bicycle hub comprising a hub axle and a hub body. The hub axle has a center axis extending between a first end and a second end. The hub body has an outer surface with a first annular groove, an interior passageway with the hub axle being rotatably supported therein and a set of first spoke openings circumferentially arranged around the hub body. Each of the first spoke openings has an insertion portion located along the first annular groove and a retaining portion. The insertion portion has a large width that permits an enlarged head portion of a spoke to pass therethrough. The retaining portion has a width that is smaller than the width of the insertion portion to retain the enlarged head portion of the spoke therein.

[0018] 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.

[0019] Referring now to the attached drawings which form a part of this original disclosure:

[0020] FIG. 1 is a side elevational view of a conventional bicycle with front and rear brake disc hubs in accordance with a first embodiment of the present invention;

[0021] FIG. 2 is a side elevational view of the rear wheel of the bicycle illustrated in FIG. 1 with the sprockets removed;

[0022] FIG. 3 is partially exploded perspective view of the rim, one of the spokes and one of the spoke nipples of the bicycle illustrated in FIG. 1;

[0023] FIG. 4 is a side elevational view of the rear brake disc hub of the rear wheel illustrated in FIG. 2 with the sprockets removed;

[0024] FIG. 5 is a side elevational view of the rear brake disc hub of the rear wheel illustrated in FIG. 3 with certain portions broken away for purposes of illustration;

[0025] FIG. 6 is a left end elevational view of the rear brake disc hub body illustrated in FIGS. 4 and 5 with the brake disc rotor bolts mounted thereto;

[0026] FIG. 7 is a left end elevational view of the rear brake disc hub body illustrated in FIGS. 4 and 5 with the brake disc rotor bolts removed;

[0027] FIG. 8 is a left end elevational view of the rear brake disc hub body illustrated in FIGS. 4 and 5 with unthreaded bolt holes;

[0028] FIG. 9 is a partial transverse cross-sectional view of the rear brake disc hub body illustrated in FIGS. 4 and 5 as seen along section line 9—9 of FIG. 4;

[0029] FIG. 10 is a partial transverse cross-sectional view of the rear brake disc hub body illustrated in FIGS. 4 and 5 as seen along section line 10—10 of FIG. 4;

[0030] FIG. 11 is a partial elevational view of one of the spoke openings of the rear brake disc hub body illustrated in FIGS. 4 and 5;

[0031] FIG. 12 is a schematic view of portion of the rear brake disc hub body illustrated in FIGS. 4 and 5 with two spokes extending outwardly therefrom;

[0032] FIG. 13 is a partial cross-sectional view of the first seal for the rear brake disc hub body illustrated in FIGS. 4 and 5;

[0033] FIG. 14 is a partial cross-sectional view of the second seal for the rear brake disc hub body illustrated in FIGS. 4 and 5;

[0034] FIG. 15 is a side elevational view of the front brake disc hub of the front wheel illustrated in FIG. 1;

[0035] FIG. 16 is a side elevational view of the front brake disc hub of the front wheel illustrated in FIG. 1 with certain portions broken away for purposes of illustration;

[0036] FIG. 17 is a partial cross-sectional view of the first seal for the front brake disc hub body illustrated in FIGS. 15 and 16;

[0037] FIG. 18 is a partial cross-sectional view of the second seal for the front brake disc hub body illustrated in FIGS. 15 and 16;

[0038] FIG. 19 is a perspective view of a first embodiment of a spoke opening cover for the hubs of the present invention;

[0039] FIG. 20 is a side elevational view of the front brake disc hub with the spoke opening cover illustrated in FIG. 19 installed thereon;

[0040] FIG. 21 is a perspective view of a second embodiment of a spoke opening cover for the hubs of the present invention;

[0041] FIG. 22 is a side elevational view of the front brake disc hub with the spoke opening cover illustrated in FIG. 21 installed thereon;

[0042] FIG. 23 is an inside elevational view of a third embodiment of a spoke opening cover for the hubs of the present invention;

[0043] FIG. 24 is an edge elevational view of the spoke opening cover illustrated in FIG. 23 for the hubs of the present invention;

[0044] FIG. 25 is a side elevational view of the front brake disc hub with the spoke opening cover illustrated in FIGS. 23 and 24 installed thereon;

[0045] FIG. 26 is a side elevational view of the rear brake disc hub in accordance with a second embodiment of the present invention with the sprockets removed;

[0046] FIG. 27 a side elevational view of the rear brake disc hub illustrated in FIG. 26 in accordance with a second embodiment of the present invention with certain portions broken away for purposes of illustration;

[0047] FIG. 28 is a side elevational view of the front brake disc hub in accordance with a second embodiment of the present invention with the sprockets removed;

[0048] FIG. 29 a side elevational view of the front brake disc hub illustrated in FIG. 28 in accordance with a second embodiment of the present invention with certain portions broken away for purposes of illustration;

[0049] FIG. 30 is a side elevational view of a front hub of a front wheel with certain portions broken away for purposes of illustration;

[0050] FIG. 31 is a side elevational view of a rear hub for a rear wheel with certain portions broken away for purposes of illustration;

[0051] FIG. 32 is a side elevational view of a rear brake disk hub for a rear wheel, with spoke opening covers coupled thereto;

[0052] FIG. 33 is a side elevational view of the rear brake disk hub illustrated in FIG. 32 with certain portions broken away for purposes of illustration and a pair of spokes attached thereto;

[0053] FIG. 34 is an exploded side elevational view of a seal with a seal support for the rear brake disk hub illustrated in FIGS. 32 and 33 with the upper portions broken away for purposes of illustration;

[0054] FIG. 35 is an end elevational view of a spoke opening cover illustrated in FIG. 32; and

[0055] FIG. 36 is a side elevational view of the spoke opening cover illustrated in FIGS. 32 and 35 in accordance with the present invention.

[0056] Referring initially to FIGS. 1-3, a bicycle 10 is illustrated with certain parts being modified in accordance with the present invention as discussed below. The bicycle 10 basically has a frame 12 with a front fork 13 movably coupled thereto. A rear wheel 14 is rotatably coupled to a rear portion of the frame 12, while a front wheel 16 is rotatably coupled to the front fork 13. The frame 12 also has a seat 18 adjustably coupled to frame 12, a handlebar 19 coupled to front fork 13 for turning front wheel 16 and a drive train 20 for propelling bicycle 10. The bicycle 10 is also provided with a pair of disc brake assemblies 21 having a caliper 21aand a brake lever 2lb.

[0057] Since these parts of bicycle 10 are well known in the art, these parts will not be discussed or illustrated in detail herein, except as they are modified in accordance with the present invention. Moreover, various conventional bicycle parts such as brakes, derailleurs, additional sprocket, etc., which are not illustrated and/or discussed in detail herein, can be used in conjunction with the present invention.

[0058] As seen in FIG. 2, the rear wheel 14 has a rear hub 22, a plurality of spokes 24 extending outwardly from the rear hub 22, a rim 26 coupled to the outer ends of spokes 24 by spoke nipples 28, and a tire 30 located on the outer surface of rim 26. The rear hub 22 is also provided with a brake disc rotor 32 that is attached to the rear hub 22 by six blots 32aand six nuts 32b,as explained below. While the illustrated embodiment is a thirty-six spoke wheel, it will be apparent to those skilled in the art from this disclosure that other spoke arrangements are possible without departing from the present invention. For example, a thirty-two spoke wheel or a forty spoke wheel can be constructed in accordance with the present invention without departing from the present invention. Basically, the number of spoke openings depends upon the rim to be used with the hub of the present invention.

[0059] Preferably, the spokes 24, the rim 26 and spoke nipples 28 are all conventional parts that are used with the rear hub 22 of the present invention as seen in FIG. 3. In other words, the unique design of the rear hub 22 allows it to be used with conventional parts, e.g., tangential spokes 24 and a conventional rim 26. Accordingly, when the rear wheel 14 is assembled, the spokes 24 extend tangentially from an imaginary circle centered on the center axis of rotation of rear hub 22. In the illustrated embodiment of FIGS. 2-5, the rear hub 22 and the rim 26 has thirty-six of the spokes 24 coupled therebetween.

[0060] The term “tangential spokes” are spokes that have a straight section 24aand a bent end 24bwith an enlarged head 24csuch that straight section 24aextends at an angle of about 95° relative to the bent end 24b. Such spokes are well known in the bicycle art. As seen in FIG. 3, the spokes 24 of the illustrated embodiment each have an outer threaded end 24dthat is located at the opposite end of the center straight section 24afrom the bent end 24b(inner end portion) with the enlarged head 24c. The bent end 24bhas a center axis that forms an angle of about 95° with the center axis of the straight section 24a. The bent ends 24bof the spokes 24 are designed to be received within the first and second spoke openings. In particular, the enlarged heads 24cof the spokes 24 engage an interior surface of the hub body 38 with the straight sections 24aextending substantially tangentially to an imaginary circle with a center on the center axis of rotation of the rear hub 22.

[0061] The rim 26 can be any conventional rim that has a plurality of spoke holes 34 for receiving the spoke nipples 28 for attaching the outer threaded ends 24dof the spokes 24 thereto. In the illustrated embodiment, the rim 26 is a conventional steel or alloy rim having a U-shaped cross section with thirty-six spoke holes 34. The spoke holes 34 are equally spaced apart in a circumferential direction. The spoke holes 34 are preferably lie in a single plane P that divides the cross section in half as seen in FIG. 3. Of course, rims with fewer or more spoke holes 34 can be used with a hub of the present invention, if needed and/or desired. For example, the rim 26 can have thirty-two spoke holes instead of thirty-six spoke holes, if the rear hub 22 is modified to have fewer holes as explained below.

[0062] As best seen in FIG. 5, the rear hub 22 basically includes a hub axle 36, a hub body or shell 38, a first bearing assembly 40a,a second bearing assembly 40b,a first spoke seal 42a,a second spoke seal 42b,a freewheel 44 and a quick release mechanism 46. Of the parts of rear hub 22, only the hub body 38 and the first and second spoke seals 42aand 42bare non-conventional parts. The remaining parts of rear hub 22 are relatively conventional, and thus, the remaining parts of rear hub 22 will not be discussed or illustrated in detail herein.

[0063] The hub axle 36 has a center axis A extending between a first end 36aand a second end 36b. The quick release mechanism 46 extends through a center bore 36cof the hub axle 36 such that the quick release mechanism 46 is coupled to the hub axle 36 in a conventional manner. The first and second ends 36aand 36bof the hub axle 36 are threaded for receiving a pair of nuts 50aand 50bthat applies an axial force on the hub body 38, the bearing assemblies 40aand 40b,the spoke seals 42aand 42b,and the freewheel 44. First and second bearing assemblies 40aand 40brotatably mount the hub body 38 with the freewheel 44 on the hub axle 36. The freewheel 44 allows the hub axle 36 to rotate freely relative to the hub body 38 in one direction, but fixedly couples the hub axle 36 relative to the hub body 38 in the opposite rotational direction.

