BR112020021900B1 - EXERCISE BICYCLE - Google Patents

Abstract

EXERCISE BICYCLE. An exercise bicycle includes a frame, a rotor assembly, and a drive assembly mounted to the frame, wherein the drive assembly is configured to drive rotation of the rotor assembly, and a cover configured to at least partially cover the rotor assembly. Drive assembly and rotor assembly components include structures that improve exercise bike performance, including, but not limited to, strong, rigid construction and improvements in belt tracking, user feel, effort consistency, synchronization and rotor performance.

Description

REFERENCE TO RELATED PATENT APPLICATIONS

[001] The present patent application claims priority to US Patent Application No. 16/045,475, filed on July 25, 2018, which is a non-provisional patent application of US Provisional Patent Application No. 62/663,090, filed on April 26, 2018, and the present patent application claims priority to both of those patent applications, which are hereby incorporated by reference in their entireties.

FIELD OF INVENTION

[002] This disclosure relates to exercise bicycles, and more specifically to exercise bicycles that have features that provide improved energy efficiency, improved sensation and greater durability, among other benefits.

FUNDAMENTALS

[003] Exercise bikes and other exercise equipment that use human effort to drive the rotation of a rotor to provide resistance for exercise purposes are common and known in the art. Such equipment can be provided in a wide variety of configurations, with many different features. However, existing equipment of this type also suffers from many drawbacks, and there is a need for improvements; for example, many existing exercise bikes have frames that do not provide rigid construction, smooth and consistent user effort, or close synchronization between components during use, leading to to an overall “feel” that is unsatisfactory for many users. This unsatisfactory “feel” is particularly important in equipment that may be used repeatedly, even daily or more frequently by some users. The present disclosure solves these and other problems with exercise bikes and other existing exercise equipment.

BRIEF SUMMARY

[004] General aspects of the present disclosure relate to an exercise bike or other article of exercise equipment that has a supporting frame, a rotor supported by the frame, and a drive system that drives rotation of the rotor.

[005] Aspects of the disclosure relate to an exercise bicycle that includes a frame configured to rest on a ground surface and having a seat configured to support a user, a rotor supported by the frame, and a drive mechanism operatively connected to the rotor to drive rotor rotation. The rotor includes a hub supported by the frame for rotation about a first axis and a plurality of blades connected to the hub, wherein the hub and the plurality of blades are configured to rotate together about the first axis. The plurality of blades includes a first blade having a proximal end connected to the hub and an elongate body extending outwardly in a longitudinal direction from the hub to a distal end, with the elongate body having upper and lower and first and second surfaces. opposing edges that extend between the proximal and distal ends. The first blade also includes a first flange connected to the body and extending from the body transversely to the upper and lower surfaces. The other blades can have the same structure as the first blade in a configuration. The drive mechanism includes a set of pulleys supported by the frame operatively connected to the rotor, and a set of pedals and a set of arms operatively connected to the set of pulleys for driving rotation of the rotor through the set of pulleys.

[006] According to one aspect, the first flange of the first blade extends along the first edge for an entire length of the first edge in the longitudinal direction, and the first blade further includes a second flange that extends along the second edge for an entire length of the second edge in the longitudinal direction.

[007] According to another aspect, the first flange extends downwardly from the body of the first blade and forms a 90° angle with the body at a junction between the body and the first flange.

[008] According to another aspect, the first flange has a first height that is greater at the proximal end and smaller at the distal end. The first blade may also include a second flange that has a second height that is greater at the proximal end and smaller at the distal end. In one configuration, the first height and/or the second height decreases continuously from the proximal end to the distal end. In another configuration, the first flange extends along the first edge of the first blade, and the second flange extends transversely to the upper and lower surfaces along the second edge.

[009] According to yet another aspect, the first flange extends along the first edge of the first blade, and the first blade further includes a second flange that extends transversely to the upper and lower surfaces along the second edge. The first flange has a first extension extending outwardly in the longitudinal direction from the proximal end of the body to form a first bezel that is contiguous to the first flange, and the second flange has a second extension extending outwardly in the longitudinal direction. from the proximal end of the body to form a second bezel that is contiguous to the second flange, where the first and second bezels are connected to the hub to connect the first blade to the hub.

[0010] According to yet another aspect, the body of the first blade includes an upper portion extending in the longitudinal direction in a central area of the first blade, a first lower portion extending in the longitudinal direction along the first edge, and a second lower portion extending in the longitudinal direction along the second edge. The upper portion is offset vertically from the first and second lower portions, and the body of the first blade further includes a first stepped portion extending downwardly from the upper portion to the first lower portion and a second stepped portion extending downward from the upper portion to the second lower portion.

[0011] According to another aspect, a width of the first blade, measured between the first and second edges, is constant from the proximal end to the distal end.

[0012] According to a further aspect, the first blade has a first mating surface spaced from a connection point between the first bezel and the hub, and the hub has a complementary mating surface that mates to the first mating surface. of the first blade to resist articulation of the first blade around the connection point. In one configuration, the first mating surface is located at one end of the first bezel, and the complementary mating surface is formed by a projection of the hub that bears on the first mating surface.

[0013] Additional aspects of the disclosure relate to an exercise bicycle that includes a frame configured to rest on a ground surface and having a seat configured to support a user, a rotor supported by the frame, and a drive mechanism operatively connected to the rotor to drive rotor rotation. The rotor includes a hub supported by the frame for rotation about a first axis and a plurality of blades connected to the hub, wherein the hub and the plurality of blades are configured to rotate together about the first axis. The plurality of blades includes a first blade having a proximal end connected to the hub and an elongate body extending outwardly in a longitudinal direction from the hub to a distal end, with the elongate body having upper and lower surfaces and two edges that extend between the proximal and distal ends. The body of the first blade includes an upper portion extending in the longitudinal direction in a central area of the first blade, a first lower portion extending in the longitudinal direction along the first edge, and a second lower portion extending in the longitudinal direction. along the second edge. The upper portion is offset vertically from the first and second lower portions, and the body of each blade further includes a first stepped portion extending downwardly from the upper portion to the first lower portion and a second stepped portion extending downward from the upper portion to the second lower portion. The other blades can have the same structure as the first blade in a configuration. The drive mechanism includes a set of pulleys supported by the frame operatively connected to the rotor, and a set of pedals and a set of arms operatively connected to the set of pulleys for driving rotation of the rotor through the set of pulleys.

[0014] According to one aspect, the upper portion, the first lower portion and the second lower portion of the first blade are generally planar and parallel to each other, and the first lower portion and the second lower portion of the first blade are coplanar.

[0015] According to another aspect, the upper portion of the first blade is also laterally displaced from the first lower portion and the second lower portion, the first and second stepped portions extending laterally outwardly and downwardly from the upper portion up to the first and second lower portions. In one configuration, the first and second stepped portions form angles with the upper portion of 120o-140o.

[0016] According to another aspect, a degree of vertical displacement between the upper portion and the first and second lower portions of the first blade is greater than a thickness of the first blade measured between the upper and lower surfaces.

[0017] According to yet another aspect, the first blade has a first bezel extending outwardly in the longitudinal direction from the proximal end along the first edge and a second bezel extending outwardly in the longitudinal direction from the proximal end along the second edge.

[0018] According to yet another aspect, the upper portion, the first and second lower portions, and the first and second stepped portions extend from the proximal end to the distal end of the first blade.

[0019] Additional aspects of the disclosure relate to an exercise bicycle that includes a frame configured to rest on a ground surface and having a seat configured to support a user, a rotor supported by the frame, and a drive mechanism operatively connected to the rotor to drive rotor rotation. The rotor includes a hub supported by the frame for rotation about a first axis, a sprocket operatively connected to the hub, a plurality of blades connected to the hub, and a plurality of connectors connecting the blades to the hub such that the hub, the wheel gear and the plurality of blades are configured to rotate together about the first axis. The plurality of blades includes a first blade having a proximal end connected to the hub and an elongate body extending outwardly in a longitudinal direction from the hub to a distal end, with the elongate body having upper and lower surfaces and two edges that extend between the proximal and distal ends. In this configuration, 70-90% of a rotor weight is located within 75% of a maximum rotor diameter. The other blades can have the same structure as the first blade in a configuration. The drive mechanism includes a set of pulleys supported by the frame operatively connected to the rotor sprocket, and a set of pedals and a set of arms operatively connected to the set of pulleys for driving rotation of the rotor through the set of pulleys.

[0020] According to one aspect, 50-70% of the rotor weight is located within 50% of the maximum rotor diameter and/or 30-50% of the rotor weight is located within 25% of the maximum rotor diameter .

[0021] According to another aspect, the hub and connectors connecting the blades to the hub form a single support structure for the blades, such that the distal ends of the blades are free ends that are not connected to any structure.

