Granted Patent B2

US 12,208,850 · App. 18/348,441 · Granted Jan 28, 2025

Inventor: Jonathan Staples (Garibaldi Highlands, CA)

Assignee: D3 Innovation Inc.

B62J1/08B62K19/36B62J2001/085

Abstract

Claims (74)

1. A dropper post assembly for supporting a bicycle seat, the dropper post assembly comprising:

a) an outer tube extending axially along a post axis between a lower end and an upper end;

b) an inner tube extending axially between

i. an upper end that is connectable to a bicycle seat; and

ii. a lower end that is disposed within the outer tube and comprises a tube engagement member that is integrally formed on an inner surface of the inner tube, the inner tube being axially movable relative to the outer tube between an extended position and a retracted position;

c) a spring cartridge assembly configurable in an unlocked configuration in which the spring cartridge assembly biases the inner tube toward its extended position and a locked configuration, the spring cartridge assembly comprising:

i. a cartridge tube providing a cylinder and being disposed within and movable with the inner tube, the cartridge tube extending between an upper end disposed at the upper end of the inner tube and a lower end that is disposed at the lower end of the inner tube;

ii. a lower seal assembly disposed at a lower end of the cartridge tube and sealing a lower end of the cylinder;

iii. a piston movably received within the cylinder to provide a first chamber defined between the piston and the lower seal assembly and disposed on a lower side of the piston, and a second chamber between the piston and an upper end of the cylinder and disposed on an opposing, upper side of the piston, whereby moving the inner tube toward the retracted position expands the first chamber, the piston including a valve that is configurable in an open position in which fluid communication is established between the first chamber and second chamber and the spring cartridge assembly is in the unlocked configuration, and a closed position in which the first chamber is fluidly isolated from the second chamber and the spring cartridge assembly is in the locked configuration, and when the dropper post assembly is oriented so that the second chamber is above the first chamber the spring cartridge assembly operates as a self-bleeding cartridge, in which when the valve is in its open position gas contained in the first chamber escapes through the valve and is collected in the second chamber;

iv. a cartridge rod extending axially through the lower seal assembly between an inner end engaging the piston and an outer lower end at the lower end the outer tube; and

v. a fastening member that is removably insertable in the lower end of the inner tube, the fastening member comprising a second engagement member configured to releasably engage the tube engagement member so that when the fastening member is inserted so that the second engagement member engages the tube engagement member the cartridge tube is compressed axially between the abutment surface and the upper end of the inner tube so that the cartridge tube is axially fixed relative to the inner tube and movable with the inner tube relative to the outer tube;

d) an actuator having a body disposed adjacent the outer end of the cartridge rod and being operable to actuate the valve to change the spring cartridge assembly between the locked configuration and the unlocked configuration,

wherein the inner tube comprises an upper captive portion at its upper end having a first internal diameter that is substantially the same as an outer diameter of the cartridge tube so that the upper end of the cartridge tube is closely/snugly received in the upper captive portion but remains axially removable and lateral movement between the cartridge tube and the inner tube is inhibited.

2. The dropper post assembly of claim 1 , wherein the tube engagement member comprises threads formed in the inner surface of the inner tube.

3. The dropper post assembly of claim 1 , wherein the upper end of the cartridge tube does not include a fastening mechanism engaging the inner tube in a manner that restrains axial movement of the cartridge relative to the inner tube.

4. The dropper post assembly of claim 1 , wherein an axially upper most portion of the spring cartridge is disposed within the inner tube and does not extend axially beyond the upper end of the inner tube, whereby an entirety of the spring cartridge is disposed axially inboard of the upper end of the inner tube.

5. The dropper post assembly of claim 1 , wherein the inner tube comprises an upper end wall that covers the upper end of the inner tube and the cartridge tube comprises an axially facing upper cap surface that opposes the upper end wall when the cartridge tube is disposed within the inner tube, wherein the upper cap surface and upper end wall are complimentary to each other and generally planar and the cartridge tube is located axially inboard of the upper end wall.

6. The dropper post assembly of claim 1 , wherein when the spring cartridge is axially removable via the lower end of the inner tube after removing the fastening member and wherein the cylinder remains sealed and the spring cartridge assembly remains operable when the spring cartridge assembly is removed from the inner tube.

