# US 11,999,191 B1 · Bicycle drive assembly > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,999,191 B1 - Document ID: US11999191B1 - Status: Granted - Kind: B1 - Application number: 18/072,789 - Filed: 2022-12-01 - Published: 2024-06-06 - Granted: 2024-06-04 - Earliest claimed: 2022-12-01 - Assignees: ENVE Composites, LLC - Applicants: ENVE Composites, LLC - Inventors: Kevin E. Nelson - Web page: https://patentgrep.com/patent/US11999191B1 ## CPC - B60B 27/047: {comprising a freewheel mechanisms} - B60B 27/023: {specially adapted for bicycles} - F16D 41/30: with hinged pawl co-operating with teeth, cogs, or the like - F16D 41/36: with clutching ring or disc axially shifted as a result of lost motion between actuating members - B60B: VEHICLE WHEELS (making wheels or wheel parts by rolling B21H1/00, by forging, hammering or pressing B21K1/28); CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION - F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES ## Abstract A bicycle drive assembly may include an axle, a hub shell rotatably mounted on the axle by a first bearing, a free hub rotatably mounted on the axle by a second bearing, and a ratchet mechanism releasably coupling the free hub to the hub shell to transmit torque from the free hub to the hub. The ratchet mechanism may include a first ratchet ring having an inner surface joined to the hub shell for rotation with the hub shell and a second ratchet ring having an inner surface joined to the free hub for rotation with the free hub. The first ratchet ring and the second ratchet ring encircle and radially overlap the first bearing and the second bearing, respectively. At least one spring resiliently biases the first ratchet face and the second ratchet face into engagement to transmit torque from the free hub to the hub shell. ## Claims ### Claim 1 A bicycle drive assembly comprising: an axle extending along an axis; a hub shell rotatably mounted on the axle by a first bearing; a free hub rotatably mounted on the axle by a second bearing; and a ratchet mechanism releasably coupling the free hub to the hub shell to transmit torque from the free hub to the hub, the ratchet mechanism comprising: a first ratchet ring having an inner surface joined to the hub shell for rotation with the hub shell, the first ratchet ring encircling and radially overlapping the first bearing, the first ratchet ring having a first ratchet face; a second ratchet ring having an inner surface joined to the free hub for rotation with the free hub, the second ratchet ring encircling and radially overlapping the second bearing; and at least one spring resiliently biasing the first ratchet face and the second ratchet face into engagement to transmit torque from the free hub to the hub shell, wherein the first ratchet ring has an L-shaped cross section having a first leg and a second leg, the second leg having a series of splines in engagement with the hub shell, wherein an entirety of the first ratchet face is radially outward of the series of splines, and wherein the first leg extends radially outward from the second leg and comprises the first ratchet face. ### Claim 2 (depends on 1) The bicycle drive assembly of claim 1, wherein the inner surface of the second ratchet ring is interlocked to the free hub to transmit torque from the free hub to the second ratchet ring and wherein the inner surface of the first ratchet ring is interlocked to the hub shell to transmit torque from the first ratchet ring to the hub shell. ### Claim 3 (depends on 2) The bicycle drive assembly of claim 2, wherein the inner surface of the first ratchet ring and the inner surface of the second ratchet ring are each splined. ### Claim 4 (depends on 3) The bicycle drive assembly of claim 3, wherein the first ratchet face has at least 40 teeth. ### Claim 5 (depends on 4) The bicycle drive assembly of claim 4, wherein the free hub is formed from a first material having a first hardness and wherein the second ratchet ring is formed from a second material having a second hardness greater than the first hardness. ### Claim 6 (depends on 5) The bicycle drive assembly of claim 5, wherein the free hub is formed from aluminum alloy and wherein the second ratchet ring is formed from steel or titanium alloy. ### Claim 7 (depends on 3) The bicycle drive assembly of claim 3, wherein the first ratchet face has at least 60 teeth. ### Claim 8 (depends on 3) The bicycle drive assembly of claim 3, wherein the first ratchet face has at least 80 teeth. ### Claim 9 (depends on 3) The bicycle drive assembly