[0022] According to another aspect, the first blade has a front surface that includes all surfaces of the first blade facing a direction of forward rotation of the rotor, and wherein the front surface of the first blade has a surface area of at least 129 cm2 (20 square inches), or a surface area of 129-258 cm2 (20-40 square inches).

[0023] According to yet another aspect, the plurality of blades includes 8-12 blades and has a total weight of 4-5 kg (9-11 pounds).

[0024] According to yet another aspect, a portion of 38-56% of a rotor's total moment of inertia is located within 75% of the rotor's maximum diameter.

[0025] According to a further aspect, the first blade has a cross-sectional area obtained perpendicular to the longitudinal direction that decreases in the longitudinal direction along at least a portion of a length of the first blade between the proximal end and the distal end .

[0026] According to another aspect, the first blade has an incremental mass that decreases in the longitudinal direction along at least a portion of a length of the first blade between the proximal end and the distal end.

[0027] Still other aspects of the disclosure relate to an exercise bicycle that includes a frame configured to rest on a ground surface and having a seat configured to support a user, a rotor supported by the frame, and a drive mechanism connected operatively to the rotor to drive rotor rotation. The rotor includes a hub supported by the frame for rotation about a first axis, a sprocket operatively connected to the hub, and a plurality of blades connected to the hub, wherein the hub, sprocket and the plurality of blades are configured to rotate together in around the first axis. The plurality of blades includes a first blade having a proximal end connected to the hub and an elongate body extending outwardly in a longitudinal direction from the hub to a distal end, with the body having upper and lower surfaces and first and second edges. opposite ends that extend between the proximal and distal ends. The first blade also includes a first flange extending downwardly and transversely to the upper and lower surfaces along the first edge in the longitudinal direction and a second flange extending downwardly and transversely to the upper and lower surfaces along the second edge in the longitudinal direction. longitudinal direction. The first flange has a first extension extending outwardly in the longitudinal direction from the proximal end of the body to form a first bezel that is contiguous to the first flange, and the second flange has a second extension extending outwardly in the longitudinal direction. from the proximal end of the body to form a second bezel that is contiguous to the second flange. The first and second bezels are connected to the hub by one or more connectors. The drive mechanism includes a pulley assembly that includes an input pulley supported by the frame for rotation on a second axis spaced from the first axis and a belt connected to the input pulley and rotor sprocket for transferring power from the input pulley to the sprocket, as well as a set of pedals and a set of arms. The pedal assembly includes a pair of pedals operatively connected to the input pulley for driving rotation of the input pulley, and the arm assembly includes a pair of reciprocating arms operatively connected to the input pulley for driving rotation of the input pulley, so as to that the pedal assembly and arm assembly are configured to drive rotor rotation via the input pulley, belt, and sprocket.

[0028] According to one aspect 70-90% of a rotor weight is located within 75% of a maximum rotor diameter, 50-70% of the rotor weight is located within 50% of a maximum rotor diameter , and 30-50% of the rotor weight is located within 25% of a maximum rotor diameter, and the front surface of each blade has a surface area of 129-258 cm2 (20-40 square inches).

[0029] According to another aspect, the exercise bike further includes a rotor cover that at least partially covers the rotor so that the rotor is configured to rotate within the rotor cover while allowing air passage to and from the rotor. The rotor cover includes a front piece that forms a front half of the rotor cover, an upper back piece that forms an upper rear quarter of the rotor cover, and a lower back piece that forms a lower back quarter of the rotor cover, of so that the front piece, the upper back piece and the lower back piece are connected together to form the rotor cover.

[0030] According to another aspect, the first blade has a first mating surface located on the first bezel and spaced from a first connection point between the first bezel and the hub, and a second mating surface located on the second bezel and spaced from a second connection point between the second bezel and the hub, and the hub has complementary first and second mating surfaces that mate with the first and second mating surfaces of the first blade to resist articulation of the first blade in around the first and second connection points.

[0031] Other features and advantages of the disclosure will be evident from the following description considered in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] To allow a more complete understanding of the present disclosure, it will now be described by way of example, with reference to the attached drawings in which: FIG. 1 is a top front perspective view of an embodiment of an exercise bike, in accordance with aspects of the disclosure; FIG. 2 is a top rear perspective view of the exercise bike of FIG. 1; FIG. 3 is a right side view of the exercise bike of FIG. 1; FIG. 4 is a left side view of the exercise bike of FIG. 1; FIG. 5 is a top front perspective view of the exercise bike of FIG. 1, with some external components removed to show internal detail; FIG. 6 is a top rear perspective view of the exercise bike of FIG. 1, with some external components removed to show internal detail; FIG. 7 is a right side view of the exercise bike of FIG. 1, with some external components removed and some additional components represented in dashed lines to show internal detail; FIG. 8 is a left side view of the exercise bike of FIG. 1, with some external components removed and some additional components represented in dashed lines to show internal detail; FIG. 9 is a top front perspective view of a portion of a pulley assembly and rotor assembly of the exercise bike of FIG. 1; FIG. 9A is a top front perspective view of a portion of the rotor assembly of the exercise bike of FIG. 1; FIG. 9B is an enlarged side view of a portion of the rotor assembly of the exercise bike of FIG. 1; FIG. 9C is an enlarged perspective view of a portion of the rotor assembly of the exercise bike of FIG. 1; FIG. 10 is a top front perspective view of a pulley roller of FIG. 9; FIG. 11 is a perspective view of a blade of the rotor assembly of FIG. 9; FIG. 12 is a perspective view of an articulated system of the exercise bike of FIG. 1; FIG. 13 is a top front perspective view of another embodiment of an exercise bike, in accordance with aspects of the disclosure; FIG. 14 is a top rear perspective view of the exercise bike of FIG. 13; FIG. 15 is a top rear perspective view of the exercise bike of FIG. 13, with some external components removed to show internal detail; FIG. 16 is a lower front perspective view of the exercise bike of FIG. 13, with some external components removed to show internal detail; FIG. 17 is an exploded perspective view of the exercise bike of FIG. 13, with some external components removed; FIG. 18 is a side view of a rotor of the exercise bike of FIG. 17; FIG. 19 is a perspective view of the rotor of FIG. 18; FIG. 20 is a schematic view illustrating the rotor of FIG. 18 with boundaries illustrating 25%, 50%, 75% and 100% of the maximum rotor diameter 30; FIG. 21 is a perspective view of a rotor blade of FIG. 18; FIG. 22 is a top view of the blade of FIG. 21; FIG. 23 is an end view of the blade of FIG. 21; FIG. 24 is a cross-sectional view taken along lines 24-24 of FIG. 22; FIG. 25 is a schematic side view showing an output pulley and a tension pulley of the exercise bike of FIG. 17; FIG. 26 is a schematic side view showing an input pulley and a tension pulley of the exercise bike of FIG. 17; and FIG. 27 is a perspective view of the blade of FIG. 21, with shading to indicate a front surface of the blade.

DETAILED DESCRIPTION

[0033] Although the invention is susceptible to embodiments in many different forms, exemplary embodiments of the invention are shown in the drawings and will be described in detail herein with the understanding that the present disclosure should be considered as an exemplification of the principles of the invention and not is intended to limit the broad scope of the invention to the illustrated embodiments. In the following description of various exemplary structures in accordance with the invention, reference is made to the accompanying drawings, which form a part thereof, and in which are shown by way of illustration various exemplary devices, systems and environments in which aspects of the invention may be practiced. It should be understood that other specific arrangements of exemplary parts, devices, systems and environments may be used and structural and functional modifications may be made without departing from the scope of the present invention.

[0034] With reference now to the figures, and initially to FIGS. 1-12, an embodiment of an exercise bike or stationary bicycle 10 configured for stationary exercise is shown. The bicycle 10 generally includes a frame or frame assembly 12, a motor assembly 14 mounted on the frame 12, a drive mechanism 16 mounted on the frame 12 and configured to drive rotation of the rotor assembly 14, and a cover 18 configured to at least partially cover the rotor assembly 14. The bicycle 10 may also include other components, such as a computer system that includes a computer interface 19 as shown in FIGS. 1-8.

