MODULAR BICYCLE TRAINER

Abstract

In order to allow for easier design, easier shipping, and simple assembly and upgrade to functional systems, a modular bicycle trainer that separates components into modules corresponding with functional systems is provided. The modular bicycle trainer includes a frame, a drive unit assembly, a handlebar assembly, a seat assembly, and a console.

Description

PRIORITY

This application claims the benefit of U.S. Provisional Patent Application No. 62/820,814, filed on Mar. 19, 2019, which is hereby incorporated by reference in its entirety.

BACKGROUND

1. Field of the Disclosure

The present disclosure is generally directed to a bicycle trainer, and more particularly, to a modular bicycle trainer.

2. Description of Related Art

Bicycle trainers are known in the art and are typically used for stationary indoor training on a bicycle. Existing or known bicycle trainers are sometimes configured such that a user is not able to use their own bicycle with the trainer. Instead, a bicycle trainer may be a single monolithic machine that is pre-assembled and delivered to a user. While such a bicycle trainer requires little or no assembly by the user, delivery is difficult due to the size, shape, and weight of the pre-assembled bicycle trainer, and customization and upgrade is difficult due to the monolithic nature of the bicycle trainer. Components such as, for example, base support legs, a display, a handlebar mast, and/or a seat mast may be removed for shipping, and a user or a technician may install these components after delivery.

SUMMARY

In one example, a drive unit for a bicycle trainer includes a housing, a body rotatably attached to the housing, and an axle rotatably attached to the housing. The axle is operatively connected to the body, such that the body is driveable via the axle. The drive unit also includes a motion resistor supported by the housing. The motion resistor is configured to apply a resistive force to the body when the body is rotating. The drive unit includes a first guide within or supported by the housing. The first guide corresponds to a second guide. The second guide is disposed on a frame of the bicycle trainer.

In one example, the first guide includes a plurality of openings through a portion of the frame. The second guide includes a plurality of captive fasteners. The drive unit is positionable on the frame, such that the plurality of captive fasteners extend through the plurality of openings.

In one example, the body is a flywheel.

In one example, the drive unit further includes a wheel rotatably attached to the housing. An axis of rotation of the wheel is in line with an axis of rotation of the axle. A diameter of the wheel is larger than a diameter of the flywheel. The drive unit further includes a belt or a chain disposed around the wheel. The axle is operatively connected to the flywheel via the wheel and the belt or the chain.

In one example, the wheel is a first wheel. The drive unit further includes a second wheel rotatably attached to the housing. An axis of rotation of the second wheel is in line with an axis of rotation of the flywheel. A diameter of the second wheel is smaller than the diameter of the first wheel and the diameter of the flywheel. The belt or the chain is disposed around the second wheel. The axle is operatively connected to the flywheel via the first wheel, the belt or the chain, and the second wheel.

In one example, the motion resistor includes an electromagnet supported by the housing at a fixed distance relative to the flywheel, a permanent magnet supported by the housing at a variable distance relative to the flywheel, a generator, or a mechanical motion resistor that is movable into contact with the flywheel.

In one example, the motion resistor includes the mechanical motion resistor. The mechanical motion resistor includes a plunger that is movable into contact with the flywheel.

In one example, the housing has a first portion and a second portion. The second portion of the housing extends away from a side of the first portion of the housing. The first guide is disposed within the second portion of the housing.

In one example, the second portion of the housing weighs at least as much as a remainder of the drive unit.

In one example, the flywheel is attached to the housing at or adjacent to the side of the first portion of the housing, such that the flywheel and the second portion of the housing are disposed on a same side of the first portion of the housing.

In one example, the side of the first portion of the housing is a first side of the first portion of the housing. The wheel is attached to the housing at or adjacent to a second side of the first portion of the housing. The second side of the first portion of the housing is opposite the first side of the first portion of the housing.

In one example, the axle extends through at least part of the first portion of the housing and at least part of the second portion of the housing.

In one example, a bicycle trainer includes a drive unit and a frame. The drive unit includes a housing, a drivable flywheel rotatably attached to the housing, and a motion resister supported by the housing. The motion resister is configured to apply a force to the drivable flywheel. The drive unit also includes a first guide within or supported by the housing. The frame includes one or more supports and a second guide within or supported by the one or more supports, the second guide corresponds to the first guide. The drive unit is removably attached to the frame via the first guide and the second guide.