[0064] The hub body 38 is illustrated in accordance with one embodiment of the present invention. In this embodiment, the hub body 38 is a hollow member that defines an interior passageway 52 with the hub axle 36 being rotatably supported therein by the first and second bearing assemblies 40aand 40b.Thus, the hub body 38 is a substantially tubular member. Specifically, the hub body 38 has a center tubular portion 38cwith first and second end sections 38aand 38bbeing integral formed with the center tubular portion 38cas a one-piece, unitary member. The first end section 38ahas an integrally mounted brake rotor attachment portion 38d,while a second end section 38bhas the freewheel 44 fixedly coupled thereto.

[0065] A set of first spoke openings 60aare provided at the first end section 38aof the hub body 38 for receiving the bent ends 24bof the spokes 24. Similarly, the second end section 38bof the hub body 38 is provided with a second set of spoke openings 60bfor receiving the bent ends 24bof the spokes 24. In the illustrated embodiment, the first end section 38ais provided with nine of the first spoke openings 60aand the second end section 38bis provided with nine of the second spoke openings 60b.The spoke openings 60aand 60bare equally spaced apart about the circumference of the hub body 38. Each of the spoke openings 60aand 60bare also designed to receive two spokes 24 as explained below. Accordingly, the rear hub 22 is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

[0066] Preferably, the first and second sets of spoke openings 60aand 60bare identical. The first and second spoke openings 60aand 60bare designed to be used with conventional tangential spokes 24. Of course, it is possible that the first and second sets of spoke openings 60aand 60bcan be different such that tangential spokes 24 are used in one end of the hub body 38 and a different types of spokes are used in the other end of the hub body 38. The first spoke openings 60aare circumferentially arranged around the hub body 38 adjacent to the brake rotor attachment portion 38d.Preferably, the first spoke openings 60aare spaced axially inward of the brake rotor attachment portion 38dso that brake disc rotor 32 can be easily attached with the bolts 32aand nuts 32b.

[0067] In this embodiment, the first and second spoke openings 60aand 60bare elongated slots that are each provided with an insertion portion 61 and a pair of retaining portions 62. Accordingly, each of the spoke openings 60aand 60bis designed to have a pair of spokes 24 retained therein with the spokes 24 extending in opposite directions.

[0068] The insertion portion 61 of each spoke opening is located between the pair of retaining portions 62 of each spoke opening. Each insertion portion 61 is formed by a pair of opposed curved surfaces 64 that are spaced apart so as to be equal to or slightly larger than the widths or diameters of the enlarged heads 24cof the spokes 24. Thus, the inner ends (bent ends 24bwith enlarged heads 24c) of the spokes 24 can be easily inserted into the spoke openings 60aand 60bthrough the insertion portions 61.

[0069] The retaining portions 62 have smaller widths or diameters than the insertion portions 61. More specifically, the diameters or widths of the retaining portions 62 are smaller than the diameters or widths of the enlarged heads 24cof the spokes 24 so as to retain the spokes 24 within the spoke openings 60aand 60b.The retaining portions 62 are each preferably defined by a partial cylindrical surface 66 that is connected to the curved surfaces 64 of the associated insertion portion 61 by a pair of straight surfaces 68.

[0070] The spoke openings 60aand 60bare formed as elongated slots that are angled relative to the axis A. Accordingly, the insertion portions 61 are arranged in a circumferential pattern with one set of the retaining portions 62 being located axially outward from the insertion portions 61 and the other set of retaining portions 62 being spaced axially inward from the insertion portions 61. In other words, a first set of retaining portions 62 form an outer circumferential row of the retaining portions 62, and a second set of the retaining portions 62 form an inner circumferential row of retaining portions 62 with the insertion portions 61 being located between the rows of retaining portions 62.

[0071] Preferably, the insertion portion 61 and the retaining portions 62 of each spoke opening are formed simultaneously. Also preferably, the inner and outer ends of the retaining portions 62 of the spoke openings 60aand 60bare tapered to avoid sharp edges engaging the spokes 24.

[0072] Each of the insertion portions 61 has a center longitudinal axis C₁that passes through the center axis A of the hub axle 36. The retaining portions 62, on the other hand, have center longitudinal axes C₂that are parallel to the center longitudinal axis C₁of the insertion portion 61 for each of the spoke openings 60aand 60b.Thus, the center longitudinal axes C₂of the retaining portions 62 do not pass through the center axis of the hub axle 36. Rather, the center longitudinal axes C₂of the retaining portions 62 are angled with respect to center axis A. Preferably, the center longitudinal axis C₂of each retaining portion 62 is angled between about 5° and about 20° from a radial orientation in the hub body 38. In the illustrated embodiment, the retaining portions 62 are angled about 10° with respect to center axis A for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. For a twenty-six inch rim with thirty-two spoke holes and a hub having a diameter approximately 22 millimeters, the retaining portions 62 are preferably angled about 11° with respect to center axis A. This angled configuration of the retaining portions 62 results in the straight sections 24aof the spokes 24 being easily arranged in a tangential direction relative to an imaginary circle centered on the hub body 38. Moreover, this angled configuration of the retaining portions 62 allows the straight sections 24aof the spokes 24 to be easily aligned with the spoke holes 34 of the rim 26 without significant bending of the spokes 24. In the illustrated embodiment, the spokes 24 are not bent more than about five degrees. Of course, the less bending of the spokes 24, the better.

[0073] If the retaining portions 62 were formed with their center axis passing through the center axis A of the hub axle 36, then the conventional spokes 24 would be placed under excessive bending forces, which could result in the spokes 24 breaking during use of the wheel. In particular, if the retaining portions 62 have their center axes passing through the center of the hub axle 36, then the center straight section 24awould have to be bent from 95° to 108° for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. In contrast, with the retaining portions 62 of the spokes 24 being angled, the amount of bending of the spokes 24 can be reduced and/or eliminated.

[0074] The brake rotor attachment portion 38dis integrally formed with the center tubular portion 38cof the hub body 38 as a one-piece, unitary member. In the illustrated embodiment, the brake rotor attachment portion 38dis formed with six attachment members or points with through bores 70. While six individual attachment points are illustrated, it will be apparent to those skilled in the art from this disclosure that fewer or more attachment points can be utilized. Moreover, it will be apparent to those skilled in the art from this disclosure that the attachment portions could be a continuous flange, if needed and/or desired. The through bore 70 can be threaded (FIG. 7) or unthreaded (bores 70′ of FIG. 8). By using through bores 70 instead of blind bores, the rear hub 22 can be easily manufactured at a relatively lower cost.

[0075] As seen in FIG. 8, the through bores 70″ can be unthreaded bores. In the case of unthreaded through bores 70″, the bolts 32aextend into openings in the brake disc rotor 32 and then through the through bores 70″. The free ends of the bolts 32ahave nuts 32bthreaded thereon for attaching the brake disc rotor 32 to the hub body 38. This arrangement allows the hub body 38 and the brake rotor attachment portion 38dto be formed out of the same a lightweight material, such as aluminum. In this arrangement, the hub body 38 does not need to be replaced if the through bores 70″ become damaged.

[0076] As seen in FIG. 7, the through bores 70 are threaded. In the case of threaded through bores 70, the bolts 32aextend into openings in the brake disc rotor 32 and then threaded into the through bores 70. Optionally, the free ends of the bolts 32acan have the nuts 32bthreaded thereon for more securely attaching the brake disc rotor 32 to the hub body 38. In this arrangement, if the threads of through bores 70 become damaged, the hub body 38 does not need to be replaced. Rather, the bolts 32aand the nuts 32bsecurely attach the brake disc rotor 32 to the hub body 38.

[0077] Bearing assemblies 40aand 40brotatably supports hub body 38 on hub axle 36. The bearing assembly 40abasically includes a plurality of balls 74alocated between an inner race member 76aand an outer race member 78a.Similarly, the bearing assembly 40bbasically includes a plurality of balls 74blocated between an inner race member 76band an outer race member 78b.Since bearing assemblies 40aand 40bare well known in the bicycle art, they will not be discussed or illustrated in detail herein.

[0078] Turning now to FIGS. 13 and 14, the spoke seals 42aand 42bare arranged in the interior passageway 52 of the hub body 38 so as to be adjacent the spoke openings 60aand 60bto isolate the spoke openings 60aand 60bfrom the hub axle 36. In other words, the spoke seals 42aand 42bprevent contaminants from entering the rear hub 22 through the spoke openings 60aand 60b.The spoke seals 42aand 42bare preferably resilient members that are constructed of rubber or the like. Of course, it will be apparent to those skilled in the art from this disclosure that the seals could be created from other types of materials, depending upon their shape and arrangement. Moreover, it will be apparent to those skilled in the art from this disclosure that while the spoke seals 42aand 42bare illustrated as a pair of separate sealing members, the spoke seals 42aand 42bcan be formed as a one-piece, unitary member.

[0079] In the preferred embodiment, the spoke seals 42aand 42balso aid in the assembly of the spokes 24 with the hub body 38 and the rim 26. Specifically, in the preferred embodiments, the seals 42aand 42bare arranged so that they restrain movement of the spokes 24 within the spoke openings 60aand 60bso that the bent ends 24bof the spokes 24 stays in the retaining portions 62 of the spoke openings 60aand 60b.

[0080] In the illustrated embodiment, the spoke seal 42ahas a tubular section 80aand a center annular flange 82a.The center annular flange 82aextends in a circumferential direction about the tubular section 80a.The center annular flange 82acan either contact the interior surface of the tubular section 80aor be spaced from the tubular section 80a.The ends 84aand 86aof the tubular section 80aare configured to engage a ring member 88aand an abutment 90aof the inner surface of the hub body 38. Of course, the particular shape of the ends 84aand 86awill vary depending on the shape of the hub body 38 and its internal components. Preferably, ends 84aand 86aof the tubular section 80aare annular flanges that contact the interior surface of the tubular section 80ato form an isolated area beneath the spoke openings 60a.This isolated area beneath the spoke openings 60ais a continuous annular space.

[0081] When the rear hub 22 is assembled, an axial force is applied to the ends 84aand 86aof the tubular section 80ato form annular seals therebetween. Accordingly, the spoke seal 42aisolates a first interior section of the interior passageway 52 from the remainder of the interior passageway 52. This interior section formed by the spoke seal 42ais continuous annular first space located beneath the spoke openings 60a.

[0082] The center annular flange 82ais preferably aligned with a radial plane passing through the centers axes C₁of the insertion portions 61 of the first spoke openings 60a.Thus, the center annular flange 82ais positioned to axially separate the two retaining portions 62 of each of the first spoke openings 60afrom each other. The center annular flange 82ais also positioned to keep spokes 24 in the retaining portions 62 of the first spoke openings 60a.Accordingly, when the enlarged heads 24cof the spokes 24 are inserted into the insertion portions 61 of the spoke openings 60a,the enlarged heads 24cof the spokes 24 contact the center annular flange 82a.The enlarged heads 24cthen pushes or deforms the center annular flange 82aone way or the other so that the enlarged heads 24cextends into the insertion portions 61 of the spoke openings 60a.The spokes 24 are then moved or slid into one of the two retaining portions 62 of each of the spoke openings 60a.The center annular flange 82awill prevent the spokes 24 from accidentally falling out of the insertion portions 61 of the spoke openings 60a.Thus, the center annular flange 82aaids in the assembly of the rear wheel 14. In other words, the center annular flange 82amust be moved or deformed again before the spokes 24 can be removed from the spoke openings 60a.For added resiliency, an annular groove 92acan be formed in the outer peripheral surface of the center flange 82a.