[0035] The frame 12 includes a base 20 configured for support on the ground or other supporting surface and a plurality of frame elements 21 that extend upwardly from the base 20 and support the other components of the bicycle 10. The base 20 in FIGS. 1-8 includes two base elements 26, which are configured as cross elements extending laterally relative to the frame 21, with each base element 26 including one or more ground-engaging structures 27 directly connected thereto. The ground-engaging structures 27 are configured as adjustable feet in FIGS. 1-8. In this configuration, the base elements 26 and the ground-coupled structures 27 support all or other components of the bicycle 10, including the remainder of the frame 12. The ground-engaged structures 27 of the base 20 may further include wheels 22 configured for movement of the bicycle 10 on the support surface. The frame elements 21 include rotor support elements 23 that support the rotor assembly 14 and drive mechanism components 16 at the front of the bicycle 10. The rotor support elements 23 in the embodiment of FIGS. 1-8 include shaft bezels 24 that maintain and/or support the shaft 33 of the rotor assembly 14 as described herein. The frame 12 may further include a user support in the form of a seat 24 for the user to sit on during operation of the bicycle 10, as well as a seat support 83 that supports the seat 24, with adjustment mechanisms 25 for adjusting the vertical position. and/or horizontal seat 24. A foot plate 17 is connected directly to the frame 12 in the embodiment of FIGS. 1-8, as shown in FIGS. 5-6, which creates a more stable and rigid structure than the existing foot plates 17 that are connected directly to a housing supported by the frame 12. The frame 12 also has several connections and bezels for connecting and assembling other components of the bicycle 10, including components of the rotor assembly 14 and/or the drive mechanism 16. For example, the frame 12 has one or more shaft housings (not shown) that hold and/or support the shaft 55 of the input pulley 51 It should be understood that the frame 12 may be differently configured in various other embodiments for desired appearance and/or ergonomics while maintaining similar functionality. In other embodiments, the frame 12 and its components and features (including the frame elements 21) may be constructed with similar structural and functional elements that have different configurations, including different ornamental appearances.

[0036] In one embodiment, as shown in FIGS. 1-8, frame 12 includes features that provide a rigid and stable construction. For example, the frame 12 may include thick and strong gauge frame elements 21 in one embodiment, which may allow a stable and rigid construction to be obtained without additional structural reinforcing elements. In the embodiments of FIGS. 1-8, the frame 12 defines an opening 28 at the bottom between the base elements 26 such that no frame elements 21 extend directly between the base elements 26. In this configuration, the frame elements 21 form an arc or extension over the opening 28, with the apex 29 formed by rising frame elements 48, 49 that are connected to the base elements 26. The rising frame elements 48, 49 include one or more front rising frame elements 48 that are connected to the front base element 26 and extend continuously upward and rearward from the front base element 26 to the apex 29, and one or more rear ascending frame elements 49 that are connected to the rear base element 26 and extend continuously toward upward and forward from the rear base element 26 to the apex 29. The ascending frame elements 48, 49 in the embodiment of FIGS. 1-8 extend linearly to apex 29 to form an angular-shaped arch, but may have a curved and/or multi-angular configuration in another embodiment. In FIGS. 1-8, frame 12 includes a pair of parallel linear front rising frame elements 48 connected to front base member 26 and extending upwardly/rearly on opposite sides of rotor 30, and a single rear rising frame element 49 connected to the rear base element 26 and extending upward/forward, dividing into two branches near the rotor 30 (forming a “tuning fork” or Y shape) to connect to the front ascending frame elements 48 at apex 29. The ascending frame elements 48, 49 in FIGS. 1-8 form a “spine” that supports the remainder of the frame 12 and all other components of the bicycle 10. In this configuration, no portion of the frame 12 extends below the tops of the base elements 26 other than the elements themselves. base 26 and any supports or connecting structures that directly connect the remainder of the frame 21 (i.e., the ascending frame elements 48, 49) to the base elements 26. Therefore, the lower portions of the frame 21 are the base elements 26. base 26 and any frame elements 21 connected directly to the base elements 26.

[0037] The seat support 83 in one embodiment includes a fixed portion 84 that is fixed relative to the remainder of the frame 12 and a movable or adjustable portion 85 that is movably connected to the fixed portion 84 to allow adjustment of the seat 24. In the embodiment of FIGS. 1-8, the movable portion 85 and the seat 24 are vertically adjusted together using a vertical adjustment mechanism 25 on the fixed portion 84, and the movable portion 85 further includes a horizontal adjustment mechanism 25 for horizontal adjustment of the seat 24 relative to the movable portion 85. It is understood that the vertical adjustment mechanism 25 may also result in some horizontal change in position, and that the horizontal adjustment mechanism 25 may similarly result in some vertical change in position. The fixed portion 84 in FIGS. 1-8 is a rectangular tube, and the movable portion 85 includes a smaller rectangular tube or post that fits within the fixed portion 84 and is axially movable with respect to the fixed portion 84. The seat support 83 further has a reinforcing structure to reinforce and provide additional stability to the fixed portion 84, which includes a reinforcement or support member 86 that has a first end 87 connected to the rear side of the fixed portion 84 and a second end 88 to a lower point on the frame 12, e.g. the rear rising frame element 49 in the embodiment of FIGS. 1-8. Reinforcement 86 intersects fixed portion 84 at a transverse angle to provide both vertical and horizontal support. In the embodiment of FIGS. 1-8, the lower end of the stiffener 86 is attached to the central “backbone” of the frame 12 (e.g., formed by the front and rear rising frame members 48, 49) which supports all other components of the bicycle 10, rather than directly to base 20 as in many current projects.

[0038] Reinforcement 86 intersects the fixed portion 84 of the seat support 83 in an elevated vertical position, for the purpose of increasing the overall rigidity of the fixed portion 84. In one embodiment, the uppermost point of the first end 87 of the reinforcement 86 (referred to as the top Gt of reinforcement 86) is within 17.78 cm (7 inches) of the top of the fixed portion 84, measured along the rear surface of the fixed portion 84, or within 12.70 cm (5 inches) in another modality. In the embodiment of FIGS. 1-8, the top Gt of the reinforcement 86 is spaced 7.62-8.89 cm (3.0-3.5 inches) from the top of the fixed portion 84, measured along the rear surface of the fixed portion 84, e.g. , approximately 8.13 cm (3.2 inches) (i.e. from the posterior Pr of the fixed portion 84). The connection between reinforcement 86 and fixed portion 84 is also closer to the top of fixed portion 84 than to the ground, which can be measured at various points on reinforcement 86 and fixed portion 84, as illustrated in FIG. 3. For example, if the intermediate point Pm of the top of the fixed portion 84 and the intermediate point Gm of the reinforcement 86 at the intersection between the reinforcement 86 and the fixed portion 84 are used as reference points, the height of the intermediate point Gm of reinforcement (measured from the ground surface GS) is 60-90% of the height of the intermediate point Pm of the top of the fixed portion 84 in one embodiment, and 70-85% in another embodiment, for example approximately 78%. As another example, if the rear and/or bottom point Pr of the top of the fixed portion 84 and the top Gt of the reinforcement 86 at the intersection between the reinforcement 86 and the fixed portion 84 are used as reference points, the height of the top Gt of reinforcement (measured from the ground surface GS) is 70-100% of the height of the rear and/or bottom point Pr of the top of the fixed portion 84 in one embodiment, and 75-90% in another embodiment, e.g. approximately 88 %. In the embodiment of FIGS. 1-8, the top of the fixed portion 84 has heights of 64.52 cm (15.4 inches) at the front and/or highest point Pf, 63.25 cm (24.9 inches) at the back and/or bottom point Pr, and 62.23 cm (24.5 inches) at the midpoint Pm, and reinforcement 86 has heights of 54.36 cm (21.4 inches) at the top Gt, 44.45 cm (17.5 inches) at the bottom Gb, and 49.53 cm (19.5 inches) at the midpoint Gm. It is understood that although the top of the fixed portion 84 is angled in the embodiment of FIGS. 1-8, so that the front Pf, the rear Pr, and the intermediate point Pm have different heights, the relative heights discussed above would be applied to a fixed portion 84 that has a level height. As an example, the height H-Pr of the rear and/or bottom point Pr of the top of the fixed portion 84 is illustrated in FIG. 3, with the understanding that the heights of other structures referenced in this document are defined in the same way.

[0039] The rotor assembly 14 in the embodiment of FIGS. 18 is illustrated in greater detail in FIGS. 9-11 and includes a rotor 30 in the form of a fan with a hub 31 and a plurality of blades 32 connected to the hub 31 and extending outwardly from the hub 31 in radial directions. The blades 32 are connected to the hub 31 by connectors 35, which may be in the form of fasteners such as bolts, screws, rivets, etc., in the embodiment of FIGS. 1-11, but additional or alternative connection structures may be used in other embodiments, such as clips, grooves, or other mechanical interlocking structures, or welding, brazing, soldering, adhesives, or other connection structures. The hub 31 rotates on a shaft or spindle 33, and the rotor assembly 14 further includes a coupling output member 34 that is coupled by the drive mechanism 16 to drive the rotation of the rotor 30. In the embodiment of FIGS. 1-11, the coupling output member 34 is a toothed wheel or pulley that is operatively connected to the rotor 30 such that the pulley 34 is rotationally fixed with respect to the rotor 30. The pulley 34 is directly connected to the rotor 30 in a embodiment, and may be integrally connected to and/or be part of a single piece with the hub 31. In other embodiments, the rotor 30 and its components (including the blades 32) may be constructed of similar structural and functional elements with different configurations. , including different ornamental appearances.