In one example, the first guide includes a plurality of holes through a portion of the housing of the drive unit. The second guide includes a plurality of captive fasteners extending away from a support of the one or more supports. The plurality of captive fasteners extend through the plurality of holes, and the portion of the housing of the drive unit abuts the support of the frame when the drive unit is attached to the frame.

In one example, the support is a first support. The one or more supports further include a second support and a third support forming a v-shape. The first support extends between the second support and the third support, such that a length of the first support defines a position of the first support and the drive unit along the second support and the third support.

In one example, the motion resister includes an electromagnet supported by the housing at a fixed distance relative to the drivable flywheel, a permanent magnet supported by the housing at a variable distance relative to the drivable flywheel, a generator, or a mechanical motion resistor that is movable into contact with the drivable flywheel.

In one example, the housing has a first portion and a second portion. The second portion of the housing extends away from a side of the first portion of the housing. The first guide is disposed within the second portion of the housing. The drivable flywheel is attached to the first portion of the housing at or adjacent to the side of the first portion of the housing, such that the drivable flywheel and the second portion of the housing are disposed on a same side of the first portion of the housing.

In one example, a frame for a bicycle trainer includes two supports, a mounting plate extending between the two supports, and one or more captive fasteners extending away from the mounting plate. The one or more captive fasteners correspond to one or more openings through a housing of a drive unit, respectively. The drive unit includes a drivable flywheel rotatably attached to the housing, and a motion resister supported by the housing and configured to apply a force to the flywheel.

In one example, the one or more captive fasteners include a plurality of captive fasteners extending away from the mounting plate. The one or more openings through the housing of the drive unit include a plurality of openings through the housing of the drive unit. The plurality of openings correspond to the plurality of captive fasteners, respectively.

In one example, the two supports form a v-shape. The mounting plate extends between the two supports, such that a length of the mounting plate defines a position of the mounting plate along the two supports.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects, features, and advantages of the present invention will become apparent upon reading the following description in conjunction with the drawing figures, in which:

FIG. 1 shows a perspective view of one example of a drive unit;

FIG. 2 shows a close-up perspective view of one example of an attachment portion of a housing of the drive unit of FIG. 1;

FIG. 3 shows a perspective view of one example of a mount positioned on a frame portion of a modular bicycle trainer;

FIG. 4 shows a close-up perspective view of one example of a mount positioned on a frame portion of a modular bicycle trainer and including fasteners;

FIG. 5 shows a first perspective view of one example of a drive unit and a frame portion of a modular bicycle trainer in an attached state;

FIG. 6 shows a second perspective view of one example of a drive unit and a frame portion of a modular bicycle trainer in an attached state;

FIG. 7 shows a front view of one example of a drive unit and a frame portion of a modular bicycle trainer in an attached state; and

FIG. 8 shows a perspective view of one example of a modular bicycle trainer.

DETAILED DESCRIPTION OF THE DISCLOSURE

The modular bicycle trainer of the present embodiments separates components of a bicycle trainer into modules that correspond with functional systems. This allows for easier design, easier shipping, and simple assembly and upgrade to the functional systems over a lifetime of the bicycle trainer.

Characteristics of the modular bicycle trainer may define separation of the modules. For example, rider touchpoints and/or engineering interaction may define the separation of the modules. With respect to rider touchpoint, the rider interacts with the modular bicycle trainer at a discrete number of touch points: feet, hands, seat, and eyes. Boundaries of the modules may be defined by the engineering systems that serve each of the discrete number of touch points. With respect to engineering interaction, the modules may maximize the engineering complexity contained within each of the modules, while engineering complexity of interfaces and/or interactions between the modules is minimized.

The modular bicycle trainer of the present embodiments may include any number of modules including, for example, a frame, a drive unit assembly, a handlebar assembly, a seat assembly, and a console. The modular bicycle trainer may include more, fewer, and/or different modules.

The drive unit assembly includes components used to create resistance and road feel at the feet of the user. For example, a drive unit includes a flywheel mass, an adjustable load device, an electronic controller, one or more adjustable load sensors, one or more drive pulleys or chainrings, a belt or chain tensioning device, a belt or chain, crank arms, and pedals. The drive unit may include more, fewer, and/or different components. For example, the drive unit may also include bearings and shrouds. In one embodiment, the drive unit may be a direct design where the crank arms drive a flywheel or a load unit directly without a belt or a chain. In another embodiment, the crank arms may drive the load unit through a gearbox (e.g., a planetary gear system).