[0083] Similar to the spoke seal 42a,the spoke seal 42bhas a tubular section 80band a center annular flange 82b.The center annular flange 82aextends in a circumferential direction about the tubular section 80a.Alternatively, the center annular flanges 82aand 82bof the spoke seals 42aand 42bcan each have a pair of center annular flanges. The ends 84band 86bof the tubular section 80bare configured to engage a ring member 88band an abutment 90bof the inner surface of the hub body 38. Of course, the particular shape of the ends 84band 86bwill vary depending on the shape of the hub body 38 and its internal components. Preferably, ends 84band 86bof the tubular section 80bare annular flanges that contact the interior surface of the tubular section 80bto form an isolated area beneath the spoke openings 60b.This isolated area beneath the spoke openings 60bis a continuous annular space.

[0084] When the rear hub 22 is assembled, an axial force is applied to the ends 84band 86bof the tubular section 80bto form annular seals therebetween. Accordingly, the spoke seal 42bisolates a second interior section of the interior passageway 52 from the remainder of the interior passageway 52. This interior section formed by the spoke seal 42bis continuous annular second space located beneath the spoke openings 60b.

[0085] Similar to the center annular flange 82a,the center annular flange 82bis preferably aligned with a radial plane passing through the centers axes C₁of the insertion portions 61 of the second spoke openings 60b.Thus, the center annular flange 82bis positioned to axially separate the two retaining portions 62 of each of the second spoke openings 60bfrom each other. The center annular flange 82bis also positioned to keep spokes 24 in the retaining portions 62 of the second spoke openings 60b.Accordingly, when the enlarged heads 24cof the spokes 24 are inserted into the insertion portions 61 of the spoke openings 60b,the enlarged heads 24cof the spokes 24 contact the center annular flange 82b.The enlarged heads 24cthen pushes or deforms the center annular flange 82bone way or the other so that the enlarged heads 24cextends into the insertion portions 61 of the spoke openings 60b.The spokes 24 are then moved or slid into one of the two retaining portions 62 of each of the spoke openings 60b.The center annular flange 82bwill prevent the spokes 24 from accidentally falling out of the insertion portions 61 of the spoke openings 60b.Thus, the center annular flange 82baids in the assembly of the rear wheel 14. In other words, the center annular flange 82bmust be moved or deformed again before the spokes 24 can be removed from the spoke openings 60b.For added resiliency, an annular groove 92bcan be formed in the outer peripheral surface of the center flange 82b.

[0086] The freewheels, such as the freewheel 44, are well known in the bicycle art, and thus, the freewheel 44 will not be illustrated or discussed in detail herein. The freewheel 44 is used to transmit a driving force from the chain to the rear bicycle wheel in one rotation direction only. The freewheel 44 allows the bicycle 10 to advance freely without any rotation of the pedals. The freewheel 44 is fastened to the rear hub 22 as integral part of the rear hub 22 in a conventional manner. The freewheel 44 has an outer tubular part 94, an inner tubular part 96 and a one-way clutch 98. The inner tubular part 96 is installed radially inwardly of the outer tubular part 94 so that the inner tubular part 96 is free to rotate relative to the outer tubular part 94. The one-way clutch 98 is installed between the outer tubular part 94 and inner tubular part 96 for transmitting the driving force from the outer tubular part 94 to the inner tubular part 96 in one rotational direction only. The outer tubular part 94 has a plurality of gears or sprockets (not shown) mounted thereon, while the inner tubular part 96 is usually mounted on the hub axle 36.

[0087] Turning now to FIGS. 15 and 16, the front hub 22′ is illustrated in accordance with the present invention. The front hub 22′ is substantially the same as the rear hub 22, except that the front hub 22′ does not have a freewheel and the spoke openings 60a′ and 60b′ are angled in the opposite direction from spoke openings 60aand 60bof the rear hub 22. Moreover, the front hub 22′ is used with spokes 24 and rim 26 discussed above. Since the front hub 22′ is substantially the same as the rear hub 22, the front hub 22′ will not be discussed or illustrated in detail herein.

[0088] The front hub 22′ basically includes a hub axle 36′, a hub body or shell 38′, a first bearing assembly 40a′, a second bearing assembly 40b′, a first spoke seal 42a′, a second spoke seal 42b′ and a quick release mechanism 46′. Of the parts of front hub 22′, only the hub body 38′ and the first and second spoke seals 42a′ and 42b′ are non-conventional parts. The remaining parts of front hub 22′ are relatively conventional, and thus, the remaining parts of front hub 22′ will not be discussed or illustrated in detail herein.

[0089] The hub axle 36′ has a center axis A extending between a first end 36a′ and a second end 36b′. The quick release mechanism 46′ extends through a center bore 36c′ of the hub axle 36′ such that the quick release mechanism 46′ is coupled to the hub axle 36′ in a conventional manner. The first and second ends 36a′ and 36b′ of the hub axle 36′ are threaded for receiving a pair of nuts 50a′ and 50b′ that applies an axial force on the hub body 38′, the bearing assemblies 40a′ and 40b′ and the spoke seals 42a′ and 42b′. First and second bearing assemblies 40a′ and 40b′ rotatably mount the hub body 38′ on the hub axle 36′.

[0090] The hub body 38′ is illustrated in accordance with one embodiment of the present invention. In this embodiment, the hub body 38′ is a hollow member that defines an interior passageway 52′ with the hub axle 36′ being rotatably supported therein by the first and second bearing assemblies 40a′ and 40b′. Thus, the hub body 38′ is a substantially tubular member. Specifically, the hub body 38′ has a center tubular portion 38c′ with first and second end sections 38a′ and 38b′ being integral formed with the center tubular portion 38c′ as a one-piece, unitary member. The first end section 38a′ has an integrally mounted brake rotor attachment portion 38d′.

[0091] A set of first spoke openings 60a′ are provided at the first end section 38a′ of the hub body 38′ for receiving the bent ends 24bof the spokes 24. Similarly, the second end section 38b′ of the hub body 38′ is provided with a second set of spoke openings 60b′ for receiving the bent ends 24bof the spokes 24. In the illustrated embodiment, the first end section 38a′ is provided with nine of the first spoke openings 60a′ and the second end section 38b′ is provided with nine of the second spoke openings 60b′. The spoke openings 60a′ and 60b′ are equally spaced apart about the circumference of the hub body 38′. Each of the spoke openings 60a′ and 60b′ are also designed to receive two spokes 24 as explained below. Accordingly, the front hub 22′ is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

[0092] Preferably, the first and second sets of spoke openings 60a′ and 60b′ are identical. The first and second spoke openings 60a′ and 60b′ are designed to be used with conventional tangential spokes 24. Of course, it is possible that the first and second sets of spoke openings 60a′ and 60b′ can be different such that tangential spokes 24 are used in one end of the hub body 38′ and a different types of spokes are used in the other end of the hub body 38′. The first spoke openings 60a′ are circumferentially arranged around the hub body 38′ adjacent to the brake rotor attachment portion 38d′. Preferably, the first spoke openings 60a′ are spaced axially inward of the brake rotor attachment portion 38d′ so that brake disc rotor 32′ can be easily attached with the bolts 32a′ and nuts 32b′.

[0093] In this embodiment, the first and second spoke openings 60a′ and 60b′ are elongated slots that are each provided with an insertion portion 61′ and a pair of retaining portions 62′. Accordingly, each of the spoke openings 60a′ and 60b′ is designed to have a pair of spokes 24 retained therein with the spokes 24 extending in opposite directions.

[0094] The insertion portion 61′ of each spoke opening is located between the pair of retaining portions 62′ of each spoke opening. Each insertion portion 61′ is formed by a pair of opposed curved surfaces 64′ that are spaced apart so as to be equal to or slightly larger than the widths or diameters of the enlarged heads 24cof the spokes 24. Thus, the inner ends (bent ends 24bwith enlarged heads 24c) of the spokes 24 can be easily inserted into the spoke openings 60a′ and 60b′ through the insertion portions 61′.

[0095] The retaining portions 62′ have smaller widths or diameters than the insertion portions 61′. More specifically, the diameters or widths of the retaining portions 62′ are smaller than the diameters or widths of the enlarged heads 24cof the spokes 24 so as to retain the spokes 24 within the spoke openings 60a′ and 60b′. The retaining portions 62′ are each preferably defined by a partial cylindrical surface 66′ that is connected to the curved surfaces 64′ of the associated insertion portion 61′ by a pair of straight surfaces 68′.

[0096] The spoke openings 60a′ and 60b′ are formed elongated slots that are angled relative to the axis A′. Accordingly, the insertion portions 61′ are arranged in a circumferential pattern with one set of the retaining portions 62′ being located axially outward from the insertion portions 61′ and the other set of retaining portions 62′ being spaced axially inward from the insertion portions 61′. In other words, a first set of retaining portions 62′ form an outer circumferential row of the retaining portions 62′ , and a second set of the retaining portions 62′ form an inner circumferential row of retaining portions 62′ with the insertion portions 61′ being located between the rows of retaining portions 62′.

[0097] Preferably, the insertion portion 61′ and the retaining portions 62′ of each spoke opening are formed simultaneously. Also preferably, the inner and outer ends of the retaining portions 62′ of the spoke openings 60a′ and 60b′ are tapered to avoid sharp edges engaging the spokes 24.

[0098] Each of the insertion portions 61′ has a center longitudinal axis C₁′ that passes through the center axis A′ of the hub axle 36′. The retaining portions 62′, on the other hand, have center longitudinal axes C₂′ that are parallel to the center longitudinal axis C₁′ of the insertion portion 61′ for each of the spoke openings 60a′ and 60b′. Thus, the center longitudinal axes C₂′ of the retaining portions 62′ do not pass through the center axis of the hub axle 36′. Rather, the center longitudinal axes C₂′ of the retaining portions 62′ are angled with respect to center axis A′. Preferably, the center longitudinal axis C₂′ of each retaining portion 62′ is angled between about 5° and about 20° from a radial orientation in the hub body 38′. In the illustrated embodiment, the retaining portions 62′ are angled about 10° with respect to center axis A for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. For a twenty-six inch rim with thirty-two spoke holes and a hub having a diameter approximately 22 millimeters, the retaining portions 62′ are preferably angled about 11° with respect to center axis A′. This angled configuration of the retaining portions 62′ results in the straight sections 24aof the spokes 24 being easily arranged in a tangential direction relative to an imaginary circle centered on the hub body 38′. Moreover, this angled configuration of the retaining portions 62′ allows the straight sections 24aof the spokes 24 to be easily aligned with the spoke holes 34 of the rim 26 without significant bending of the spokes 24. In the illustrated embodiment, the spokes 24 are not bent more than about five degrees.