[0040] The blades 32 of the rotor 30 in FIGS. 1-11 are illustrated in greater detail in FIGS. 9-9C and 11. Each blade 32 has a proximal end 36 that engages the hub 31 and a distal end or free end 37 distal to the proximal end 36 and the hub 31. Additionally, each blade 32 has an elongated body 38 that has two broad flat surfaces 43 and two opposing sides or edges 40 extending between the ends 36, 37. The direction in which each blade 32 extends from the hub 31, that is, from the proximal end 36 toward the distal end 37, is defined as a longitudinal direction L (see FIG. 11 for reference) for each individual blade 32 as referenced herein, and it is understood that the blades 32 are individually elongated along the longitudinal direction L in one embodiment. The blades 32 can also be considered to extend radially from the hub 31. The term “elongated” indicates that the body 38 has a greater dimension in the stretching direction relative to the two directions perpendicular to the stretching direction. Each blade 32 also has one or more flanges or baffles 39 extending outwardly from the body 38 transversely to the surface of the body 38. In the embodiment of FIGS. 1-9C and 11, each blade 32 has two flanges 39 that extend along opposing sides or edges 40 of the body 38. In other embodiments, one or more of the blades 32 may include a different number or arrangement of flanges 39, e.g. example, by including one or more longitudinally extending flanges 39 located between the two edges 40 in addition to or instead of the flanges 39 extending along the edges 40. In the embodiment of FIGS. 1-9C and 11, the flanges 39 extend outwardly from only one flat surface 43 of the body 38 (e.g., the top surface), so that the blade 32 has substantially a U-shape or a U-shape. C in cross section. In another embodiment, the flanges 39 may extend outwardly from both flat surfaces 43 of the body 38 so that the blade 32 is substantially I-shaped in cross section. In another embodiment, the flanges 39 may extend outwardly from opposing flat surfaces 43 of the body 38 so that the blade 32 is substantially S-shaped in cross section. In another embodiment, the flange(s) 39 may be located on only one side 40 of the body 38. The flanges 39 in FIGS. 1-9C and 11 extend the entire length of the body 38, from the proximal end 36 to the distal end 37, but may extend less than the entire length of the body 38 in other embodiments. Additionally, the flanges 39 have a greater height near the proximal end 36 and taper continuously to a smaller height near the distal end 37 in the embodiment of FIGS. 1-9C and 11.

[0041] The blades 32 also have bezels 41 that extend outwardly from the body 38 at the proximal end 36 to provide a crimp structure for connection to the hub 31. The bezels 41 extend from the proximal end 36 on both sides 40 of body 38 in the embodiment of FIGS. 1-9C and 11, and each bezel 41 has an opening 42 for receiving fasteners 35 for connection to the hub 31. The body 38 has a proximal edge 15 that extends between the bezels 41 in this embodiment. The fasteners 35 in this embodiment pass through the openings 42 in the bezels 41 and are connected to opposing side surfaces of the hub 31, such as being received in openings (not shown), which can be threaded. As illustrated in FIGS. 9-9A, the hub 31 has two plate-like circular end portions 57 with a cylindrical central body 58 that has a smaller diameter than the end portions 57, so that the end portions 57 extend radially outward from the central body 58. End portions 57 include openings 59 configured to receive fasteners 35 for connecting blades 32. The crimps 41 are contiguous to the flanges 39 in the embodiment of FIGS, 1-9C and 11 and can be considered as extensions of the flanges 39, which adds strength and 41 bezel support for a more solid and stable connection. Additionally, since the flanges 39 extend transversely (e.g., vertically) from the body 38, the positioning of the bezels 41 at the ends of the flanges 39 allows the hub connection points (i.e., openings 42) to be displaced from the general plane of the body 38. The openings 42 in FIGS. 1-9C and 11 are displaced from the plane of the body 38 in the direction of forward rotation of the rotor 30. This orientation of displacement and arrangement allows the body 38 of each blade 32 to extend radially relative to the hub 31, while providing free space for connecting fasteners 35. In the embodiment of FIGS. 1-9C and 11, the blades 32 are all connected to and supported only in the bezels 41 at the proximal ends 36, and no other structure couples the blades 32 between the proximal and distal ends 36, 37. In particular, the hub 31 and the structures connectors that connect the blades 32 to that form the single structure that supports the blades 32 and directly or indirectly connect all blades 32 together. As described elsewhere herein, other connecting or mounting structures may be used to connect the blades 32 to the hub 31 in other embodiments, and the bezels 41 may be provided with such structures (e.g., integral hooks, clips, or other connection structures) and/or configured for connection to such structures. The blades 32 may be individually made from a single integral piece, including the body 38, the flanges 39, and the bezels 41, such as by stamping.

[0042] In the embodiment of FIGS. 1-11, the rotor 30 has a stabilizing structure that engages the blades 32 to resist pivoting of the blades 32 relative to the hub 31 due to forces exerted on the blades during rotation of the rotor 30 (e.g., air resistance). . The stabilizing structure may include adjacent mating and/or interlocking surfaces 97, 98 on hub 31 and blades 32, respectively. FIGS. 9-9C illustrate one embodiment of a stabilizing structure in the form of mating surfaces 98 at the ends of the bezels 41 of each blade 32 and a cylindrical projection 99 that forms complementary mating surfaces 97 on the hub 31 that mate with and abut the mating surfaces 9-9C. coupling 98 of each blade 32. The coupling surfaces 98 on the blades 32 in the embodiment of FIGS. 9-9C are spaced from the connection point(s) between the blades 32 and the hub 31 (e.g., the fasteners 35) and have a curved contour to match the outer curved contour of the cylindrical mating surface 97 on the hub 31, creating a more stable coupling between the parts. In the embodiment shown in FIGS. 9-9C, the hub 31 has cylindrical projections 99 that form mating surfaces 97 on both sides of the hub 31, and each blade 32 has mating surfaces 98 on both bezels 41. In another embodiment, the mating surfaces 97, 98 may be positioned on just one side of the hub 31 and/or on just one bezel 41. The coupling of the coupling surfaces 97, 98 in this embodiment resists the articulation of the blades 32 around the connection point with the hub 31 (i.e. , fastener 35). It is understood that the mating surfaces 97, 98 of the hub 31 and the blades 32 may be defined in the same locations and configurations by a different structure in other embodiments. For example, the mating surfaces 97 of the hub 31 may be defined by intermittent projections around the hub 31 rather than a single cylindrical projection 99. As another example, the mating surfaces 98 of each blade 32 may be defined over extensions of the flanges 39 even if the mounting structure for connection to the hub (e.g. bezels 41) is located and/or structured differently. In other embodiments, the stabilizing structure may be in the form of one or more additional connectors 35 that connect each blade 32 to the hub 31 that are offset from the connectors 35 in FIGS. 9-9C, or a different type of interlocking and/or adjacent coupling structure. Such an alternative coupling structure may include coupling with the body 38 of the blade 32 (e.g., edge 15) and/or coupling with the end portions 57 of the central body 58 of the hub 31. Furthermore, the stabilizing structure in FIGS. 1-11 stabilizes the blades 32 against pivoting in any rotational direction relative to the connectors 35, and in another embodiment, the rotor 30 may have a stabilizing structure that only stabilizes the blades 32 against rearward rotation during forward rotation of the rotor 30 .

[0043] The blades 32 in this embodiment have increased weight and rigidity compared to existing fan blades 32 or other rotors for exercise bikes, and the flanges 39 provide blades 32 with greater stiffness and bending rigidity as well as a safe and rigid structure for assembly of blades 32 to hub 31 as described above. These heavier and stronger 32 blades have increased inertia, resulting in smoother, more consistent effort throughout the pedal stroke and less vibration, and ultimately better overall feel for the user.

[0044] In the embodiment of FIGS. 1-11, pulley 34 and rotor 30 (including hub 31, blades 32, and any fasteners 35 or other connecting structure) form a unitary rotating body. This unitary rotating body has greater mass and greater moment of inertia (MOI) with respect to the rotating axis, when compared to fans or other rotors for exercise bikes in one embodiment, due in part to the construction of the blades 32 described herein. In one embodiment, the unitary rotating body has a weight of at least 1.58 kg (3.5 pounds) or at least 4.08 kg (9 pounds), e.g., 1.58-5.98 kg (3.5 pounds). 5-13 pounds) or 2.27-4.99 kg (5-11 pounds). The blades 32 in one embodiment may be made from steel and may each weigh at least 0.27 kg (0.6 pounds), or 0.27-0.45 kg (0.6-1.0 pounds). , or approximately 0.36 kg (0.8 pounds) in one setting. The total weight of the rotor 30 in this embodiment is at least 4.08 kg (9 pounds), or 4.08-5.44 kg (9-12 pounds), or approximately 4.53-4.99 kg (10-11 pounds), and the unitary rotating body has an MOI with respect to the rotating shaft (indicated by *inch2), or approximately 0.144 kg*m2 (495 pounds*inch2). In another embodiment, the blades 32 may be made of aluminum (which term includes aluminum alloys) and may each weigh at least 0.18 kg (0.4 pounds), or 0.18-0.25 kg ( 0.4-0.5 pounds), or approximately 0.20 kg (0.45 pounds) in one setting. The total weight of the rotor 30 in this embodiment is at least 1.59 kg (3.5 pounds), or 1.59-3.63 kg (3.5-8 pounds), or approximately 2.72 kg (6 pounds) in one configuration, and the unitary rotating body has an MOI with respect to the rotating shaft of at least 0.044 kg*m2 (150 pounds*inch2), or 0.044-0.058 kg*m2 (150-200 pounds*inch2). The blades 32 may be formed from other materials in other embodiments, including other metals and alloys, polymers, or composite materials, for example, carbon fiber composites.