The drive unit is attached to the frame in a simple and secure manner. Mounting points and dimensional control of a drivetrain are included within the drive unit. A number of fasteners used to attach the drive unit to the frame is minimized. For example, guide pins and/or another locator aids alignment and makes it easy for the user to properly install the drive unit on the frame.

The frame and the drive unit are each heavy (e.g., 40 lbs. or more each) and bulky. Due to the modular nature of the bicycle trainer of the present embodiments, the frame and the drive unit may be shipped to the user separately and assembled by the user after delivery. If the modular bicycle trainer is to be moved a significant distance during the lifetime of the modular bicycle trainer, the modular bicycle trainer may be disassembled, moved, and reassembled by the user.

Turning now to the drawings, FIG. 1 illustrates a perspective view of one example of a drive unit 50. The drive unit 50 includes a housing 52 (e.g., a swing arm) that supports a drive 54 (e.g., an axle or a spindle), a load unit 56, and one or more other components (see FIGS. 6 and 7). The load unit 56 includes, for example, a flywheel 58 (e.g., a rotatable body) that is rotationally coupled to (e.g., directly or indirectly) the drive 54 (see FIGS. 6 and 7) and electronics 60 configured to control the load unit 56. Crank arms with pedals (not shown) are attachable to opposite sides of the drive 54, such that the user may pedal the modular bicycle trainer.

The electronics 60 are positioned on and/or supported by, for example, a support 62. The support 62 is, for example, a plate that is removably attached to the housing 52 of the drive unit 50. In other embodiments, the support 62 is configured differently. For example, the support 62 may be a printed circuit board (PCB). In another example, the support 62 is part of the housing 52.

The plate 62 is removably attached to the housing 52 of the drive unit 50 with, for example, one or more connectors 64 (e.g., screws and/or nut/bolt combinations). In one embodiment, the plate 62 is attached to the housing 52 of the drive unit 50 such that distances between components supported by the plate 62 (e.g., a permanent magnet or an electromagnet) and the flywheel 58 may be varied. In one embodiment, the drive unit 50 includes an actuator (e.g., an electric motor) configured to move the plate 62 and/or a component supported by the plate (e.g., the permanent magnet or the electromagnet) away from and towards the flywheel 58. In other embodiments, the plate 62 may be removably attached to other components of the modular bicycle trainer such as, for example, the frame.

The electronics 60 include any number of components including, for example, an electromagnet 66. The electromagnet 66 may include a plurality of wires 68 wrapped around and/or disposed on a core 70 of a magnetic material. The electromagnet 66 is magnetically coupled with a permanent magnet or a magnetic material on the flywheel 58. In one embodiment, positioning of the electromagnet 66 and the permanent magnet are reversed: The electromagnet 66 is positioned on the flywheel 58, and the permanent magnet is positioned on the plate 62. In one embodiment, the electromagnet 66 is formed on opposite sides of the core 70. In yet another embodiment, a plurality of cores 70 (e.g., two cores on opposite sides of the flywheel 58) are attached to the plate 62, and a plurality electromagnets 66 are formed on the plurality of cores 70.

Current flows from a source external to the drive unit and through the electromagnet 66 via a lead line 72 and a connector 74. The source may be at the wall in a location at which the modular bicycle trainer is installed or a power source (e.g., a battery) on or separate from the modular bicycle trainer. The connector 74 may be directly or indirectly (e.g., via one or more intermediate components) connected to the source.

In other embodiments, the current flows from the external source and is controlled for other types of movement resistors. For example, the current may be controlled to activate a motor to change a distance between a permanent magnet on the plate 62 and the flywheel 58, to power a generator with windings on the flywheel 58 and the plate 62, respectively, and/or to activate an actuator configured to move a plunger into towards the flywheel 58.

The electromagnet 66 generates a magnetic field when the source is connected to the electromagnet 66 via the lead line 72 and the connector 74 and current flows through the plurality of wires 68. The magnetic field interacts with the flywheel 58 (e.g., made of an electrically conductive material) and resists rotation of the flywheel 58. The electromagnet 66, when interacting with the permanent magnet or the magnetic material of the flywheel 58, acts, for example, as a motion resistor with respect to the flywheel 58. Rotation of the drive 54 rotationally coupled to the flywheel 58 is thus also resisted. An amount of rotational resistance may be set based on a power provided by the source to the electromagnet and/or a distance between the electromagnet 66 and the permanent magnet or the magnetic material of the flywheel 58. In one embodiment, the rotational resistance is provided mechanically. For example, a plunger with a felt tip (e.g., the motion resister) is in contact with a surface (e.g., a circumferential surface or a radial surface) of the flywheel 58 to resist rotation of the flywheel 58 with friction. The amount of rotational resistance may be set based on a force applied to the surface of the flywheel 58 by the rotational resistor. Other mechanical motion resisters may be provided. For example, calipers may squeeze pads against opposite sides of the flywheel 58.