[0099] If the retaining portions 62′ were formed with their center axis passing through the center axis A of the hub axle 36′, then the conventional spokes 24 would be placed under excessive bending forces, which could result in the spokes 24 breaking during use of the wheel. In particular, if the retaining portions 62′ have their center axes passing through the center of the hub axle 36′, then the center straight section 24awould have to be bent from 95° to 108° for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. In contrast, with the retaining portions 62′ of the spokes 24 being angled, the amount of bending of the spokes 24 can be reduced and/or eliminated.

[0100] The brake rotor attachment portion 38d′ is integrally formed with the center tubular portion 38c′ of the hub body 38′ as a one-piece, unitary member. In the illustrated embodiment, the brake rotor attachment portion 38d′ is formed with six attachment members or points with through bores 70′. While six individual attachment points are illustrated, it will be apparent to those skilled in the art from this disclosure that fewer or more attachment points can be utilized. Moreover, it will be apparent to those skilled in the art from this disclosure that the attachment portions could be a continuous flange, if needed and/or desired. The through bore 70′ can be threaded or unthreaded. By using through bores 70′ instead of blind bores, the front hub 22′ can be easily manufactured at a relatively lower cost.

[0101] In the case of unthreaded through bores 70′, the bolts 32a′ extend into openings in the brake disc rotor 32′ and then through the through bores 70′. The free ends of the bolts 32a′ have nuts 32b′ threaded thereon for attaching the brake disc rotor 32′ to the hub body 38′. This arrangement allows the hub body 38′ and the brake rotor attachment portion 38d′ to be formed out of the same a lightweight material, such as aluminum. Moreover, the hub body 38′ does not need to be replaced if the through bores 70′ become damaged.

[0102] In the case of threaded through bores 70′, the bolts 32a′ extend into openings in the brake disc rotor 32′ and then threaded into the through bores 70′. Optionally, the free ends of the bolts 32a′ can have the nuts 32b′ threaded thereon for more securely attaching the brake disc rotor 32′ to the hub body 38′. In this arrangement, if the threads of through bores 70′ become damaged, the hub body 38′ does not need to be replaced. Rather, the bolts 32a′ and the nuts 32b′ securely attach the brake disc rotor 32′ to the hub body 38′.

[0103] Bearing assemblies 40a′ and 40b′ rotatably supports hub body 38′ on hub axle 36′. The bearing assembly 40a′ basically includes a plurality of balls 74a′ located between an inner race member 76a′ and an outer race member 78a′. Similarly, the bearing assembly 40b′ basically includes a plurality of balls 74b′ located between an inner race member 76b′ and an outer race member 78b′. Since bearing assemblies 40a′ and 40b′ are well known in the bicycle art, they will not be discussed or illustrated in detail herein.

[0104] Turning now to FIGS. 17 and 18,the spoke seals 42a′ and 42b′ are arranged in the interior passageway 52′ of the hub body 38′ so as to be adjacent the spoke openings 60a′ and 60b′ to isolate the spoke openings 60a′ and 60b′ from the hub axle 36. In other words, the spoke seals 42a′ and 42b′ prevent contaminants from entering the front hub 22′ through the spoke openings 60a′ and 60b′. The spoke seals 42a′ and 42b′ are preferably resilient members that are constructed of rubber or the like. Of course, it will be apparent to those skilled in the art from this disclosure that the seals could be created from other types of materials, depending upon their shape and arrangement. Moreover, it will be apparent to those skilled in the art from this disclosure that while the spoke seals 42a′ and 42b′ are illustrated as a pair of separate sealing members, the spoke seals 42a′ and 42b′ can be formed as a one-piece, unitary member.

[0105] In the preferred embodiment, the spoke seals 42a′ and 42b′ also aid in the assembly of the spokes 24 with the hub body 38′ and the rim 26. Specifically, in the preferred embodiments, the seals 42a′ and 42b′ are arranged so that they restrain movement of the spokes 24 within the spoke openings 60a′ and 60b′ so that the bent ends 24bof the spokes 24 stays in the retaining portions 62′ of the spoke openings 60a′ and 60b′.

[0106] In the illustrated embodiment, the spoke seal 42a′ has a tubular section 80a′ and a center annular flange 82a′. The center annular flange 82a′ extends in a circumferential direction about the tubular section 80a′. The ends 84a′ and 86a′ of the tubular section 80a′ are configured to engage a ring member 88a′ and an abutment 90a′ of the inner surface of the hub body 38′. Of course, the particular shape of the ends 84a′ and 86a′ will vary depending on the shape of the hub body 38′ and its internal components. In other words, the spoke seal 42a′ functions the same way as the spoke seal 42aof the rear hub 22, but has a slightly modified ends 84a′ and 86a′ to accommodate front hub 22′.

[0107] When the front hub 22′ is assembled, an axial force is applied to the ends 84a′ and 86a′ of the tubular section 80a′ to form annular seals therebetween. Accordingly, the spoke seal 42a′ isolates a first interior section of the interior passageway 52′ from the remainder of the interior passageway 52′. This interior section formed by the spoke seal 42a′ is continuous annular first space located beneath the spoke openings 60a′.

[0108] The center annular flange 82a′ is preferably aligned with a radial plane passing through the centers axes C₁′ of the insertion portions 61′ of the first spoke openings 60a′. Thus, the center annular flange 82a′ is positioned to axially separate the two retaining portions 62′ of each of the first spoke openings 60a′ from each other. The center annular flange 82a′ is also positioned to keep spokes 24 in the retaining portions 62′ of the first spoke openings 60a′. Accordingly, when the enlarged heads 24cof the spokes 24 are inserted into the insertion portions 61 of the spoke openings 60a′, the enlarged heads 24cof the spokes 24 contact the center annular flange 82a′. The enlarged heads 24cthen pushes or deforms the center annular flange 82a′ one way or the other so that the enlarged heads 24cextends into the insertion portions 61′ of the spoke openings 60a′. The spokes 24 are then moved or slid into one of the two retaining portions 62′ of each of the spoke openings 60a.The center annular flange 82a′ will prevent the spokes 24 from accidentally falling out of the insertion portions 61′ of the spoke openings 60a′. Thus, the center annular flange 82a′ aids in the assembly of the front wheel 16. In other words, the center annular flange 82a′ must be moved or deformed again before the spokes 24 can be removed from the spoke openings 60a′. For added resiliency, an annular groove 92a′ can be formed in the outer peripheral surface of the center flange 82a′.

[0109] Similar to the spoke seal 42a′, the spoke seal 42b′ has a tubular section 80b′ and a center annular flange 82b′. The center annular flange 82a′ extends in a circumferential direction about the tubular section 80a′. Alternatively, the center annular flanges 82a′ and 82b′ of the spoke seals 42a′ and 42b′ can each have a pair of center annular flanges. The ends 84b′ and 86b′ of the tubular section 80b′ are configured to engage a ring member 88b′ and an abutment 90b′ of the inner surface of the hub body 38′. Of course, the particular shape of the ends 84b′ and 86b′ will vary depending on the shape of the hub body 38′ and its internal components. When the front hub 22′ is assembled, an axial force is applied to the ends 84b′ and 86b′ of the tubular section 80b′ to form annular seals therebetween. Accordingly, the spoke seal 42b′ isolates a second interior section of the interior passageway 52′ from the remainder of the interior passageway 5′. This interior section formed by the spoke seal 42b′ is continuous annular second space located beneath the spoke openings 60b′.

[0110] Similar to the center annular flange 82a′, the center annular flange 82b′ is preferably aligned with a radial plane passing through the centers axes C₁of the insertion portions 61′ of the second spoke openings 60b′. Thus, the center annular flange 82b′ is positioned to axially separate the two retaining portions 62′ of each of the second spoke openings 60b′ from each other. The center annular flange 82b′ is also positioned to keep spokes 24 in the retaining portions 62′ of the second spoke openings 60b′. Accordingly, when the enlarged heads 24cof the spokes 24 are inserted into the insertion portions 61′ of the spoke openings 60b′, the enlarged heads 24cof the spokes 24 contact the center annular flange 82b′. The enlarged heads 24cthen pushes or deforms the center annular flange 82b′ one way or the other so that the enlarged heads 24cextends into the insertion portions 61′ of the spoke openings 60b′. The spokes 24 are then moved or slid into one of the two retaining portions 62 of each of the spoke openings 60b′. The center annular flange 82b′ will prevent the spokes 24 from accidentally falling out of the insertion portions 61′ of the spoke openings 60b′. Thus, the center annular flange 82b′ aids in the assembly of the front wheel 16. In other words, the center annular flange 82b′ must be moved or deformed again before the spokes 24 can be removed from the spoke openings 60b′. For added resiliency, an annular groove 92b′ can be formed in the outer peripheral surface of the center flange 82b′.

[0111] As seen in FIGS. 19 and 20, a spoke opening cover 100 in accordance with one embodiment of the present invention is illustrated for use with the front hub 22′ of FIGS. 15 and 16. Of course, the spoke opening cover 100 can be used with the rear hub 22 of FIGS. 4 and 5 by turning the spoke opening cover 100 inside out to reverse the direction of the slits 102. Although for purposes of brevity, the spoke opening cover 100 will only be illustrated with the front hub 22′.

[0112] The spoke opening cover 100 is used to limit or prevent contaminants from entering the hub body 38 or 38′ via the spoke openings 60a,60a′ or 60b,60b′, respectively. The spoke opening cover 100 can be used instead of the spoke seals 42a,42a′ and 42b,42b′, or in conjunction with the spoke seals 42a,42a′ and 42b,42b′. The spoke opening cover 100 basically has a resilient tubular body 101 constructed from a flexible material such as rubber. The spoke opening cover 100 has a plurality of slits 102 spaced circumferential around the tubular body 101. The tubular body 101 of the spoke opening cover 100 is configured and dimensioned to snugly fit around the bicycle hub 22′ so that the spoke openings are aligned with the slits. The spoke opening cover 100 is installed on each end of the hub body 38′ prior to installation of spokes 24. Since this embodiment is used with the bicycle hubs 22 and 22′, the slits 102 extend diagonally relative a center axis of the tubular body. The slits 102 have enlarged openings 104 at each end. The enlarged openings 104 align with the retaining portions 62′ of the spoke openings 60a′ or 60b′, while the center sections of the slits 102 overlie the insertion portions 61′ of the spoke openings 60a′ or 60b′. Also, the center sections of the slits 102 hold the spokes 24 in the retaining portions 62′ to aid in the assembly of the wheel.

[0113] As seen in FIGS. 21 and 22, a spoke opening cover 100′ in accordance with an alternate embodiment of the present invention is illustrated for use with the bicycle either the rear hub 22 of FIGS. 4 and 5 or the front hub 22′ of FIGS. 15 and 16. Although for purposes of brevity, the spoke opening cover 100′ will only be illustrated with the front hub 22′.