7. The dropper post assembly of claim 1 , wherein the fastening member further comprises a captive sidewall extending axially from the abutment surface and cooperating with the abutment surface to at least partially define a tube recess sized to accommodate the lower end of the cartridge tube, wherein when the fastening member is inserted the captive sidewall is disposed laterally between the cartridge tube and the inner tube.

8. The dropper post assembly of claim 7 , wherein the captive sidewall surrounds the tube recess and defines a recess diameter that is substantially the same as an outer diameter of the cartridge tube so that the and lateral movement of the lower end of the cartridge tube relative to the fastening member and the lower end of the inner tube is inhibited cartridge tube is closely/snugly in the tube recess so that when the fastening member is inserted lateral movement between the lower end of the cartridge tube and the lower end of the inner tube is inhibited.

9. The dropper post assembly of claim 1 , wherein the second engagement member is disposed toward a lower end of the fastening member and the abutment surface is disposed toward an opposing, upper end of the fastening member.

10. The dropper post assembly of claim 1 , wherein an inner surface of the lower end of the fastening member comprises a drive portion configured to be engaged by a corresponding driving tool used to secure the fastening member within the inner tube.

11. The dropper post assembly of claim 1 , wherein when the fastening member is inserted it is at least partially axially nested within the inner tube.

12. The dropper post assembly of claim 1 , wherein when the fastening member is inserted it is entirely axially nested within the inner tube.

13. The dropper post assembly of claim 1 , further comprising an openable seat clamp assembly connected to the upper end of the inner tube and configured to releasably retain a bicycle seat, and wherein the fastening member is insertable and removable from the inner tube independently from opening the seat clamp assembly, whereby the second engagement member is disengagable from the tube engagement member without opening the seat clamp assembly.

14. The dropper post assembly of claim 1 , wherein the inner tube further comprises a clearance portion axially inboard from the upper captive portion and having a second internal diameter that is greater than the first internal diameter and the outer diameter of the cartridge tube, whereby an annular gap is formed within the clearance portion between an outer surface of the cartridge tube and an opposing inner surface of the inner tube.

15. The dropper post assembly of claim 14 , further comprising a bumper having a length in the axial direction that is less than 20% of an axial length of the cartridge tube and being positioned laterally between the cartridge tube and the inner tube within the annular gap thereby inhibiting lateral movement of the cartridge tube relative to the inner tube.

16. The dropper post assembly of claim 15 , wherein the lower end of the inner tube further comprises an engagement region that includes the tube engagement member and has a third internal diameter that is greater than the second internal diameter.

17. The dropper post assembly of claim 16 , wherein the inner diameter of the inner tube increases from its upper end to its lower end.

18. The dropper post assembly of claim 1 , wherein when the dropper post assembly is in use and oriented with the second chamber above the first chamber the first chamber contains substantially only a liquid and the second chamber contains a mixture of a liquid and a gas.

19. A dropper post assembly for supporting a bicycle seat, the dropper post assembly comprising:

a) an outer tube extending axially along a post axis between a lower end and an upper end;

b) an inner tube extending axially between

i. an upper end that is connectable to a bicycle seat; and

ii. a lower end that is disposed within the outer tube and comprises a tube engagement member that is integrally formed on an inner surface of the inner tube, the inner tube being axially movable relative to the outer tube between an extended position and a retracted position;

c) a spring cartridge assembly configurable in an unlocked configuration in which the spring cartridge assembly biases the inner tube toward its extended position and a locked configuration, the spring cartridge assembly comprising:

i. a cartridge tube providing a cylinder and being disposed within and movable with the inner tube, the cartridge tube extending between an upper end disposed at the upper end of the inner tube and a lower end that is disposed at the lower end of the inner tube;

ii. a lower seal assembly disposed at a lower end of the cartridge tube and sealing a lower end of the cylinder;

iii. a piston movably received within the cylinder to provide a first chamber defined between the piston and the lower seal assembly and disposed on a lower side of the piston, and a second chamber between the piston and an upper end of the cylinder and disposed on an opposing, upper side of the piston, whereby moving the inner tube toward the retracted position expands the first chamber, the piston including a valve that is configurable in an open position in which fluid communication is established between the first chamber and second chamber and the spring cartridge assembly is in the unlocked configuration, and a closed position in which the first chamber is fluidly isolated from the second chamber and the spring cartridge assembly is in the locked configuration, and when the dropper post assembly is oriented so that the second chamber is above the first chamber the spring cartridge assembly operates as a self-bleeding cartridge, in which when the valve is in its open position gas contained in the first chamber escapes through the valve and is collected in the second chamber;