In other embodiments, the rotational resistance may be provided by a permanent magnet supported by the housing 52 and/or the plate 62 at a variable distance relative to the flywheel 58 (e.g., via a servo motor), and/or a generator with stator windings supported by the housing 52 and/or the plate 62, and rotor windings supported by the flywheel 58. The drive unit 50 may provide the rotational resistance in more than one of these ways (e.g., with the electromagnet 66 and the mechanical motion resister).

The electronics 60 may also include a PCB 76 supported by the plate 62. The PCB 76 may support and electrically connect any number of electronic components including, for example, a processor, a memory, one or more communication devices (e.g., a wireless transmitter, antennas), one or more sensors, and/or other electronic components. The processor may be in communication with electronic components (e.g., one or more communication devices) of a handlebar assembly via the one or more communication devices. The one or more communication devices of the drive unit 50 may be paired with the one or more communication devices of the handlebar assembly and/or other modules of the modular bicycle trainer prior to communication between, for example, the drive unit 50 and the handlebar assembly. The processor may determine a power to be provided by the source and/or how much resistance to the rotation of the flywheel 58 is to be provided (e.g., a proximity of the plate 62 relative to the flywheel 58, power to be provided to the motor moving the plunger, and/or power to be provided to the generator) to be provided based on data received from the electronic components of the handlebar assembly.

For example, the processor may determine the power to be provided based on a user input (e.g., generated in response to the user pressing a resistance up button at the handlebar assembly) and instruct a communication device electrically connected to the processor via the PCB 76 to transmit the determined power to a communication device (e.g., a wireless transmitter, antennas) associated with the source and/or a controller configured to control current to the electromagnet 66. In another example, the processor determines a distance between, for example, a permanent magnet and the flywheel 58 to be provided based on the user input and instructs the communication device to transmit the determined distance to a communication device associated with a controller configured to control the actuator that moves the plate 62 and/or the core 70. The amount of rotational resistance may thus be controlled based on user input at, for example, the handlebar assembly.

The drive unit 50 is attached to the frame of the modular bicycle trainer via an attachment portion 80 of the housing 52. For example, a remainder of the housing 52 (e.g., excluding the attachment portion 80 of the housing 52) forms a first portion 81 of the housing 52, and the attachment portion 80 of the housing 52 forms a second portion of the housing 50. The housing 52 has an outer surface 82 from which the attachment portion 80 extends. In other words, the second portion 80 of the housing 52 extends away from a side (e.g., a first side) of the first portion 81 of the housing 52. The attachment portion 80 may be formed contiguously with the housing 52 or may be separate from and attached to the housing 52 in any number of ways (e.g., with one or more fasteners).

The drive unit 50 may be heavy (e.g., 25-50 lbs) and may be an irregular shape with a center of gravity at a position displaced from a frame mounting location. As discussed below, a mount for mounting the drive unit 50 to the frame may include captive fasteners (e.g., threaded bolts) or pins, allowing initial positioning of the drive unit 50 on the frame with gravity, not with the tightening of nuts, for example, on the threaded bolts. Alternatively, the attachment portion 80 may weigh as much as or more than the rest of the drive unit 50 such that the drive unit 50 may be positioned on the mount without the drive unit 50 tipping over relative to the frame. This may facilitate attachment of the drive unit 50 on the frame by the user.

Referring to FIG. 2, the attachment portion 80 includes one or more openings 84 (e.g., a first guide) to further facilitate attachment of the drive unit 50 on the frame. The one or more openings 84 may be through holes or blind holes. The one or more openings 84 may be threaded or unthreaded.

As shown in the example of FIG. 2, the attachment portion 80 includes four openings 84 extending from a first side 86 of the attachment portion 80, through the attachment portion 80, to a second side 88 of the attachment portion 80 opposite the first side 86. The drive 54 extends at least partially through the attachment portion 80 and at least partially through the first portion 81 of the housing 52. In one example, the drive 54 extends all the way through the attachment portion 80 and the first portion 81 of the housing 52 (e.g., all the way through the housing 52). The drive 54 is, for example, a spindle, and ends of the spindle 54 are shaped and sized to facilitate attachment of crank arms with pedals for use of the modular bicycle trainer by the user.