[0114] The spoke opening cover 100′ is used to limit or prevent contaminants from entering the hub body 38 or 38′ via the spoke openings 60a,60a′ or 60b,60b′, respectively. The spoke opening cover 100′ can be used instead of the spoke seals 42a,42a′ and 42b,42b′, or in conjunction with the spoke seals 42a,42a′ and 42b,42b′. In this embodiment, the spoke opening cover 100′ is a thin flexible strip or body portion 101′ having a first end 102′ and a second end 104′ with a predetermined length therebetween. The first end 102′ is provided with a first protrusion 106′, while the second end 104′ is provided with a second protrusion 108′. The first and second protrusions 106′ and 108′ are configured and dimensioned to be frictionally retained with the insertion portions 61′ of the spoke openings 60a′ or 60b′. Accordingly, the first and second protrusions 106′ and 108′ have predetermined widths or diameters that are larger that a width of an enlarged head 24cof a spoke 24. Preferably, the body portion 101′ has a predetermined width that is larger that the widths or diameters of the enlarged heads 24cof the spokes 24. In other words, the body portion 101′ of the spoke opening cover 100′ has a predetermined width that is larger than a width of insertion portions 61′ of the spoke openings 60a′ or 60b′. The spoke opening cover 100′ is designed to be installed on each end of the hub body 38′ after the spokes 24 have been installed into the spoke openings 60a′ and 60b′.

[0115] As seen in FIGS. 23-25, a spoke opening cover 100″ in accordance with another alternate embodiment of the present invention is illustrated for use with the bicycle either the rear hub 22 of FIGS. 4 and 5 or the front hub 22′ of FIGS. 15 and 16. Although for purposes of brevity, the spoke opening cover 100″ will only be illustrated with the front hub 22′.

[0116] The spoke opening cover 100″ is used to limit or prevent contaminants from entering the hub body 38 or 38′ via the spoke openings 60a,60a′ or 60b,60b′, respectively. The spoke opening cover 100″ can be used instead of the spoke seals 42a,42a′ and 42b,42b′, or in conjunction with the spoke seals 42a,42a′ and 42b,42b′. In this embodiment, the spoke opening cover 100″ is a thin flexible strip or body portion 101″ having a first end 102″ and a second end 104″ with a predetermined length therebetween.

[0117] The first end 102″ is provided with a tubular connector 106″, while the second end 104″ is provided with a mating connector 108. The tubular connector 106″ is a protrusion that is configured and dimensioned to be received in one of the insertion portions 61′ of the spoke openings 60a′ or 60b′. The mating connector 108′ is a split protrusion in the form of a resilient detent. The second end 104″ is configured and dimensioned to overlap the first end 102″ with mating connector 108″ being retained in the bore of tubular protrusion 106″ via a snap-fit. The length of body portion 101″ should be such that spoke opening cover 100″ snugly fits around the hub body 38′ when the detent 108″ is snap-fitted into the tubular protrusion 106″.

[0118] Preferably, the body portion 101″ has a predetermined width that is larger than the widths or diameters of the enlarged heads 24cof the spokes 24. In other words, the body portion 101″ of the spoke opening cover 100″ has a predetermined width that is larger than a width of insertion portions 61′ of the spoke openings 60a′ or 60b′. The spoke opening cover 100″ is designed to be installed on each end of the hub body 38′ after the spokes 24 have been installed into the spoke openings 60a′ and 60b′.

[0119] Referring now to FIGS. 26-29, bicycle rear and front hubs 122 and 122′ are illustrated in accordance with a second embodiment of the present invention. The rear and front hubs 122 and 122′ of this second embodiment are substantially the same as the first embodiment, except that the spoke hole openings 60a,60a′ and 60b,60b′ of the first embodiment have been replaced with modified spoke openings 160a,160a′ and 160b,160b′ that each receive a single spoke as explained below. Since the rear and front hubs 122 and 122′ are substantially the same as the rear and front hubs 22 and 22′ of the first embodiment, this embodiment will not be discussed or illustrated in detail herein.

[0120] Referring to FIGS. 26 and 27, the rear hub 122 basically includes a hub axle 136, a hub body 138, a first bearing assembly 140a,a second bearing assembly 140b,a first spoke seal 142a,a second spoke seal 142b,a freewheel 144 and a quick release mechanism 146. The hub axle 136 has a center axis A extending between a first end 136aand a second end 136b.

[0121] The quick release mechanism 146 extends through a center bore 136cof the hub axle 136 such that the quick release mechanism 146 is coupled to the hub axle 136 in a conventional manner. The first and second ends 136aand 136bof the hub axle 136 are threaded for receiving a pair of nuts 150aand 150bthat applies an axial force on the hub body 138, the bearing assemblies 140aand 140b,the spoke seals 142aand 142b,and the freewheel 144. First and second bearing assemblies 140aand 140brotatably mount the hub body 138 with the freewheel 144 on the hub axle 136. The freewheel 144 allows the hub axle 136 to rotate freely relative to the hub body 138 in one direction, but fixedly couples the hub axle 136 relative to the hub body 138 in the opposite rotational direction.

[0122] A set of first spoke openings 160aare provided at the first end section 138aof the hub body 138 for receiving the bent ends 24bof the spokes 24. Similarly, the second end section 138bof the hub body 138 is provided with a second set of spoke openings 160bfor receiving the bent ends 24bof the spokes 24. In the illustrated embodiment, the first end section 138ais provided with eighteen of the first spoke openings 160aand the second end section 138bis provided with eighteen of the second spoke openings 160b.The spoke openings 160aand 160bare grouped into pairs that are equally spaced apart about the circumference of the hub body 138. Accordingly, the rear hub 122 is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

[0123] Preferably, the first and second sets of spoke openings 160aand 160bare arranged identical. The first and second spoke openings 160aand 160bare designed to be used with conventional tangential spokes 24. Of course, it is possible that the first and second sets of spoke openings 160aand 160bcan be different such that tangential spokes 24 are used in one end of the hub body 138 and a different types of spokes are used in the other end of the hub body 138. The first spoke openings 160aare circumferentially arranged around the hub body 138 adjacent to the brake rotor attachment portion 138d.Preferably, the first spoke openings 160aare spaced axially inward of the brake rotor attachment portion 138dso that brake disc rotor 132 can be easily attached with the bolts 132aand nuts 132b.

[0124] In this embodiment, the spoke openings 160aand 160bare arranged to form two circumferential rows of spoke openings 160aat end section 138aand two circumferential rows of spoke openings 160bat end section 138b.Each of the spoke openings 160aand 160bhas an insertion portion 161 and a retaining portion 162. Adjacent pairs of the spoke openings 160aand 160bare oriented in opposite directions so that the spokes 24 extend in generally opposite directions from the hub body 138.

[0125] Each insertion portion 161 is formed by a curved or partial cylindrical surface 164 that has a width or diameter that is equal to or slightly larger than the widths or diameters of the enlarged heads 24cof the spokes 24. Thus, the inner ends (bent ends 24bwith enlarged heads 24c) of the spokes 24 can be easily inserted into the spoke openings 160aand 160bthrough the insertion portions 161.

[0126] The retaining portions 162 have smaller widths or diameters than the insertion portions 161. More specifically, the diameters or widths of the retaining portions 162 are smaller than the diameters or widths of the enlarged heads 24cof the spokes 24 so as to retain the spokes 24 within the spoke openings 160aand 160b.The retaining portions 162 are each preferably defined by a partial cylindrical surface 166 that is connected to the curved surface 164 of the associated insertion portion 161.

[0127] Preferably, the insertion portion 161 and the retaining portions 162 of each spoke opening are formed simultaneously. Also preferably, the inner and outer ends of the retaining portions 162 of the spoke openings 160aand 160bare tapered to avoid sharp edges engaging the spokes 24.

[0128] Similar to the first embodiment, discussed above, each of the insertion portions 161 has a center longitudinal axis that passes through the center axis A of the hub axle 136. The retaining portions 162, on the other hand, have center longitudinal axes that are parallel to the center longitudinal axis of the associated insertion portion 161 for each of the spoke openings 160aand 160b.Thus, the center longitudinal axes of the retaining portions 162 do not pass through the center axis of the hub axle 136, similar to the first embodiment. Rather, the center longitudinal axes of the retaining portions 162 are angled with respect to center axis A. Preferably, the center longitudinal axis of each retaining portion 162 is angled between about 5° and about 20° from a radial orientation in the hub body 138. In the illustrated embodiment, the retaining portions 162 are angled about 10° with respect to center axis A for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. For a twenty-six inch rim with thirty-two spoke holes and a hub having a diameter approximately 22 millimeters, the retaining portions 162 are preferably angled about 11° with respect to center axis A. This angled configuration of the retaining portions 162 results in the straight sections 24aof the spokes 24 being easily arranged in a tangential direction relative to an imaginary circle centered on the hub body 138. Moreover, this angled configuration of the retaining portions 162 allows the straight sections 24aof the spokes 24 to be easily aligned with the spoke holes of the rim without significant bending of the spokes 24. In the illustrated embodiment, the spokes 24 are not bent more than about five degrees.

[0129] Referring to FIGS. 28 and 29, the front hub 122′ basically includes a hub axle 136′, a hub body 138′, a first bearing assembly 140a′, a second bearing assembly 140b′, a first spoke seal 142a′, a second spoke seal 142b′, and a quick release mechanism 146′. The hub axle 136′ has a center axis A′ extending between a first end 136a′ and a second end 136b′.

[0130] The quick release mechanism 146′ extends through a center bore 136c′ of the hub axle 136′ such that the quick release mechanism 146′ is coupled to the hub axle 136′ in a conventional manner. The first and second ends 136a′ and 136b′ of the hub axle 136′ are threaded for receiving a pair of nuts 150a′ and 150b′ that applies an axial force on the hub body 138′, the bearing assemblies 140a′ and 140b′ and the spoke seals 142a′ and 142b′. First and second bearing assemblies 140a′ and 140b′ rotatably mount the hub body 138′ on the hub axle 136′.

[0131] A set of first spoke openings 160a′ are provided at the first end section 138a′ of the hub body 138′ for receiving the bent ends 24bof the spokes 24. Similarly, the second end section 138b′ of the hub body 138′ is provided with a second set of spoke openings 160b′ for receiving the bent ends 24bof the spokes 24. In the illustrated embodiment, the first end section 138a′ is provided with eighteen of the first spoke openings 160a′ and the second end section 138b′ is provided with eighteen of the second spoke openings 160b′. The spoke openings 160a′ and 160b′ are grouped into pairs that are equally spaced apart about the circumference of the hub body 138′. Accordingly, the front hub 122′ is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

[0132] The first spoke openings 160a′ are circumferentially arranged around the hub body 138′ adjacent to the brake rotor attachment portion 138d′. Preferably, the first spoke openings 160a′ are spaced axially inward of the brake rotor attachment portion 138d′ so that brake disc rotor 132′ can be easily attached with the bolts 132a′ and nuts 132b′.

[0133] In this embodiment, the spoke openings 160a′ and 160b′ are arranged to form two circumferential rows of spoke openings 160a′ at end section 138a′ and two circumferential rows of spoke openings 160b′ at end section 138b′. Each of the spoke openings 160a′ and 160b′ has an insertion portion 161′ and a retaining portion 162′. Adjacent pairs of the spoke openings 160a′ and 160b′ are oriented in opposite directions so that the spokes 24 extend in generally opposite directions from the hub body 138′.