[0045] The rotor 30 in FIGS. 1-9C has 10 blades 32, and in one embodiment, the rotor 30 has no more than twelve blades 32, for example 8 to 12 blades 32. The diameter of this rotor may be 68.58 cm (27 inches) in one embodiment. Current exercise bike rotors typically include a much greater number of blades, and such current rotors do not achieve a moment of inertia as described herein with as few as 8 to 12 blades. Additionally, blades 32 as described herein provide a large surface area, a correspondingly large aerodynamic profile and air displacement, and a large reflected MOI (the MOI perceived by the user after incorporation of mechanical advantage through the drive mechanism 16) with a small number of slides 32, for example, 8 to 12 slides as described herein. For example, the surface area of the unitary rotating body as described herein may be at least 0.64 m2 (1,000 inches2), or 0.64-0.77 m2 (1,000-1,200 inches2), or approximately 0.71 m2 ( 1,100 inches2). The surface area of the front surface 44 of each blade 32, that is, the surfaces facing the forward rotation direction that encounter direct air resistance during rotation, is at least 129.03 cm2 (20 inches2) or 129.03258, 06 cm2 (20-40 inches2) in one modality, or 161.29225.30 cm2 (25-35 inches2) in another modality. The front surface 44 in the embodiments of FIGS. 1-24 and 27 is formed from the forward-facing edges of the flanges 39 and the surface 43 between the flanges 39. An example of the front surface 44 is indicated by shading in FIG. 27. The surface area of the front surface 44 of each fan blade 32 in FIGS 1-11 is approximately 219.36 cm2 (34 inches2), and the surface area of the front surface 44 of each fan blade 32 in FIGS. 1-11 is approximately 219.35 cm2 (34 inches2), and the surface area of the front surface of each fan blade 32 in FIGS 13-24 and 27 is approximately 180.65 cm2 (28 inches2). In one embodiment, the surface 43 of each blade 32 on the front surface 44 faces directly in the direction of rotation of the rotor 30, that is, perpendicular to the tangential direction of travel during rotation. The configuration increases drag and air resistance and provides a uniform feel during use. As another example, the reflected MOI of the unitary rotating body including a mechanical advantage (gear ratio) of 7.540 is at least 0.00263 kg*m2 (9 pounds*inch2), or 0.00263-0.0035 kg*m2 ( 9-12 pounds*inch2), or approximately 0.0030 kg*m2 (10.25 pounds*inch2).

[0046] The weight/mass of rotor 30 is more evenly distributed across the diameter of rotor 30 compared to many current rotors, which are perimeter weighted. For example, in one embodiment, approximately 30-50% of the weight of the rotor 30 and/or the unitary rotating body is located within 25% of the maximum diameter of the rotor 30, and in another embodiment, this ratio is 35-45%. for example, approximately 40%. As another example, in one embodiment, approximately 50-70% of the weight of the rotor 30 and/or the unitary rotating body is located within 50% of the maximum diameter of the rotor 30, and in another embodiment, this ratio is 5565%, e.g. example, approximately 60%. As another example, in one embodiment, approximately 70-90% of the weight of the rotor 30 and/or the unitary rotating body is located within 75% of the maximum diameter of the rotor 30, and in another embodiment, this ratio is 75-85% , for example, approximately 80%. In the embodiment of FIGS. 13-24, the unitary rotating body has a total weight of 4.80 kg (10.6 pounds) and a diameter of 68.58 cm (27 inches), and the weight located within 25% of the maximum diameter is approximately 1 .86 kg (4.1 pounds), the weight located within 50% of the maximum diameter is 2.49 kg (6.5 pounds), and the weight located within 75% of the maximum diameter is 3.95 kg (8 .7 pounds).

[0047] It is understood that components or properties (e.g., mass/weight or MOI) are within a specified "XX%" of the maximum diameter of the rotor 30 or unitary rotating body as shown in FIG. 20 and described herein refers to being within a linear distance of XX% of the diameter of the rotor 30, measured from the rotating axis of the rotor 30 in use to the outermost periphery of the rotor 30, and measured perpendicular to the rotating axis. In other words, this phrase means that the components or properties are located within a cylinder that has a central axis aligned with the rotary axis of the rotor 30 in use and a cylindrical diameter of XX% of the diameter of the rotor 30, measured from the axis rotary axis from the rotor 30 in use to the outermost periphery of the rotor 30, and measured perpendicular to the rotary axis. Additionally, as used herein, the portion (ratio or %) of the total MOI of the rotor 30 or unitary rotating body that is formed by the structures within a specific XX% of the maximum diameter of the rotor 30 (as shown in FIG. 20) is referred to as a “partial MOI”.

[0048] The MOI of the rotor 30 is affected by the mass distribution described above, and the resulting MOI is also more evenly distributed across the diameter of the rotor 30 compared to current rotors, and perimeter-weighted rotors in particular. In the embodiments of FIGS. 1-11 and FIGS. 13-24 described herein, the unitary rotating body has a diameter of 68.58 cm (27 inches) and a total MOI of 0.127-0.155 kg*m2 (435-531 pounds*inch2) or approximately 0.141 kg*m2 (483 .0 pounds*inch2), and the portion of the MOI located within 25% of the maximum diameter is 0.00292-0.0038 kg*m2 (10-13 pounds*inch2) or approximately 0.0034 kg*m2 (11, 6 pounds*inch2), the portion of the MOI located within 50% of the maximum diameter is 0.020-0.023 kg*m2 (67-81 pounds*inch2) or approximately 0.022 kg*m2 (73.9 pounds*inch2), and the portion of the MOI located within 75% of the maximum diameter is 0.059-0.072 kg*m2 (201-245 pounds*inch2) or approximately 0.065 kg*m2 (223.2 pounds*inch2). In such an embodiment, the partial MOI of the rotor 30 or the unitary rotating body located within 25% of the maximum diameter is 2-3%, the partial MOI located within 50% of the maximum diameter is 13-19%, and the partial MOI located within 75% of the maximum diameter is 38-56%. In another embodiment, at least a 40% portion of the total MOI of the rotor 30 or unitary rotating body is located within 75% of the maximum diameter.

[0049] In one embodiment, the cross-sectional area and incremental weight of each blade 32 decreases in the longitudinal direction L, over at least a portion of the length of the blade 32. As used herein, “cross-sectional area” refers The area of the blade 32 is perpendicular to the longitudinal direction L, for example, as shown in FIG. 24. Additionally, as used herein, “incremental weight” refers to the weight of each of a number (e.g., 10, 100, 1,000, etc.) of equal-length sequential incremental segments of blade 32 along the longitudinal direction L. In embodiments where the rotor 30 includes a plurality of such blades 32, the incremental radial weight of the rotor 30 also decreases over at least a portion of the diameter of the rotor 30, from the outside of the hub 31 to the outside diameter (i.e. that is, the distal ends 37 of the blades 32). As used herein, “incremental radial weight” refers to the weight of each of a number (e.g., 10, 100, 1,000, etc.) of sequential incremental annular or tubular segments of the rotor 30 along the centered radial direction on the axis of rotation of the rotor 30 and having equal radial widths. For example, in one embodiment, the cross-sectional area and incremental weight of a blade 32 decreases in the longitudinal direction L, along at least 25%, at least 50%, or at least 75% of the length of the blade 32. Similarly , the incremental radial weight of the rotor 30 in such embodiments may also decrease by at least 25%, at least 50%, or at least 75% of the diameter of the rotor 30. In the embodiment of FIGS. 1-11, the cross-sectional area and incremental weight of each blade 32 decreases continuously in the longitudinal direction L, along the entire length of the blade 32, from the proximal edge 15 or from the proximal end 36 to the distal end 37. In In embodiments where the rotor 30 includes a plurality of such blades 32, the incremental radial weight of the rotor 30 also decreases continuously over the entire diameter of the rotor 30, from the outside of the hub 31 to the outside diameter (i.e., the distal ends 37 of the blades 32).