The four openings 84 include two first openings 84a adjacent to a first edge 90 and two second openings 84b adjacent to a second edge 92 opposite the first edge 90. Positioning of the first openings 84a and the second openings 84b is symmetrical about the spindle 54 extending through the attachment portion 80. The attachment portion 80 may include more or fewer openings 84, and/or the openings 84 may be positioned differently relative to each other and/or relative to the first edge 90 and/or the second edge 92.

Referring to FIG. 3, the openings 84 through the attachment portion 80 of the housing 52 may correspond to openings 94 (e.g., four openings) through a mount 96 for the drive unit 50 supported by a frame 100 of the modular bicycle trainer. The openings 94 through the mount 96 at least partially form a second guide (e.g., with captive fasteners). The frame 100 of the modular bicycle trainer includes a base 102 and one or more supports 104 extending away from the base 102. For example, the one or more supports 104 include two supports 104 extending in directions away from the base 102, such that the two supports 104 form a V-shape. The two supports 104 may form a V-shape in that the two supports 104 extend away from each other from the base 102 (e.g., with or without contacting each other). A seat assembly may be attached to a first support 104a of the two supports 104, and a handlebar assembly may be attached to a second support 104b of the two supports 104.

The mount 96 may be configured in any number of ways including, for example, as a mounting plate. The first support 104a of the frame 100, the second support 104b of the frame 100, and/or the mounting plate 96 may include notches and/or the mounting plate 96 may be sized (e.g., of a particular length) such that positioning of the mounting plate 96 in a predetermined position and orientation (e.g., with desired tolerances) relative to other mounting locations on the frame (e.g., for the seat assembly and the handlebar assembly) is facilitated. Once the mounting plate 96 is positioned in the predetermined position and orientation, the mounting plate 96 may be attached to the first support 104a and/or the second support 104b in any number of ways including, for example, with one or more connectors (e.g., fasteners). Alternatively, the attachment of the mounting plate 96 to the first support 104a and the second support 104b may be a friction fit attachment.

In one embodiment, the first support 104a and the second support 104b include a number of sets of notches at different heights relative to the base 102, respectively. Different sized mounting plates 96 (e.g., with different lengths) may then be used depending on the height of the notches used relative to the base 102. For example, the length of the mounting plate 96 may define a position of the mounting plate 96, and thus the drive unit 50, along the first support 104a and the second support 104b.

Referring to FIG. 4, connectors 120 may extend through the openings 94 through the mount 96 and the openings 84 through the attachment portion 80 of the housing 52 of the drive unit 50. When the attachment portion 80 of the housing 52 of the drive unit 50 is attached to the mount 96 via the connectors 120 through the openings 84 through the attachment portion 80 of the housing 52 of the drive unit 50, the attachment portion 80 may abut the mount 96.

The number of connectors 120 may be equal to the number of openings 94 through the mount 96 and the number of openings 84 through the attachment portion 80 of the housing 52 of the drive unit 50. Alternatively, the number of connectors 120 may be less than the number of the openings 94 through the mount 96 and/or the number of the openings 84 through the attachment portion 80 of the housing 52 of the drive unit 50.

The connectors 120 may include any number of different types of connectors (e.g., fasteners) including, for example, threaded bolts 122. The connectors 120 may include captive fasteners that are captive at the mounting plate 96 (e.g., captive threaded bolts 122). Other connectors 120 may be used. For example, alternative or in addition to the threaded fasteners, the connectors 120 may include clamps (e.g., over-center clamps), circular or other geometric interlocking geometries, quick release mechanisms, guide pins, and/or other connectors.

FIG. 5 shows one example of the drive unit 50 and the frame 100 in an attached state. In the example shown, the drive unit 50 is attached to the frame 100 with the threaded bolts 122 and threaded nuts 124. In one embodiment, the threaded nuts 124 include tapered ends (e.g., similar to a tapered lug nut on a wheel of a road vehicle), respectively, that engage the attachment portion 80 of the housing 52 of the drive unit 50. The attached state using, for example, the threaded bolts 122 and the threaded nuts 124, is a rigid attachment. The drive unit 50 does not flex or move relative to the frame outside of a predetermined tolerance during operation of the modular bicycle trainer, even under heavy load.