[0134] Each insertion portion 161′ is formed by a curved or partial cylindrical surface 164′ that has a width or diameter that is equal to or slightly larger than the widths or diameters of the enlarged heads 24cof the spokes 24. Thus, the inner ends (bent ends 24bwith enlarged heads 24c) of the spokes 24 can be easily inserted into the spoke openings 160a′ and 160b′ through the insertion portions 161′.

[0135] The retaining portions 162′ have smaller widths or diameters than the insertion portions 161′. More specifically, the diameters or widths of the retaining portions 162′ are smaller than the diameters or widths of the enlarged heads 24cof the spokes 24 so as to retain the spokes 24 within the spoke openings 160a′ and 160b′. The retaining portions 162′ are each preferably defined by a partial cylindrical surface 166′ that is connected to the curved surface 164′ of the associated insertion portion 161′.

[0136] Preferably, the insertion portion 161′ and the retaining portions 162′ of each spoke opening are formed simultaneously. Also preferably, the inner and outer ends of the retaining portions 162′ of the spoke openings 160a′ and 160b′ are tapered to avoid sharp edges engaging the spokes 24.

[0137] Similar to the first embodiment, discussed above, each of the insertion portions 161′ has a center longitudinal axis that passes through the center axis A′ of the hub axle 136′. The retaining portions 162′, on the other hand, have center longitudinal axes that are parallel to the center longitudinal axis of the associated insertion portion 161′ for each of the spoke openings 160a′ and 160b′. Thus, the center longitudinal axes of the retaining portions 162′ do not pass through the center axis of the hub axle 136′, similar to the first embodiment. Rather, the center longitudinal axes of the retaining portions 162′ are angled with respect to center axis A′. Preferably, the center longitudinal axis of each retaining portion 162′ is angled between about 5° and about 20° from a radial orientation in the hub body 138′. In the illustrated embodiment, the retaining portions 162′ are angled about 10° with respect to center axis A′ for a twenty-six inch rim with thirty-six spoke holes and a hub having a diameter approximately 22 millimeters. For a twenty-six inch rim with thirty-two spoke holes and a hub having a diameter approximately 22 millimeters, the retaining portions 162′ are preferably angled about 11° with respect to center axis A′. This angled configuration of the retaining portions 162′ results in the straight sections 24aof the spokes 24 being easily arranged in a tangential direction relative to an imaginary circle centered on the hub body 138′. Moreover, this angled configuration of the retaining portions 162′ allows the straight sections 24aof the spokes 24 to be easily aligned with the spoke holes of the rim without significant bending of the spokes 24. In the illustrated embodiment, the spokes 24 are not bent more than about five degrees.

[0138] Referring now to FIG. 30, a front bicycle hub 222 is illustrated in accordance with a third embodiment of the present invention. The front hub 222 of this third embodiment is substantially the same as the front hub 22′ shown in FIG. 16, except that the left half of the front hub 222 has been modified to be substantially a mirror image of the right half of the front hub 222. In other words, the front hub 222 is not designed to have a disc rotor coupled thereto. Since the front hub 222 is substantially the same as the front hub 22′ of the first embodiment, this third embodiment will not be discussed or illustrated in detail herein.

[0139] The front hub 222 basically includes a hub axle 236, a hub body or shell 238, a first bearing assembly 240a,a second bearing assembly 240b,a first spoke seal 242a,a second spoke seal 242band a quick release mechanism 246. Of the parts of front hub 222, only the hub body 238 and the first and second spoke seals 242aand 242bare non-conventional parts. The remaining parts of front hub 222 are relatively conventional, and thus, the remaining parts of front hub 222 will not be discussed or illustrated in detail herein.

[0140] The hub axle 236 has a center axis A extending between a first end 236aand a second end 236b.The quick release mechanism 246 extends through a center bore 236cof the hub axle 236 such that the quick release mechanism 246 is coupled to the hub axle 236 in a conventional manner. The first and second ends 236aand 236bof the hub axle 236 are threaded for receiving a pair of nuts 250aand 250bthat apply an axial force on the hub body 238, the bearing assemblies 240aand 240band the spoke seals 242aand 242b.First and second bearing assemblies 240aand 240brotatably mount the hub body 238 on the hub axle 236.

[0141] The hub body 238 is illustrated in accordance with one embodiment of the present invention. In this embodiment, the hub body 238 is a hollow member that defines an interior passageway 252 with the hub axle 236 being rotatably supported therein by the first and second bearing assemblies 240aand 240b.Thus, the hub body 238 is a substantially tubular member. Specifically, the hub body 238 has a center tubular portion 238cwith first and second end sections 238aand 238bbeing integral formed with the center tubular portion 238cas a one-piece, unitary member.

[0142] A set of first spoke openings 260aare provided at the first end section 238aof the hub body 238 for receiving the bent ends of the spokes 224. Similarly, the second end section 238bof the hub body 238 is provided with a second set of spoke openings 260bfor receiving the bent ends of the spokes 224. In the illustrated embodiment, the first end section 238ais provided with nine of the first spoke openings 260aand the second end section 238bis provided with nine of the second spoke openings 260b.The spoke openings 260aand 260bare equally spaced apart about the circumference of the hub body 238. Each of the spoke openings 260aand 260bare also designed to receive two spokes 224 as explained below. Accordingly, the front hub 222 is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

[0143] Preferably, the first and second sets of spoke openings 260aand 260bare identical, expect that the first and second sets of spoke openings 260aand 260bare circumferential offset, i.e., not axially aligned. The first and second spoke openings 260aand 260bare designed to be used with tangential spokes 224. Of course, it is possible that the first and second sets of spoke openings 260aand 260bcan be different such that tangential spokes 224 are used in one end of the hub body 238 and a different types of spokes are used in the other end of the hub body 238.

[0144] In this embodiment, the first and second spoke openings 260aand 260bare elongated slots that are each provided with an insertion portion 261 and a pair of retaining portions 262. Accordingly, each of the spoke openings 260aand 260bis designed to have a pair of spokes 224 retained therein with the spokes 224 extending in opposite directions. The first and second spoke openings 260aand 260bhave the identical shapes as the spoke openings 60aas seen in FIGS. 9-11.

[0145] Bearing assemblies 240aand 240brotatably supports hub body 238 on hub axle 236. In this embodiment, bearing assemblies 240aand 240bare identical to each other, except that they are mirror images of each other. The bearing assembly 240abasically includes a plurality of balls 274alocated between an inner race member 276aand an outer race member 278a.Similarly, the bearing assembly 240bbasically includes a plurality of balls 274blocated between an inner race member 276band an outer race member 278b.Since bearing assemblies 240aand 240bare well known in the bicycle art, they will not be discussed or illustrated in detail herein.

[0146] However, the arrangement of the bearing assemblies 240aand 240brelative to the first and second spoke openings 260aand 260bis unique in that the bearing assemblies 240aand 240bare located at least partially beneath the first and second spoke openings 260aand 260b.This arrangement provides for better rigidity of the wheel and the hub axle 236. Specifically, the outer circumferential rows of the retaining portions 262 of the first and second spoke openings 260aand 260bhave their centers lying on radial planes P₁and P₂, respectively. As seen in FIG. 30, the planes P₁and P₂intersect at least part of the bearing assemblies 240aand 240b,respectively. Plane P₁passes through the balls 274a,the inner race member 276aand the outer race member 278a.Similarly, the plane P₂passes through the balls 274b,the inner race member 276band the outer race member 280b.

[0147] The spoke seals 242aand 242bare arranged in the interior passageway 252 of the hub body 238 so as to be adjacent the spoke openings 260aand 260bto isolate the spoke openings 260aand 260bfrom the hub axle 236. In other words, the spoke seals 242aand 242bprevent contaminants from entering the front hub 222 through the spoke openings 260aand 260b.The spoke seals 242aand 242bare preferably resilient members that are constructed of rubber or the like. Of course, it will be apparent to those skilled in the art from this disclosure that the seals could be created from other types of materials, depending upon their shape and arrangement.

[0148] In the preferred embodiment, the spoke seals 242aand 242balso aid in the assembly of the spokes 224 with the hub body 238 and the rim. Specifically, in the preferred embodiments, the seals 242aand 242bare arranged so that they restrain movement of the spokes 224 within the spoke openings 260aand 260bso that the bent ends of the spokes 224 stays in the retaining portions 262 of the spoke openings 260aand 260b.The seals 242aand 242bare identical in construction to the seal 42b′ as seen in FIG. 18.

[0149] Referring now to FIG. 31, a rear bicycle hub 322 is illustrated in accordance with a third embodiment of the present invention. The rear hub 322 of this third embodiment includes many of the same features of the rear hub 22 as seen in FIG. 5. Therefore, the common features between the rear hub 22 and the rear hub 322 will not be discussed herein when describing the rear hub 322.

[0150] The rear hub 322 basically includes a hub axle 336, a hub body or shell 338 (two parts), a first bearing assembly 340a,a second bearing assembly 340b,a first spoke seal 342a,a second spoke seal 342b,a freewheel 344 and a quick release mechanism 346. Of the parts of rear hub 322, only the hub body 338 and the first and second spoke seals 342aand 342bare non-conventional parts. The remaining parts of rear hub 322 are relatively conventional, and thus, the remaining parts of rear hub 322 will not be discussed or illustrated in detail herein.

[0151] The hub axle 336 has a center axis A extending between a first end 336aand a second end 336b.The quick release mechanism 346 extends through a center bore 336cof the hub axle 336 such that the quick release mechanism 346 is coupled to the hub axle 336 in a conventional manner. The first and second ends 336aand 336bof the hub axle 336 are threaded for receiving a pair of nuts 350aand 350bthat apply an axial force on the hub body 338, the bearing assemblies 340aand 340b,the spoke seals 342aand 342b,and the freewheel 344. First and second bearing assemblies 340aand 340brotatably mount the hub body 338 with the freewheel 344 on the hub axle 336. The freewheel 344 allows the hub axle 336 to rotate freely relative to the hub body 338 in one direction, but fixedly couples the hub axle 336 relative to the hub body 338 in the opposite rotational direction.

[0152] The hub body 338 of this embodiment of the present invention is constructed of two pieces. In this embodiment, the hub body 338 is a hollow member that defines an interior passageway 352 with the hub axle 336 being rotatably supported therein by the first and second bearing assemblies 340aand 340b.Thus, the hub body 338 is a substantially tubular member. Specifically, the hub body 338 has a center tubular portion 338cwith first and second end sections 338aand 338b.

[0153] The first end section 338ais integrally formed with the center tubular portion 338cand the inner ring portion 388bas a one-piece, unitary member. The second end section 338bof the hub body 338 is constructed of two pieces (outer member or portion 339 and inner ring member or portion 388b). The second end section 338bhas the freewheel 344 fixedly coupled thereto. Preferably, the outer portion 339 has internal threads that engage external threads of the inner ring portion 388bto fixedly couple them together and to prevent relative rotation therebetween. The outer portion 339 is held on the inner ring portion 388bby the axial force applied to the various parts of the hub 322 by nuts 350aand 350b.This type of arrangement reduces the manufacturing costs of the hub shell or body 338.