[0050] The drive mechanism 16 is operatively connected to the rotor assembly 14 and configured to drive rotation of the rotor assembly 16 through mechanical effort exerted by a user. The drive mechanism 16 in FIGS. 1-12 includes a set of pulleys or set of belts and pulleys 50 that drives rotation of the rotor assembly 14, a set of pedals 60 configured to drive the set of pulleys 50 by rotary motion, and a set of arms 70 configured to activate the set of pulleys 50 by reciprocal movement.

[0051] The pulley assembly 50 includes at least one input pulley 51 operatively coupled to and configured to receive input power from the pedal assembly 60 and/or the arm assembly 70, an output pulley in the form of the sprocket or pulley 34 configured to transfer power to rotor 30, and a belt 52 that couples the input pulley 51 and the output pulley 34 to transfer power from the input pulley 51 to the output pulley 34. The input pulley 51 rotates about an axis or spindle 55, and the output pulley 34 rotates about the axis 33 of the rotor 30. The pulley assembly 50 may also include one or more tension pulleys 53 located between the input pulley 51 and the output pulley 34. The pulley input pulley 51 and output pulley 34 couple to the inner surface of the belt 52, and in the embodiment of FIGS. 1-10, the inner surface of the belt 52 has multiple grooves 56 that run along the length of the belt 52 to assist in guiding the belt 52. The belt 52 may have another configuration in other embodiments, including being configured as a chain or other flexible mesh structure. The pulley assembly 50 in FIGS. 1-10 includes two tension pulleys 53 located near the input pulley 51 and the output pulley 34, respectively. The tension pulleys 53 couple to the outer surface of the belt 52 to increase the tension on the belt 52 and to increase the surface area coupling between the belt 52 and the input and output pulleys 51, 34, for the purpose of reducing Slipping. The tension pulleys 53 can be considered to divert the path of the belt 52 and create a more winding path for the belt 52 so that the belt 52 does not extend directly between the input and output pulleys 51, 34. In this embodiment, effort by the user on the pedal system 60 and/or the arm system 70 causes rotation of the input pulley 51, which drives the rotation of the output pulley 34, thereby driving the rotation of the rotor 30. It is understood that the relative diameters of the input pulley 51 and the output pulley 34 may be designed to create a desired mechanical advantage, and that the diameter of the input pulley 51 may be greater than the diameter of the output pulley 34 for that reason. The input pulley 51, the output pulley 34 and the tension pulley(s) 53 in the embodiment of FIGS. 1-10 are made of metal for greater durability, but can be made of other materials in other embodiments.

[0052] The tension pulleys 53 in the embodiments of FIGS. 1-10 individually have a concave annular surface 54 that engages the belt 52. The concave surface 54 has been demonstrated through testing to assist in guiding the belt 52 and reducing lateral movement or disconnection of the belt 52. The effectiveness of the concave surface 54 to increase stability and decrease lateral movement of the belt 52 is surprising, because general knowledge in pulley art says that the annular surface 54 should be convex, rather than concave. Generally, belts are known to travel toward the point of greatest tension, and a convex surface creates the point of greatest tension in the center of the pulley, which should translate into better performance in resisting lateral displacement. A pulley with a concave surface 54 should provide worse performance based on general knowledge in the art. However, the concave pulley surface 54 has been shown to outperform the tension pulleys 53, so that the belt 52 remains centered on the input pulley 51 and the output pulley 34 much longer during use. The concave surface 54 may have a radius of curvature of 2.54-3.81 cm (1.0-1.5 inches) in one embodiment, and the concave surface 54 in FIGS. 1-10 has a bend radius of approximately 3.175 cm (1.25 inches).

[0053] The input pulley 51, the output pulley 34 and the tension pulleys 53 in various embodiments can be positioned to increase contact between the belt 52 and the pulleys 51, 34. FIGS. 25 and 26 illustrate an embodiment of the input pulley 51, the output pulley 34 and the tension pulleys 53 that may be used in connection with embodiments described herein. The tension pulley 53 next to the output pulley 34 has a radius R1 of 15-25 mm or approximately 20 mm in one embodiment, and the output pulley 34 has a radius R2 of 20-30 mm or approximately 25 mm in one embodiment. . The tension pulley 53 and the tension pulley 34 are positioned so that the smallest distance D1 between the pulleys in this embodiment is 10-20 mm, or approximately 15 mm, and the pulleys 34, 53 are positioned so that the belt 52 is coupled to 50-65% of the circumference of the output pulley 34, or approximately 57% in one embodiment. The tension pulley 53 next to the input pulley 51 has a radius R4 of 17-28 mm or approximately 17.5 mm in one embodiment, and the input pulley 51 has a radius R3 of 130-170 mm or approximately 150 mm in one embodiment. a modality. The tension pulley 53 and the input pulley 51 are positioned so that the smallest distance D2 between the pulleys in this embodiment is 45-55 mm, or approximately 51 mm, and the pulleys 51, 53 are positioned so that the belt 52 is engaged with 60-75% of the circumference of the output pulley 34, or approximately 69% in one embodiment. Pulleys 51, 34, 53 of FIGS. 25-26 may be used in connection with any embodiments described herein.

[0054] The pedal assembly 60 as shown in FIGS. 1-10 generally includes two pedals 61 each attached to the end of one of two cranks 62 by means of spindle mechanisms, with each of the cranks 62 operatively connected to the input pulley 51 on opposite sides of the input pulley 51 to drive the rotation of the input pulley 51. In the embodiment of FIGS. 1-10, cranks 62 are connected to input pulley 51 by bell cranks 63 to create an eccentric rotating mechanism. Each bell crank 63 has a pivot connection 64 that is rotatably fixed to the input pulley 51 and allows the bell crank 63 to rotate on or in alignment with the shaft 55 of the input pulley 51, as well as an arm 65 with a connection orbital 66 at or near its distal end. Orbital connection 66 orbits pivot connection 64 and is connected to pedal 61, such as by the spindle mechanism discussed herein. The cyclic movement of the pedals 61 by user effort therefore drives the rotation of the input pulley 51. The pedal assembly 60 may include additional components, such as spindles, axles, and connecting structures for connecting the components of the pedal assembly. 60 to each other and/or to other components such as the frame 12 or the pulley assembly 50. For example, in one embodiment, the hinged connection 64 may be connected to drive the rotation of the shaft 55 to thereby drive the rotation of the pulley input 51, and in another embodiment, the hinged connection 64 may be connected directly to the input pulley 51 so that both the bell crank 63 and the input pulley 51 rotate freely on shaft 55. It is understood that other pedal mechanisms may be used to drive rotation of the input pulley 51 in other embodiments, such as a spindle mechanism where cranks 62 drive rotation of the input pulley 51 by rotation of the spindle.

[0055] The set of arms 70 as shown in FIGS. 1-12 generally includes two arms 71 each connected to a shaft 72 at a pivot point 73, with each of the shafts 72 connected to a lever arm 74 and each of the lever arms 74 connected to a pivot rod or connection 75 that is operatively connected to the pulley assembly 50 and the pedal assembly 60. One of the articulated systems 75 is shown in greater detail in FIG. 12. Each of the arms 71 is an elongated member with a handle 76 that can extend transversely to the arm 71. The arms 71 are connected to the axles 72 and are configured to pivot back and forth about the pivot point 73 in an oscillatory motion, and the user can use the wrists 76 to pull and push the arms 71 in this oscillatory motion. Handles 76 as shown in FIGS. 1-8 extend perpendicular to the arms 71, but may be configured at oblique (i.e., not perpendicular) angles to the arms 71 in other embodiments. For example, the handles 76 may extend outward and rearward (i.e., toward the seat 24) at oblique angles to the arms 71 in one embodiment, which may improve ergonomics. Furthermore, the handles 76 shown in FIGS. 1-8 are fixed relative to the arms 71, but may additionally or alternatively be connected to the arms 71 in a manner so as to rotate freely about their elongation axes.