During assembly of the modular bicycle trainer, the user places the drive unit 50 in a predetermined position relative to the frame 100 by positioning the drive unit 50 over the mounting plate 96, aligning the threaded bolts 122, for example, with the openings 84 through the attachment portion 80 of the housing 52 of the drive unit 50, and moving the drive unit 50 onto the mounting plate 96 such that the threaded bolts 122 extend through the openings 84 through the attachment portion 80 of the housing 52 of the drive unit 50. In such an attachment, the drive unit 50 is not sufficiently rigidly attached to the frame 100 for operation of the modular bicycle trainer, but the drive unit 50 is located and will not tip or fall off of the frame 100. The user may then use both hands to install the threaded nuts 124, for example, on the threaded bolts 122 and rigidly secure the drive unit 50 to the frame 100.

Referring to FIGS. 6 and 7, the one or more other components of the drive unit 50 include a large pulley 140 (e.g., a large wheel) rotationally coupled to the drive 54 (e.g., via a direct connection such that an axis of rotation of the large pulley 140 is in line with an axis of rotation of the drive 54) and a small pulley 142 (e.g., a small wheel) rotationally coupled to the large pulley 140. The small pulley 142 is rotationally coupled to the large pulley 140 with, for example, a belt or a chain 144. The small pulley 142 is rotationally coupled with the flywheel 58 (e.g., via a direct connection such that an axis of rotation of the flywheel 58 is in line with an axis of rotation of the small pulley 142). The one or more other components of the drive unit 50 may include any number of additional and/or different components including, for example, an additional pulley 146 (e.g., an idler pulley). The additional pulley 146, for example, is rotationally coupled to the large pulley 140 and the small pulley 142 with the belt or the chain 144. The large pulley 140, the small pulley 142, and, for example, the additional pulley 146 are rotatably supported by the housing 52 of the drive unit (e.g., via bearings attached to the housing 52).

In one embodiment, a diameter of the large pulley 140 is larger than a diameter of the flywheel 58 and larger than a diameter of the small pulley 142; the diameter of the flywheel 58 is larger than the diameter of the small pulley 142. The flywheel 58, the large pulley 140, and the small pulley 142 may be made of any number of materials. For example, the flywheel 58, the large pulley 140, and the small pulley 142 may be made of aluminum. One or more of the flywheel 58, the large pulley 140, and the small pulley 142 may be made of different materials.

All mounting locations of, for example, the large pulley 140, the small pulley 142, the additional pulley 146, the flywheel 58, the electromagnet 66, the core 70, the plate 62, the electromagnet 66, and/or other components of the drive unit 50 are within or on the housing 52 (e.g., the first portion 81 of the housing 52) of the drive unit 50. In other words, none of the mounting locations of, for example, the large pulley 140, the small pulley 142, and the additional pulley 146 are on the frame 100. These components may be preassembled (e.g., prior to shipping to the user) and thus part of the drive unit 50 module. Accordingly, dimensional control locations and tolerances for these components are isolated to the drive unit 50.

In the embodiment shown in FIGS. 6 and 7, the attachment portion 80 and the flywheel 58 are disposed on a same side of the first portion 81 of the housing 52 (e.g., at or adjacent to the first side of the first portion 81 of the housing 52), and the large pulley 140, the small pulley 142, the additional pulley 146, and the belt or chain 144 are disposed on a same other side of the first portion 81 of the housing 52 (e.g., at or adjacent to a second side of the first portion 81 of the housing 52, which is opposite the first side of the first portion 81 of the housing 52).

The drive unit 50 may include additional components. For example, the drive unit 50 includes safety shrouds that protect the user from injury at the large pulley 140, the small pulley 142, the additional pulley 146, the flywheel 58, and/or additional pinch points. All of the safety shrouds and other protection devices may be attached to the drive unit 50 such that all corresponding dimensional control is provided in the drive unit 50.

FIG. 8 shows one example of a modular bicycle trainer 200. The modular bicycle trainer 200 of the present embodiments may include any number of modules including, for example, the frame 100, a drive unit assembly (e.g., the drive unit 50), a handlebar assembly 201 (e.g., control bars), a seat assembly 202, and a console 204. The modular bicycle trainer 200 may include more, fewer, and/or different modules.

The frame 100 includes, for example, two supports (e.g., the first support 104a and the second support 104b), the base 102 including base support legs 206a, 206b, and 206c, a seat mast 208, a handlebar mast 210, a console mount 212, and an electronic device mount (e.g., for a tablet or phone). The frame 100 may include more, fewer, and/or different components. For example, the frame 100 may also include water bottle mounts and/or exercise accessory mounts (e.g., for weights). As another example, the frame 100 may include more or fewer supports 104 and/or base support legs 206 and/or different supports 104 and/or base support legs 206 (e.g., different shapes).