[0154] A set of first spoke openings 360aare provided at the first end section 338aof the hub body 338 for receiving the bent ends of the spokes 324. Similarly, the second end section 338bof the hub body 338 is provided with a second set of spoke openings 360bfor receiving the bent ends of the spokes 324. In the illustrated embodiment, the first end section 338ais provided with nine of the first spoke openings 360aand the second end section 338bis provided with nine of the second spoke openings 360b.The spoke openings 360aand 360bare equally spaced apart about the circumference of the hub body 338. Each of the spoke openings 360aand 360bare also designed to receive two spokes 324 as explained below. Accordingly, the rear hub 322 is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

[0155] Preferably, the first and second sets of spoke openings 360aand 360bare identical, expect that the first and second sets of spoke openings 360aand 360bare circumferential offset, i.e., not axially aligned. The first and second spoke openings 360aand 360bare designed to be used with tangential spokes 324.

[0156] In this embodiment, the first and second spoke openings 360aand 360bare elongated slots that are each provided with an insertion portion 361 and a pair of retaining portions 362. Accordingly, each of the spoke openings 360aand 360bis designed to have a pair of spokes 324 retained therein with the spokes 324 extending in opposite directions. The first and second spoke openings 360aand 360bhave the identical shapes as the spoke openings 60aas seen in FIGS. 9-10.

[0157] Bearing assemblies 340aand 340brotatably supports hub body 338 on hub axle 336. The bearing assembly 340abasically includes a plurality of balls 374alocated between an inner race member 376aand an outer race member 378a.Similarly, the bearing assembly 340bbasically includes a plurality of balls 374blocated between an inner race member 376band an outer race member 378b.Since bearing assemblies 340aand 340bare well known in the bicycle art, they will not be discussed or illustrated in detail herein.

[0158] The spoke seals 342aand 342bare arranged in the interior passageway 352 of the hub body 338 so as to be adjacent the spoke openings 360aand 360bto isolate the spoke openings 360aand 360bfrom the hub axle 336. In other words, the spoke seals 342aand 342bprevent contaminants from entering the rear hub 322 through the spoke openings 360aand 360b.The spoke seals 342aand 342bare preferably resilient members that are constructed of rubber or the like. Of course, it will be apparent to those skilled in the art from this disclosure that the seals could be created from other types of materials, depending upon their shape and arrangement.

[0159] In the preferred embodiment, the spoke seals 342aand 342balso aid in the assembly of the spokes 324 with the hub body 338 and the rim. Specifically, in the preferred embodiments, the seals 342aand 342bare arranged so that they restrain movement of the spokes 324 within the spoke openings 360aand 360bso that the bent ends of the spokes 324 stay in the retaining portions 362 of the spoke openings 360aand 360b.

[0160] In this embodiment, the ring-shaped member 388aand the inner ring member or portion 388bsupport the spoke seals 342aand 342bfrom moving inwardly in a radial direction. More specifically, these members are constructed of rigid material and have an annular ring-shape that prevents the radial inward movement of the spoke seals 342aand 342b.The particular shape of the ring members 388aand 388bdepend upon the adjacent structures of the hub. Accordingly, their specific shapes will not be discussed or illustrated in detail herein.

[0161] In the illustrated embodiment, the spoke seal 342ahas a tubular section and a center annular flange. The center annular flange of the spoke seal 342aextends in a circumferential direction about the tubular section. The center annular flange can either contact the interior surface of the hub body 338 or be spaced from the hub body 338. The particular shape of the ends of the spoke seal 342awill vary depending on the shape of the hub body 338 and its internal parts.

[0162] When the rear hub 322 is assembled, an axial force is applied to the ends of the tubular section of the spoke seal 342ato form annular seals therebetween. Thus, the spoke seal 342aisolates a first interior section of the interior passageway 352 from the remainder of the interior passageway 352. This interior section formed by the spoke seal 342ais continuous annular first space located beneath the spoke openings 360a.Basically, the construction of the spoke seal 342ais substantially identical in construction to the seal 32a′ as seen in FIG. 17, except that the center flange has been made wider and the inner end of the seal 342ahas a slightly different shape. However, the spoke seal 342aperforms the same function as the seal 42a′, discussed above. In particular, the spoke seal 342ais positioned to axially separate the two retaining portions 362 of each of the first spoke openings 360afrom each. The center annular flange of spoke seal 342ais also positioned to keep the spokes 324 in the retaining portions 362 of the first spoke openings 360a.

[0163] Similar to the spoke seal 342a,the spoke seal 342bhas a tubular section and a center annular flange. The center annular flange of the spoke seal 342bextends in a circumferential direction about the tubular section. The ends of the tubular section of the spoke seal 342bare configured to engage a ring member 388band an abutment 390bof the inner surface of the hub body 338. Of course, the particular shape of the ends of the spoke seal 342bwill vary depending on the shape of the hub body 338 and its internal components.

[0164] When the rear hub 322 is assembled, an axial force is applied to the ends of the tubular section of the spoke seal 342bto form annular seals therebetween. Accordingly, the spoke seal 342bisolates a second interior section of the interior passageway 352 from the remainder of the interior passageway 352. This interior section formed by the spoke seal 342bis a continuous annular second space located beneath the spoke openings 360b.

[0165] The center annular flange of the spoke seal 342bis preferably aligned with a radial plane passing through the centers axes of the insertion portions 361 of the second spoke openings 360b.Thus, the center annular flange of the spoke seal 342bis positioned to axially separate the two retaining portions 362 of each of the second spoke openings 360bfrom each other. The center annular flange of the spoke seal 342bis also positioned to keep spokes 324 in the retaining portions 362 of the second spoke openings 360b.Accordingly, when the enlarged heads of the spokes 324 are inserted into the insertion portions 361 of the spoke openings 360b,the enlarged heads of the spokes 324 contact the center annular flange of the spoke seal 342b.The enlarged heads then push or deform the center annular flange of the spoke seal 342bone way or the other so that the enlarged heads extend into the insertion portions 361 of the spoke openings 360b.The spokes 324 are then moved or slid into one of the two retaining portions 362 of each of the spoke openings 360b.The center annular flange of the spoke seal 342bwill prevent the spokes 324 from accidentally falling out of the insertion portions 361 of the spoke openings 360b.In other words, the center annular flange of the spoke seal 342bmust be moved or deformed again before the spokes 324 can be removed from the spoke openings 360b.

[0166] The freewheels, such as the freewheel 344, are well known in the bicycle art, and thus, the freewheel 344 will not be illustrated or discussed in detail herein. The freewheel 344 is used to transmit a driving force from the chain to the rear bicycle wheel in one rotation direction only. The freewheel 344 allows the bicycle to advance freely without any rotation of the pedals. The freewheel 344 is fastened to the rear hub 322 as integral part of the rear hub 322 in a conventional manner. The freewheel 344 has an outer tubular part 394, an inner tubular part 396 and a one-way clutch 398. The inner tubular part 396 is installed radially inwardly of the outer tubular part 394 so that the inner tubular part 396 is free to rotate relative to the outer tubular part 394. The one-way clutch 398 is installed between the outer tubular part 394 and inner tubular part 396 for transmitting the driving force from the outer tubular part 394 to the inner tubular part 396 in one rotational direction only. The outer tubular part 394 has a plurality of gears or sprockets (not shown) mounted thereon, while the inner tubular part 396 is usually mounted on the hub axle 336.

[0167] Referring now to FIGS. 32-36, a rear bicycle hub 422 is illustrated in accordance with a third embodiment of the present invention. The rear hub 422 of this third embodiment includes many of the same features of the rear hub 22 as seen in FIG. 5. Therefore, the common features between the rear hub 22 and the rear hub 422 will not be discussed herein when describing the rear hub 422.

[0168] The rear hub 422 basically includes a hub axle 436, a hub body or shell 438, a first bearing assembly 440a,a second bearing assembly 440b,a first spoke seal 442awith a seal support 443a,a second spoke seal 442b,a freewheel 444 and a quick release mechanism 446. Of the parts of rear hub 422, only the hub body 438 and the first and second spoke seals 442aand 442bare non-conventional parts. The remaining parts of rear hub 422 are relatively conventional, and thus, the remaining parts of rear hub 422 will not be discussed or illustrated in detail herein.

[0169] The hub axle 436 has a center axis A extending between a first end 436aand a second end 436b.The quick release mechanism 446 extends through a center bore 436cof the hub axle 436 such that the quick release mechanism 446 is coupled to the hub axle 436 in a conventional manner. The first and second ends 436aand 436bof the hub axle 436 are threaded for receiving a pair of nuts 450aand 450bthat applies an axial force on the hub body 438, the bearing assemblies 440aand 440b,the spoke seals 442aand 442b,and the freewheel 444. First and second bearing assemblies 440aand 440brotatably mount the hub body 438 with the freewheel 444 on the hub axle 436. The freewheel 444 allows the hub axle 436 to rotate freely relative to the hub body 438 in one direction, but fixedly couples the hub axle 436 relative to the hub body 438 in the opposite rotational direction.

[0170] The hub body 438 is illustrated in accordance with one embodiment of the present invention. In this embodiment, the hub body 438 is a hollow member that defines an interior passageway 452 with the hub axle 436 being rotatably supported therein by the first and second bearing assemblies 440aand 440b.Thus, the hub body 438 is a substantially tubular member. Specifically, the hub body 438 has a center tubular portion 438cwith first and second end sections 438aand 438bbeing integral formed with the center tubular portion 438cas a one-piece, unitary member. The first end section 438ahas an integrally mounted brake rotor attachment portion 438d,while a second end section 438bhas the freewheel 444 fixedly coupled thereto. Each of the end sections 438aand 438bhas an annular groove 439cand 439b,respectively, for receiving spoke opening covers 100′ or 100″ or 500 as explained below.

[0171] A set of first spoke openings 460aare provided at the first end section 438aof the hub body 438 for receiving the bent ends 424bof the spokes 424. Similarly, the second end section 438bof the hub body 438 is provided with a second set of spoke openings 460bfor receiving the bent ends 424bof the spokes 424. In the illustrated embodiment, the first end section 438ais provided with nine of the first spoke openings 460aand the second end section 438bis provided with nine of the second spoke openings 460b.The spoke openings 460aand 460bare equally spaced apart about the circumference of the hub body 438. Each of the spoke openings 460aand 460bare also designed to receive two spokes 424 as explained below. Accordingly, the rear hub 422 is designed to have thirty-six spokes extending outwardly therefrom in a generally tangential direction.

[0172] Preferably, the first and second sets of spoke openings 460aand 460bare identical. The first and second spoke openings 460aand 460bare designed to be used with conventional tangential spokes 424. Of course, it is possible that the first and second sets of spoke openings 460aand 460bcan be different such that tangential spokes 424 are used in one end of the hub body 438 and a different types of spokes are used in the other end of the hub body 438. The first spoke openings 460aare circumferentially arranged around the hub body 438 adjacent to the brake rotor attachment portion 438d.Preferably, the first spoke openings 460aare spaced axially inward of the brake rotor attachment portion 438dso that a brake disc rotor can be easily attached thereto via the bolts and nuts in the same manner as illustrated in FIG. 5.