of claim 3, wherein the first ratchet face has at least 100 teeth. ### Claim 10 (depends on 1) The bicycle drive assembly of claim 1, wherein the first ratchet ring and the second ratchet ring are identical to one another. ### Claim 11 (depends on 10) The bicycle drive assembly of claim 10, wherein the first ratchet face and the second ratchet face each have at least 40 teeth. ### Claim 12 (depends on 11) The bicycle drive assembly of claim 11, wherein the first ratchet face and the second ratchet face each have a radial length of at least 3 mm. ### Claim 13 (depends on 11) The bicycle drive assembly of claim 11, wherein the first ratchet face and the second ratchet face each have an inner diameter of at least 24 mm. ### Claim 14 (depends on 11) The bicycle drive assembly of claim 11, wherein the at least 40 teeth have a pitch diameter of at least 25.5 mm. ### Claim 15 (depends on 1) The bicycle drive assembly of claim 1, wherein the first bearing is axially spaced from the second bearing by no greater than 5 mm. ### Claim 16 (depends on 1) The bicycle drive assembly of claim 1, wherein the second leg has a rear face directly opposite the first ratchet face and wherein the at least one spring comprises a spring in contact with the rear face. ### Claim 17 (depends on 1) The bicycle drive assembly of claim 1, wherein the second ratchet ring has an L-shaped cross section having a first leg and a second leg, the second leg of the second ratchet ring having a series of splines in engagement with the free hub and the first leg extending radially outward from the second leg of the second ratchet ring and comprising the second ratchet face and a rear face directly opposite the second ratchet face, the bicycle drive assembly further comprising: a retainer secured to the hub shell and in engagement with the rear face of the first leg of the second ratchet ring to retain the second ratchet ring against the first ratchet ring upon separation of the free hub from the hub shell. ### Claim 18 (depends on 1) The bicycle drive assembly of claim 1 further comprising: a retainer having a retainer surface facing in a direction away from the first ratchet ring and in engagement with the second ratchet ring, the retainer being secured to the hub shell by projecting into an outwardly extending undercut in the hub shell, the undercut having an undercut surface in contact with the retainer surface to inhibit separation of the first ratchet ring and the second ratchet ring upon separation of the free hub from the hub shell. ### Claim 19 (depends on 1) The bicycle assembly of claim 1, wherein the second ratchet ring has an L-shaped cross section having a first leg and a second leg, the second leg of the second ratchet ring having a series of splines in engagement with the free hub and the first leg extending radially outward from the second leg of the second ratchet ring and comprising the second ratchet face and a rear face directly opposite the second ratchet face, the bicycle drive assembly further comprising: a resiliently flexible flap captured between an outer surface of the second leg of the second ratchet ring and the hub shell. ### Claim 20 A bicycle drive assembly comprising: an axle extending along an axis; a hub shell rotatably mounted on the axle by a first bearing; a free hub rotatably mounted on the axle by a second bearing; and a ratchet mechanism releasably coupling the free hub to the hub shell to transmit torque from the free hub to the hub, the ratchet mechanism comprising: a first ratchet ring having an inner surface joined to the hub shell for rotation with the hub shell, the first ratchet ring encircling and radially overlapping the first bearing, the first ratchet ring having a first ratchet face; a second ratchet ring having an inner surface joined to the free hub for rotation with the free hub, the second ratchet ring encircling and radially overlapping the second bearing; at least one spring resiliently biasing the first ratchet face and the second ratchet face into engagement to transmit torque from the free hub to the hub shell; and a retainer having a retainer surface facing in a direction away from the first ratchet ring and in engagement with the second ratchet ring, the retainer being secured to the hub shell by projecting into an outwardly extending undercut in the hub shell, the undercut having an undercut surface in contact with the retainer surface to inhibit separation of the first ratchet ring and the second ratchet ring upon separation of the free hub from the hub shell.