iv. a cartridge rod extending axially through the lower seal assembly between an inner end engaging the piston and an outer lower end at the lower end the outer tube; and

v. a fastening member that is removably insertable in the lower end of the inner tube, the fastening member comprising a second engagement member configured to releasably engage the tube engagement member so that when the fastening member is inserted so that the second engagement member engages the tube engagement member the cartridge tube is compressed axially between the abutment surface and the upper end of the inner tube so that the cartridge tube is axially fixed relative to the inner tube and movable with the inner tube relative to the outer tube;

d) an actuator having a body disposed adjacent the outer end of the cartridge rod and being operable to actuate the valve to change the spring cartridge assembly between the locked configuration and the unlocked configuration,

wherein the inner tube comprises an upper end wall that covers the upper end of the inner tube and the cartridge tube comprises an axially facing upper cap surface that opposes the upper end wall when the cartridge tube is disposed within the inner tube, wherein the upper cap surface and upper end wall are complimentary to each other and generally planar and the cartridge tube is located axially inboard of the upper end wall.

20. The dropper post assembly of claim 19 , wherein the tube engagement member comprises threads formed in the inner surface of the inner tube.

21. The dropper post assembly of claim 19 , wherein the upper end of the cartridge tube does not include a fastening mechanism engaging the inner tube in a manner that restrains axial movement of the cartridge relative to the inner tube.

22. The dropper post assembly of claim 19 , wherein an axially upper most portion of the spring cartridge is disposed within the inner tube and does not extend axially beyond the upper end of the inner tube, whereby an entirety of the spring cartridge is disposed axially inboard of the upper end of the inner tube.

23. The dropper post assembly of claim 19 , wherein when the spring cartridge is axially removable via the lower end of the inner tube after removing the fastening member and wherein the cylinder remains sealed and the spring cartridge assembly remains operable when the spring cartridge assembly is removed from the inner tube.

24. The dropper post assembly of claim 19 , wherein the fastening member further comprises a captive sidewall extending axially from the abutment surface and cooperating with the abutment surface to at least partially define a tube recess sized to accommodate the lower end of the cartridge tube, wherein when the fastening member is inserted the captive sidewall is disposed laterally between the cartridge tube and the inner tube.

25. The dropper post assembly of claim 24 , wherein the captive sidewall surrounds the tube recess and defines a recess diameter that is substantially the same as an outer diameter of the cartridge tube so that the and lateral movement of the lower end of the cartridge tube relative to the fastening member and the lower end of the inner tube is inhibited cartridge tube is closely/snugly in the tube recess so that when the fastening member is inserted lateral movement between the lower end of the cartridge tube and the lower end of the inner tube is inhibited.

26. The dropper post assembly of claim 19 , wherein the second engagement member is disposed toward a lower end of the fastening member and the abutment surface is disposed toward an opposing, upper end of the fastening member.

27. The dropper post assembly of claim 19 , wherein an inner surface of the lower end of the fastening member comprises a drive portion configured to be engaged by a corresponding driving tool used to secure the fastening member within the inner tube.

28. The dropper post assembly of claim 19 , wherein when the fastening member is inserted it is at least partially axially nested within the inner tube.

29. The dropper post assembly of claim 19 , further comprising an openable seat clamp assembly connected to the upper end of the inner tube and configured to releasably retain a bicycle seat, and wherein the fastening member is insertable and removable from the inner tube independently from opening the seat clamp assembly, whereby the second engagement member is disengagable from the tube engagement member without opening the seat clamp assembly.