[0173] In this embodiment, the first and second spoke openings 460aand 460bare elongated slots that are each provided with an insertion portion 461 and a pair of retaining portions 462. Accordingly, each of the spoke openings 460aand 460bis designed to have a pair of spokes 424 retained therein with the spokes 424 extending in opposite directions.

[0174] The insertion portion 461 of each spoke opening is located between the pair of retaining portions 462 of each spoke opening. Each insertion portion 461 is formed by a pair of opposed curved surfaces that are spaced apart so as to be equal to or slightly larger than the widths or diameters of the enlarged heads of the spokes 424. Thus, the inner ends (bent ends 424bwith enlarged heads) of the spokes 424 can be easily inserted into the spoke openings 460aand 460bthrough the insertion portions 461.

[0175] The brake rotor attachment portion 438dis integrally formed with the center tubular portion 438cof the hub body 438 as a one-piece, unitary member. In the illustrated embodiment, the brake rotor attachment portion 438dis formed with six attachment members or points with through bores 470. While six individual attachment points are preferred, it will be apparent to those skilled in the art from this disclosure that fewer or more attachment points can be utilized. Moreover, it will be apparent to those skilled in the art from this disclosure that the attachment portions could be a continuous flange, if needed and/or desired. The through bore 470 can be threaded or unthreaded. By using through bores 470 instead of blind bores, the rear hub 422 can be easily manufactured at a relatively lower cost.

[0176] Bearing assemblies 440aand 440brotatably supports hub body 438 on hub axle 436. The bearing assembly 440abasically includes a plurality of balls 474alocated between an inner race member 476aand an outer race member 478a.Similarly, the bearing assembly 440bbasically includes a plurality of balls 474blocated between an inner race member 476band an outer race member 478b.Since bearing assemblies 440aand 440bare well known in the bicycle art, they will not be discussed or illustrated in detail herein.

[0177] The spoke seals 442aand 442bare arranged in the interior passageway 452 of the hub body 438 so as to be adjacent the spoke openings 460aand 460bto isolate the spoke openings 460aand 460bfrom the hub axle 436. In other words, the spoke seals 442aand 442bprevent contaminants from entering the rear hub 422 through the spoke openings 460aand 460b.The spoke seals 442aand 442bare preferably resilient members that are constructed of rubber or the like. Of course, it will be apparent to those skilled in the art from this disclosure that the seals could be created from other types of materials, depending upon their shape and arrangement. Moreover, it will be apparent to those skilled in the art from this disclosure that while the spoke seals 442aand 442bare illustrated as a pair of separate sealing members, the spoke seals 442aand 442bcan be formed as a one-piece, unitary member.

[0178] In the preferred embodiment, the spoke seals 442aand 442balso aid in the assembly of the spokes 424 with the hub body 438 and the rim. Specifically, in the preferred embodiments, the seals 442aand 442bare arranged so that they restrain movement of the spokes 424 within the spoke openings 460aand 460bso that the bent ends 424bof the spokes 424 stays in the retaining portions 462 of the spoke openings 460aand 460b.As best seen in FIG. 34, a left sealing assembly is formed of the spoke seal 442aand seal support 443a.The seal support 443ais constructed of a hard rigid plastic material that prevents the spoke seal 442afrom being deflected radially inwardly into the interior of the hub. In other words, the seal support 443amaintains the spoke seal 442ain a sealing position.

[0179] In the illustrated embodiment, the spoke seal 442ahas a tubular section 480aand a center annular flange 482a.The center annular flange 482aextends in a circumferential direction about the tubular section 480a.The center annular flange 482acan either contact the interior surface of the hub body 438 or be spaced slightly from the hub body 438. The ends 484aand 486aof the tubular section 480aare configured to engage a ring member 488aand an abutment 490aof the inner surface of the hub body 438. Of course, the particular shape of the ends 484aand 486awill vary depending on the shape of the hub body 438 and its internal components. Preferably, ends 484aand 486aof the tubular section 480aare annular flanges that contact the interior surface of the hub body 438 to form an isolated area beneath the spoke openings 460a.This isolated area beneath the spoke openings 460ais a continuous annular space.

[0180] When the rear hub 422 is assembled, an axial force is applied to the ends 484aand 486aof the tubular section 480ato form annular seals therebetween. Accordingly, the spoke seal 442aisolates a first interior section of the interior passageway 452 from the remainder of the interior passageway 452. This interior section formed by the spoke seal 442ais continuous annular first space located beneath the spoke openings 460a.

[0181] The center annular flange 482ais preferably aligned with a radial plane passing through the centers axes of the insertion portions 461 of the first spoke openings 460a.Thus, the center annular flange 482ais positioned to axially separate the two retaining portions 462 of each of the first spoke openings 460afrom each other. The center annular flange 482ais also positioned to keep spokes 424 in the retaining portions 462 of the first spoke openings 460a.Accordingly, when the enlarged heads 424cof the spokes 424 are inserted into the insertion portions 461 of the spoke openings 460a,the enlarged heads 424cof the spokes 424 contact the center annular flange 482a.The enlarged heads 424cthen push or deform the center annular flange 482aone way or the other so that the enlarged heads 424cextends into the insertion portions 461 of the spoke openings 460a.The spokes 424 are then moved or slid into one of the two retaining portions 462 of each of the spoke openings 460a.The center annular flange 482awill prevent the spokes 424 from accidentally falling out of the insertion portions 461 of the spoke openings 460a.Thus, the center annular flange 482aaids in the assembly of the rear wheel. In other words, the center annular flange 482amust be moved or deformed again before the spokes 424 can be removed from the spoke openings 460a.

[0182] The seal support 443a,as seen in FIGS. 33 and 34, is a substantially tubular member constructed of a relatively hard rigid material, such as a hard plastic material. The configuration of seal support 443ashould basically compliment the interior surface of the spoke seal 442a.In other words, the seal support 443ais located within the interior bore of the spoke seal 442aso as to provide radial support to spoke seal 442a.In the illustrated embodiment, the seal support 443ahas a first tubular portion 470a,an annular flange 472aand a second annular or cylindrical portion 474a.When the seal support 443ais located within seal 442a,the exterior surfaces of the cylindrical portions 470aand 474acontact the step-shaped inner surface of the tubular section 480a.

[0183] Similar to the spoke seal 442a,the spoke seal 442bhas a tubular section 480band a center annular flange 482b.The center annular flange 482aextends in a circumferential direction about the tubular section 480a.Alternatively, the center annular flanges 482aand 482bof the spoke seals 442aand 442bcan each have a pair of center annular flanges. The end 484bof the tubular section 480bis configured to engage a ring member 488band an abutment 490bof the inner surface of the hub body 438. The end 486bof the tubular section 480bis configured to be engaged to the ring member 488band a part of the freewheel 444. Of course, the particular shape of the ends 484band 486bwill vary depending on the shape of the hub body 438 and its internal components. Preferably, the end 486bof the tubular section 480bhas an inwardly extending annular flange that contacts the outer surface of the ring member 488b.

[0184] When the rear hub 422 is assembled, an axial force is applied to the ends 484band 486bof the tubular section 480bto form annular seals therebetween. Accordingly, the spoke seal 442bisolates a second interior section of the interior passageway 452 from the remainder of the interior passageway 452. This interior section formed by the spoke seal 442bis continuous annular second space located beneath the spoke openings 460b.

[0185] Similar to the center annular flange 482a,the center annular flange 482bis preferably aligned with a radial plane passing through the centers axes of the insertion portions 461 of the second spoke openings 460b.Thus, the center annular flange 482bis positioned to axially separate the two retaining portions 462 of each of the second spoke openings 460bfrom each other. The center annular flange 482bis also positioned to keep spokes 424 in the retaining portions 462 of the second spoke openings 460b.Accordingly, when the enlarged heads 424cof the spokes 424 are inserted into the insertion portions 461 of the spoke openings 460b,the enlarged heads 424cof the spokes 424 contact the center annular flange 482b.The enlarged heads 424cthen pushes or deforms the center annular flange 482bone way or the other so that the enlarged heads 424cextends into the insertion portions 461 of the spoke openings 460b.The spokes 424 are then moved or slid into one of the two retaining portions 462 of each of the spoke openings 460b.The center annular flange 482bwill prevent the spokes 424 from accidentally falling out of the insertion portions 461 of the spoke openings 460b.Thus, the center annular flange 482baids in the assembly of the rear wheel. In other words, the center annular flange 482bmust be moved or deformed again before the spokes 424 can be removed from the spoke openings 460b.

[0186] The ring-shaped member 488bis non-rotatably coupled to the hub body 438. The ring member 488bhas the freewheels 444 rotatably mounted thereon. The ring member 488balso provides radial support for the spoke seal 442b.

[0187] The freewheels, such as the freewheel 444, are well known in the bicycle art, and thus, the freewheel 444 will not be illustrated or discussed in detail herein. The freewheel 444 is used to transmit a driving force from the chain to the rear bicycle wheel in one rotation direction only. The freewheel 444 allows the bicycle to advance freely without any rotation of the pedals. The freewheel 444 is fastened to the rear hub 422 as integral part of the rear hub 422 in a conventional manner. The freewheel 444 has an outer tubular part 494, an inner tubular part 496 and a one-way clutch 498. The inner tubular part 496 is installed radially inwardly of the outer tubular part 494 so that the inner tubular part 496 is free to rotate relative to the outer tubular part 494. The one-way clutch 498 is installed between the outer tubular part 494 and inner tubular part 496 for transmitting the driving force from the outer tubular part 494 to the inner tubular part 496 in one rotational direction only. The outer tubular part 494 has a plurality of gears or sprockets (not shown) mounted thereon, while the inner tubular part 496 is usually mounted on the hub axle 436.

[0188] As seen in FIGS. 35 and 36, a spoke opening cover 500 in accordance with another embodiment of the present invention is illustrated for use with the rear hub 422 of FIGS. 32 and 33. Of course, the spoke opening cover 500 can be used with other hubs disclosed herein. Although for purposes of brevity, the spoke opening cover 500 will only be illustrated with the rear hub 422.

[0189] The spoke opening cover 500 is used to limit or prevent contaminants from entering the hub body 438 via the spoke openings 460aor 460b,respectively. The spoke opening cover 500 can be used instead of the spoke seals 442aand 442bor in conjunction with the spoke seals 442aand 442b.The spoke opening cover 500 basically has a resilient tubular body 501 constructed from a flexible material such as rubber. The tubular body 501 of the spoke opening covers 500 are configured and dimensioned to snugly fit around the bicycle hub body 438 within the annular grooves 439aand 439band to be substantially flush with the outer surface of the hub body 438 as seen in FIG. 32. The spoke opening cover 500 is installed on each end of the hub body 438 prior to installation of spokes 424. Of course, the annular grooves 439cand 439bcan receive other types of spoke opening covers. For example, spoke opening covers 100′ or 100″ can be positioned within the annular grooves 439aand 439bso that the outer surfaces of the spoke opening covers 100′ or 100″ are flush with the outer surface of the hub body 438.

[0190] 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 description 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.