[0056] In the embodiment of FIGS. 1-12, the proximal ends of the lever arms 74 are rotationally fixed with respect to the ends of the arms 71, such as by the arms 71 and the lever arms 74 both being rotationally fixed with respect to respective axes 72. In this configuration, the arms lever arms 74 move with the same pivoting and oscillating motion as the arms 71. The distal ends of the lever arms 74 are connected to a first end 77 of each of the hinged systems 75 in a connecting structure 82 so that the pivot system 75 can rotate freely relative to the distal ends of the lever arms 74. Oscillatory movement of the arms 71 and the lever arms 74 results in reciprocal forward and backward movement of the pivot systems 75. A second end 78 of each of the articulated systems 75 is connected to the orbital connection 66 at the distal end of the bell crank 63 by a connecting structure 82 and is also freely rotatable with respect to the orbital connection 66. In this configuration, the reciprocal movement of the articulated systems 75 drives the orbital movement of the bell crank 63 and thus also drives the rotation of the input pulley 51 through mechanisms described in this document. Consequently, the user can exert force to drive rotation of the main pulley 51 through rotary effort on the pedals 61 and reciprocal or oscillatory effort on the arms 71. The connecting structures 82 of each articulated system 75 in FIGS. 1-10 and 12 are in the form of openings that receive other structures through them, for example, bearings, shafts, spindles, etc. In another embodiment, the linkages 75 and the cranks 62 may be connected to different orbital connections 66 on the arm 65 of the bell crank 63, such that the cranks 62 are individually connected to a first orbital connection 66 on the respective bell crank 63 and the articulated systems 75 are individually connected to a second orbital connection 66 on the respective bell crank 63.

[0057] The articulated systems 75 in the embodiment of FIGS. 1-10 and 12 have side edges 79 extending in the direction of reciprocating movement that are straight and parallel to each other. In other words, each of the hinges 75 extends in a straight linear fashion between the ends 77, 78. In this configuration, the body of each hinged system 75 has a flat surface 80 that extends the entire distance between the ends 77 , 78 on both inner and outer sides. It is understood that the hinged systems 75 may have a ridge and/or recess 81 on the inner and/or outer sides for the purpose of increasing rigidity, but such ridge/recess 81 does not extend to any of the side edges 79 of the hinged systems 75 This configuration is different from current articulated systems, which typically have a side bend or similar structure to accommodate differences in width between the arm connections and the pedal connections. The resulting structure in FIGS. 1-10 and 12 allows a straight line to be drawn between the connecting structures 82 at the ends 77, 78 that extend over the flat surface(s) 80 for their entire length and/or for a plane to be drawn that intersects both connecting structures 82 and traverses both edges 79 for the entire distance between the connecting structures 82. In this configuration, the entire force exerted along the length of each hinged system 75 is a compressive force or tension, rather than a shear force, bending force, or moment that might exist if the hinged system 75 were not straight. This results in greater rigidity and efficiency in use compared to articulated systems that are not straight, which can waste energy through flexing or arching, as well as a superior sense of synchronization between the movement of the arms 71 and pedals 61 compared to articulated systems. with some degree of flexion.

[0058] In another embodiment, the set of pulleys 50 of FIGS. 1-11 may be incorporated into an exercise bike that does not have a set of arms 70, or into other types of exercise equipment that utilize one or more sets of pulleys with or without a fan or other type of rotor assembly. Similarly, the set of arms 70 and articulated systems 75 of FIGS. 1-10 and 12 may be incorporated into an exercise bike that uses a different type of pulley set 50 or does not use a pulley set, or in other types of exercise equipment that use articulated arms to drive movement.

[0059] In one embodiment, the bicycle 10 may have a computer system connected to various components of the bicycle 10 to monitor and/or collect data regarding the operation of the bicycle 10, as well as make calculations based on such data. For example, one such computer system may include a rotary sensor for detecting rotational speed of the rotor 30, as well as a computer memory for storing data gathered by the rotary sensor, and a computer processor for making calculations based on such data, e.g. to calculate virtual distance traveled or calories burned. In one embodiment, the computational system for each individual bicycle 10 may be calibrated to that bicycle's power input requirements (determined through testing and/or calculation), such that calculated caloric expenditure data has increased accuracy. Bicycle 10 in FIGS. 1-10 includes an interface 19 that is positioned to be viewed and/or manipulated by a user and may include visual output, audio output, and/or buttons or other input device(s) for manipulation.

[0060] Bicycle 10 in FIGS. 1-10 also includes various covers and similar components for storing and/or hiding moving parts of the bicycle. Many such coverings are not shown in FIGS. 5-10 for the purpose of revealing internal details. For example, the bicycle 10 includes a rotor cover 18 that covers the rotor 30 to protect it from contact with the rotor 10 during rotation. The rotor cover 18 is a cage or similar structure with multiple openings that allow air to pass through, as shown in FIGS. 1-4 and 13-17, which protects the rotor 30 while allowing air displaced by the rotor 30 to flow freely through the rotor cover 18. The rotor cover 18 includes one or more openings or cutouts 91 to allow the hinged systems 75 pass through the rotor cover 18 to connect the set of arms 70 to the pedal set 60 and also to allow the belt 52 to pass through the rotor cover 18 to drive rotation of the rotor 30. It is understood that the rotor cover 18 can be formed by two or more pieces that are connected together. The rotor cover 18 in FIGS. 1-10 is formed of three pieces, as is the rotor cover 18 in FIGS. 13-17, and this structure is illustrated more clearly in FIG. 17. The configuration of the rotor cover 18 in this embodiment includes a front piece 18A that forms approximately the front half of the cover 18 and two rear pieces 18B that each form upper and lower rear quarters of the cover 18. This configuration can provide greater stability and ease of connection compared to existing “clamshell” cover configurations. As shown in FIGS. 13-14, the bicycle 10 may further include an air shield 92 that may be positioned to cover an upper rear portion of the rotor cover 18 to prevent air displaced by the rotor 30 from blowing into the user's face. The air shield 92 may be connected to the frame 12 and/or the rotor cover 18 in this position. In other embodiments, the rotor cover 18 and the air shield 92 may be constructed of similar structural and functional elements that have different configurations, including different ornamental appearances.

[0061] As another example, the bicycle 10 may include a pulley cover 93 that covers certain components of the pulley assembly 50 and the pedal assembly 60, as well as portions of the linkages 75. The pulley cover 93 in FIGS. 1-4 is positioned immediately adjacent to the rotor cover 18 and has an opening 94 adjacent to the opening 91 of the rotor cover 18 so that the hinges 75 can extend directly from the rotor cover 18 into the pulley cover 93 and are not exposed at any point. The pulley cover 93 may be formed from multiple pieces, such as two half pieces each positioned over one side of the input pulley 51. As another example, the bicycle 10 may include pedal covers 95 that are positioned to cover the bell cranks. 63 of pedal assembly 60. Pedal covers 95 in FIGS. 1-4 are fixedly coupled to the cranks 62 of the pedal assembly 60 and rotate together with the bell cranks 63. Other covers and similar components may be used in other embodiments. In other embodiments, the pulley cover 83, pedal covers 95, and other bicycle cover components 10 may be constructed of similar structural and functional elements that have different configurations, including different ornamental appearances.

[0062] FIGS. 13-24 illustrate another embodiment of the bicycle 10 of FIGS. 1-12 in many ways. Bicycle 10 in FIGS. 13-24 will therefore be described only in relation to significant differences from bicycle 10 in FIGS. 1-12, for reasons of brevity. Any of the features, components and configurations described herein in relation to FIGS. 13-24 may be used in connection with other embodiments described herein, including the embodiments of FIGS. 1-12 and vice versa. It is understood that any components and features described herein in relation to FIGS 1-12 are considered to be present in the embodiment of FIGS. 13-24, and vice versa, unless otherwise specified. In the embodiment of FIGS. 13-24, bicycle 10 has an air shield 92 as described above connected to rotor cover 90. Additionally, bicycle 10 in FIGS. 13-24 have pedal covers 95 that are ornamentally different from the pedal covers 95 in FIGS. 1-4, as well as other components with ornamental differences. Bicycle 10 in FIGS. 13-24 further has a device holder 96 configured to support a mobile device, such as a telephone, in a position easily visible and accessible to the user. Another difference between the modality of FIGS. 13-24 and the embodiment of FIGS. 1-12 is the structure of the bell cranks 63, which is seen more clearly in FIG. 17. In this embodiment, the bell crank 63 on the side of the frame 12 with the input pulley 51 has a body 67 connected directly to the input pulley 51 and a spindle 68 extending from the body 67 and forming the axis 55 of the pulley. input. The body 67 may be considered to constitute the arm 65 of the bell crank 63 as described herein. Spindle 68 also runs through the frame and connects to bell crank 63 on the opposite side. FIG. 17 does not illustrate the air shield 92 or the device holder 96. Another difference between the embodiment of FIGS. 13-24 and the embodiment of FIGS. 1-12 is the structure of the blades 32 of the rotor 30. The blades 32 of the embodiment of FIGS. 13-24 are shown in greater detail in FIGS. 21-24 and are described below. It is noted that FIG. 17 depicts several components that are not visible or are only partially visible in other figures, many of which may not be specifically described herein. FIG. 17 illustrates the location, orientation and structure of these components, and one skilled in the art will recognize the identity and function of such components.