The frame 100 includes mounting locations for the other modules. Mounting mechanisms (e.g., the mount 96 and the fasteners 120) for mounting the other modules are configured to minimize complexity of assembly. The frame 100 may be further disassembled to reduce a volume during shipping, while allowing for reassembly by the user.

The handlebar assembly 201 includes primary surfaces and controls 216 the user (e.g., the rider) uses while riding the modular bicycle trainer 200. For example, the handlebar assembly 201 includes a handlebar mount 218 (e.g., a mounting mechanism), a handlebar 220, and the user controls 216. The handlebar assembly 201 may include more, fewer, and/or different components.

In an embodiment, in which the handlebar assembly 201 includes the mounting mechanism 218. the mounting mechanism 218 allows the handlebar 220 to be attached to the handlebar mast 210. The mounting mechanism 218 is configured so that the user may detach and reattach the handlebar assembly 201 quickly and without tools. This allows multiple users to use a same modular bicycle trainer 200 with multiple different handlebars 220 (e.g., corresponding to the different users).

Electronic components of the handlebar assembly 201 are connected to the drive unit 50, the console 204, and/or other electronics via wired or wireless communication. The handlebar assembly 201 may be powered through a wired power supply, batteries, and/or in another way. Electronic technology and controls for bicycle trainers may evolve over time. The modular design of the handlebar assembly 201 allows the user to upgrade the handlebar assembly 201 over the life of the bicycle trainer 200 to a newer generation handlebar assembly 201 with different or improved electronic technology and/or controls.

The seat assembly 202 includes, for example, a seat mount 222 (e.g., a saddle mount mechanism) and a seat 224 (e.g., a saddle). The seat assembly 202 may include more, fewer, and/or different components.

The saddle mount mechanism 222 allows the seat assembly 202 to be attached to the seat mast 208. The saddle mount mechanism 222 is configured so that the user may detach and reattach the seat assembly 202 quickly and without tools. This allows multiple users to use the same modular bicycle trainer 200 with multiple different seats 224 (e.g., corresponding to the different users). The saddle mount mechanism 222 may preserve an angle or a tilt of the saddle 224 between installations, as this may be an important adjustment for comfort while riding.

The modular bicycle trainer 200 of the present disclosure may include the console 204 (e.g., including one or more displays). The console 204 may include, for example, a display screen, a computer processing unit (CPU), and wired or wireless networking equipment. The console 204 may include more, fewer, and/or different components. For example, the console 204 may include secondary user controls such as volume up and down and/or a power control. The console 204 mounts to the frame 100 and is powered by an external source or batteries. The console 204 communicates with other electronic systems of the modular bicycle trainer 200 (e.g., the handlebar assembly and/or the drive unit) wirelessly and/or via one or more wired connections

The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.

While this specification contains many specifics, these should not be construed as limitations on the scope of the invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

Similarly, while operations and/or acts are depicted in the drawings and described herein in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that any described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

One or more embodiments of the disclosure may be referred to herein, individually and/or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, are apparent to those of skill in the art upon reviewing the description.

The Abstract of the Disclosure is provided to comply with 37 C.F.R. § 1.72(b) and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, various features may be grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all of the features of any of the disclosed embodiments. Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.

It is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.

Claims

1. A drive unit for a bicycle trainer, the drive unit comprising:

a housing;

a body rotatably attached to the housing;

an axle rotatably attached to the housing, the axle being operatively connected to the body, such that the body is driveable via the axle;

a motion resistor supported by the housing, the motion resistor being configured to apply a resistive force to the body when the body is rotating; and

a first guide within or supported by the housing, the first guide corresponding to a second guide, the second guide being disposed on a frame of the bicycle trainer.

2. The drive unit of claim 1, wherein the first guide includes a plurality of openings through a portion of the frame,

wherein the second guide includes a plurality of captive fasteners,

wherein the drive unit is positionable on the frame, such that the plurality of captive fasteners extend through the plurality of openings.

3. The drive unit of claim 1, wherein the body is a flywheel.

4. The drive unit of claim 3, further comprising:

a wheel rotatably attached to the housing, an axis of rotation of the wheel being in line with an axis of rotation of the axle, a diameter of the wheel being larger than a diameter of the flywheel; and

a belt or a chain disposed around the wheel,

wherein the axle is operatively connected to the flywheel via the wheel and the belt or the chain.