30. A dropper post assembly for supporting a bicycle seat, the dropper post assembly comprising:

a) an outer tube extending axially along a post axis between a lower end and an upper end;

b) an inner tube extending axially between

i. an upper end that is connectable to a bicycle seat; and

ii. a lower end that is disposed within the outer tube and comprises a tube engagement member that is integrally formed on an inner surface of the inner tube, the inner tube being axially movable relative to the outer tube between an extended position and a retracted position;

c) a spring cartridge assembly configurable in an unlocked configuration in which the spring cartridge assembly biases the inner tube toward its extended position and a locked configuration, the spring cartridge assembly comprising:

i. a cartridge tube providing a cylinder and being disposed within and movable with the inner tube, the cartridge tube extending between an upper end disposed at the upper end of the inner tube and a lower end that is disposed at the lower end of the inner tube;

ii. a lower seal assembly disposed at a lower end of the cartridge tube and sealing a lower end of the cylinder;

iii. a piston movably received within the cylinder to provide a first chamber defined between the piston and the lower seal assembly and disposed on a lower side of the piston, and a second chamber between the piston and an upper end of the cylinder and disposed on an opposing, upper side of the piston, whereby moving the inner tube toward the retracted position expands the first chamber, the piston including a valve that is configurable in an open position in which fluid communication is established between the first chamber and second chamber and the spring cartridge assembly is in the unlocked configuration, and a closed position in which the first chamber is fluidly isolated from the second chamber and the spring cartridge assembly is in the locked configuration, and when the dropper post assembly is oriented so that the second chamber is above the first chamber the spring cartridge assembly operates as a self-bleeding cartridge, in which when the valve is in its open position gas contained in the first chamber escapes through the valve and is collected in the second chamber;

iv. a cartridge rod extending axially through the lower seal assembly between an inner end engaging the piston and an outer lower end at the lower end the outer tube; and

v. a fastening member that is removably insertable in the lower end of the inner tube, the fastening member comprising a second engagement member configured to releasably engage the tube engagement member so that when the fastening member is inserted so that the second engagement member engages the tube engagement member the cartridge tube is compressed axially between the abutment surface and the upper end of the inner tube so that the cartridge tube is axially fixed relative to the inner tube and movable with the inner tube relative to the outer tube;

d) an actuator having a body disposed adjacent the outer end of the cartridge rod and being operable to actuate the valve to change the spring cartridge assembly between the locked configuration and the unlocked configuration,

wherein the fastening member further comprises a captive sidewall extending axially from the abutment surface and cooperating with the abutment surface to at least partially define a tube recess sized to accommodate the lower end of the cartridge tube, wherein when the fastening member is inserted the captive sidewall is disposed laterally between the cartridge tube and the inner tube.

31. The dropper post assembly of claim 30 , wherein the tube engagement member comprises threads formed in the inner surface of the inner tube.

32. The dropper post assembly of claim 30 , wherein the upper end of the cartridge tube does not include a fastening mechanism engaging the inner tube in a manner that restrains axial movement of the cartridge relative to the inner tube, and wherein an axially upper most portion of the spring cartridge is disposed within the inner tube and does not extend axially beyond the upper end of the inner tube, whereby an entirety of the spring cartridge is disposed axially inboard of the upper end of the inner tube.

33. The dropper post assembly of claim 30 , wherein when the spring cartridge is axially removable via the lower end of the inner tube after removing the fastening member and wherein the cylinder remains sealed and the spring cartridge assembly remains operable when the spring cartridge assembly is removed from the inner tube.

34. The dropper post assembly of claim 30 , wherein the captive sidewall surrounds the tube recess and defines a recess diameter that is substantially the same as an outer diameter of the cartridge tube so that the and lateral movement of the lower end of the cartridge tube relative to the fastening member and the lower end of the inner tube is inhibited cartridge tube is closely/snugly in the tube recess so that when the fastening member is inserted lateral movement between the lower end of the cartridge tube and the lower end of the inner tube is inhibited.

35. The dropper post assembly of claim 30 , wherein the second engagement member is disposed toward a lower end of the fastening member and the abutment surface is disposed toward an opposing, upper end of the fastening member.

36. The dropper post assembly of claim 30 , wherein an inner surface of the lower end of the fastening member comprises a drive portion configured to be engaged by a corresponding driving tool used to secure the fastening member within the inner tube.

37. The dropper post assembly of claim 30 , wherein when the fastening member is inserted it is at least partially axially nested within the inner tube.

38. The dropper post assembly of claim 30 , further comprising an openable seat clamp assembly connected to the upper end of the inner tube and configured to releasably retain a bicycle seat, and wherein the fastening member is insertable and removable from the inner tube independently from opening the seat clamp assembly, whereby the second engagement member is disengagable from the tube engagement member without opening the seat clamp assembly.

Continuity (3)

References Cited (187)