5. The drive unit of claim 4, wherein the wheel is a first wheel,

wherein the drive unit further comprises a second wheel rotatably attached to the housing, an axis of rotation of the second wheel being in line with an axis of rotation of the flywheel, a diameter of the second wheel being smaller than the diameter of the first wheel and the diameter of the flywheel,

wherein the belt or the chain is disposed around the second wheel, and

wherein the axle is operatively connected to the flywheel via the first wheel, the belt or the chain, and the second wheel.

6. The drive unit of claim 3, wherein the motion resistor comprises:

an electromagnet supported by the housing at a fixed distance relative to the flywheel;

a permanent magnet supported by the housing at a variable distance relative to the flywheel;

a generator; or

a mechanical motion resistor that is movable into contact with the flywheel.

7. The drive unit of claim 6, wherein the motion resistor comprises the mechanical motion resistor, and

wherein the mechanical motion resistor includes a plunger that is movable into contact with the flywheel.

8. The drive unit of claim 4, wherein the housing has a first portion and a second portion, the second portion of the housing extending away from a side of the first portion of the housing, and

wherein the first guide is disposed within the second portion of the housing.

9. The drive unit of claim 8, wherein the second portion of the housing weighs at least as much as a remainder of the drive unit.

10. The drive unit of claim 8, wherein the flywheel is attached to the housing at or adjacent to the side of the first portion of the housing, such that the flywheel and the second portion of the housing are disposed on a same side of the first portion of the housing.

11. The drive unit of claim 10, wherein the side of the first portion of the housing is a first side of the first portion of the housing,

wherein the wheel is attached to the housing at or adjacent to a second side of the first portion of the housing, the second side of the first portion of the housing being opposite the first side of the first portion of the housing.

12. The drive unit of claim 9, wherein the axle extends through at least part of the first portion of the housing and at least part of the second portion of the housing.

13. A bicycle trainer comprising:

a drive unit comprising: a housing; a drivable flywheel rotatably attached to the housing; a motion resister supported by the housing and configured to apply a force to the drivable flywheel; and a first guide within or supported by the housing;

a frame comprising: one or more supports; a second guide within or supported by the one or more supports, the second guide corresponding to the first guide,

wherein the drive unit is removably attached to the frame via the first guide and the second guide.

14. The bicycle trainer of claim 13, wherein the first guide includes a plurality of holes through a portion of the housing of the drive unit,

wherein the second guide includes a plurality of captive fasteners extending away from a support of the one or more supports, and

wherein the plurality of captive fasteners extend through the plurality of holes, and the portion of the housing of the drive unit abuts the support of the frame when the drive unit is attached to the frame.

15. The bicycle trainer of claim 14, wherein the support is a first support, and

wherein the one or more supports further include a second support and a third support forming a v-shape, the first support extending between the second support and the third support, such that a length of the first support defines a position of the first support and the drive unit along the second support and the third support.

16. The bicycle trainer of claim 13, wherein the motion resister comprises:

an electromagnet supported by the housing at a fixed distance relative to the drivable flywheel;

a permanent magnet supported by the housing at a variable distance relative to the drivable flywheel;

a generator; or

a mechanical motion resistor that is movable into contact with the drivable flywheel.

17. The bicycle trainer of claim 13, wherein the housing has a first portion and a second portion, the second portion of the housing extending away from a side of the first portion of the housing,

wherein the first guide is disposed within the second portion of the housing, and

wherein the drivable flywheel is attached to the first portion of the housing at or adjacent to the side of the first portion of the housing, such that the drivable flywheel and the second portion of the housing are disposed on a same side of the first portion of the housing.

18. A frame for a bicycle trainer, the frame comprising:

two supports;

a mounting plate extending between the two supports; and

one or more captive fasteners extending away from the mounting plate, the one or more captive fasteners corresponding to one or more openings through a housing of a drive unit, respectively, the drive unit including a drivable flywheel rotatably attached to the housing, and a motion resister supported by the housing and configured to apply a force to the flywheel.

19. The frame of claim 18, wherein the one or more captive fasteners include a plurality of captive fasteners extending away from the mounting plate, and

wherein the one or more openings through the housing of the drive unit include a plurality of openings through the housing of the drive unit, the plurality of openings corresponding to the plurality of captive fasteners, respectively.

20. The frame of claim 18, wherein the two supports form a v-shape, the mounting plate extending between the two supports, such that a length of the mounting plate defines a position of the mounting plate along the two supports.