[0063] The blades 32 in the embodiment of FIGS. 13-24 have a stepped or terraced cross-sectional shape and an asymmetrical profile at the distal end 37. The asymmetrical distal end 37 is illustrated more clearly in FIG. 22, wherein one of the sides 40 (and the flange 39 extending along that side 40) is shorter in length than the longer side 40 and extends further from the proximal end 36 than the longer side 40. The result of this configuration is that the distal end 37 has an asymmetrical configuration. The distal end 37 in FIG. 22 has a curvilinear arc contour, where the apex of the arc is located off-center and closer to the longer side 40 than the shorter side 40. In other embodiments, the distal end 37 in such an asymmetrical configuration may be straight linear and not perpendicular to the sides 40, and/or may have a protruding or chamfered configuration, among others.

[0064] The cross-sectional shape of the blades 32 in FIGS. 13-24 is shown more clearly in FIGS. 21 and 2324. In a stepped or terraced configuration, one or both surfaces 43 of blade 32 have a first or upper portion 45 and a second or lower portion 46 that are connected together by one or more bosses or stepped portions 47 The upper portion 45, the lower portion 46 and the stepped portions 47 all extend longitudinally and are positioned side by side in this embodiment. It is understood that "top" and "bottom" as used herein depends on orientation, and the present description of the top and bottom portions 45, 46 is made in relation to the orientation shown in FIGS. 23-24. The flanges 39 in this embodiment are positioned at an angle A1 with the upper portion 45 which is approximately 90°. In the embodiment of FIGS. 21 and 23-24, the upper and lower portions 45, 46 are generally planar and parallel to each other and therefore the angle between the flanges 39 and the lower portions 46 are also equivalent to A1. Additionally, the lower portions 46 are parallel and coplanar with each other. The blades 32 in FIGS. 21 and 23-24 are thin sections (with thickness T which is 1-2 mm, e.g. 1.5 mm), with opposing surfaces 43 which are mirror images of each other. As seen in FIGS. 21 and 23-24, the upper portion 45 is located in the gap or central area of the blade 32, with two lower portions 46 extending from the ends of the upper portion 45 to the sides 40 of the blades 32. The upper and lower portions 45 , 46 are offset vertically relative to each other, and the stepped portions 47 extend from opposite edges of the upper portion 45 to the two lower portions. The stepped portions 47 extend both outwardly and downwardly (relative to the orientation in FIGS. 23-24) from the upper portion 45 to the lower portion 46, and in the configuration shown, the stepped portions 47 form oblique angles. (i.e., not perpendicular) with the upper and lower portions 45, 46. The stepped portions 47 form angles A2 with the upper portion 45 of 120o-140o, and as shown in FIG. 24, this angle A2 is approximately 129o. In a configuration where the upper and lower portions 45 are parallel to each other, the angle between the lower portions 45 and the stepped portions 47 is equivalent to A2. The resulting angle A3 between the stepped portions 47 and the flanges 39 can be represented by the equation A3 = A2 - A1, and as shown in FIG. 24 where A1 is approximately 90o, this angle A3 is approximately 39o. In another embodiment, the stepped portions 47 may be inclined differently relative to the upper portion 45 and/or the lower portions 46, including at right angles. The height H of the stepped portions 47 is defined as the difference in height between the surfaces of the upper and lower portions 45, 46, and can therefore be considered equivalent to the degree of vertical displacement between the upper and lower portions 45, 46. The height H is 2-3 mm in one embodiment, or approximately 2.5 mm in the embodiment of FIG. 24. In one embodiment, the height H of the stepped portions 47 is greater than the thickness T of the blade 32. As seen in FIGS. 21 and 22, the upper portion 45, the lower portions 46, and the stepped portions 47 extend in the longitudinal direction along the entire length of the blade 32, from the proximal end 36 to the distal end 37. This stepped configuration improves rigidity. and flexural strength of the blades 32.

[0065] The various embodiments of an exercise bike 10 shown and described in this document provide advantages over current exercise bikes and other exercise equipment. The bicycle 10 has a strong construction, with greater rigidity and weight in the components of the rotor assembly 14 and the drive mechanism 16 compared to other exercise bicycles. For example, the blades 32 of the rotor assembly 14 have greater weight and structures to increase the rigidity and bending resistance of the blades 32, which creates better feel, less vibration and noise, and more consistent effort throughout the course of the exercise. As another example, the linkage systems 75 have a larger gauge and straight or planar shape, which reduces energy loss and increases synchronization between the arm set 70 and the pedal set 60. Other components of the bicycle 10 provide improved performance, such as the concave structure of the resistance pulleys 53, which surprisingly improved traction and kept the belt 52 better centered during use. Still other benefits and advantages are recognizable to those skilled in the art.

[0066] Several alternative embodiments and examples have been described and illustrated in this document. A person skilled in the art would understand the features of the individual embodiments, and the possible combinations and variations of the components. A person skilled in the art would further understand that any of the modalities could be provided in any combination with the other modalities described herein. It is understood that the invention can be embodied in other specific forms without diverging from its spirit and its central characteristics. The present examples and embodiments, therefore, should be considered in all respects as illustrative and not restrictive, and the invention is not limited to the details given herein. The terms “top”, “bottom”, “front”, “rear”, “side”, “back”, “proximal”, “distal” and the like, as used in this document, are intended for illustrative purposes only and not limit the modalities in any way. Nothing in this specification shall be deemed to require a specific three-dimensional orientation of structures for the purpose of falling within the scope of this invention, unless explicitly specified by the claims. “Integral joining technique,” as used herein, means a technique for joining two parts so that the two parts effectively become a single integral part, including, but not limited to, irreversible joining techniques such as welding, brazing, welding, or similar, where the separation of the joined parts cannot be carried out without structural damage to them. Additionally, the term “plurality,” as used herein, indicates any number greater than one, both disjunctively and conjunctively, when necessary, up to an infinite number. The term “approximately”, as used in this document, indicates a variance of +/- 10% of the stated nominal value. For quantitative values described in this document that do not include decimal points, each digit to the left of the decimal point is considered to be a significant digit. Accordingly, although specific embodiments have been illustrated and described, numerous modifications come to mind without significantly diverging from the spirit of the invention and the scope of protection is only limited by the scope of the appended claims.

Claims (26)

1. Exercise bicycle (10) comprising: a frame (12) configured to rest on a ground surface and having a seat (24) configured to support a user; a rotor (30) supported by the frame, the rotor comprising a hub (31) supported by the frame for rotation about a first axis (X), and a plurality of blades (32) connected to the hub, wherein the hub and the plurality of blades are configured to rotate together about the first axis, and wherein the plurality of blades includes a first blade having a proximal end (36) connected to the hub and an elongated body (38) extending outward in a longitudinal direction. (L) from the hub to a distal end (37), the elongated body having upper and lower surfaces (43) and first and second edges (40) extending between the proximal and distal ends; and a drive mechanism (16) operatively connected to the rotor for driving rotation of the rotor; characterized by the fact that: the body of the first blade comprises an upper portion (45) extending in the longitudinal direction in a first area of the first blade and a first lower portion (46) extending in the longitudinal direction in a second area of the first blade, wherein the upper portion is vertically displaced from the first lower portion, and wherein the body of the first blade further comprises a first stepped portion (47) extending downwardly from the upper portion to the first lower portion, wherein the upper portion of the first blade is also laterally displaced from the first lower portion, and wherein the first stepped portion extends laterally outwardly and downwardly from the upper portion to the first lower portion. 2. Exercise bicycle, according to claim 1, characterized by the fact that the hub comprises a first and a second circular plates (57) and a cylindrical central body (58) that extends axially between the first and second plates circular plates, the central body having a smaller diameter than that of the first and second circular plates, and wherein the first blade is formed as a single integral piece and is engaged by a connecting structure to connect the first blade to the first circular plate of the hub at a first connection point near the first edge and to connect the first blade to the second circular plate of the hub at a second connection point near the second edge. 3. The exercise bicycle of claim 2, wherein the rotor further comprises a toothed wheel (34) operatively connected to the hub, wherein the plurality of blades includes 8 to 12 blades and the rotor has a total weight of 4,085.44 kg (9 to 12 pounds), and each of the blades weighs 0.27 to 0.45 kg (0.6 - 1.0 pounds). 4. Exercise bicycle according to claim 1, characterized by the fact that 70-90% of the weight of the rotor is located within 75% of the maximum diameter of the rotor. 5. Exercise bicycle according to claim 4, characterized by the fact that 50-70% of the weight of the rotor is located within 50% of the maximum diameter of the rotor, and wherein 30-50% of the weight of the rotor is located within 25% of the maximum rotor diameter. 6. Exercise bicycle according to claim 2, characterized in that the hub and the connecting structure connecting the blades to the hub form a single support structure for the blades. 7. Exercise bicycle according to claim 4, characterized by the fact that the rotor has a partial moment of inertia of 38-56% located within 75% of the maximum diameter of the rotor. 8. The exercise bicycle of claim 1, wherein the first blade has a cross-sectional area obtained perpendicular to a longitudinal direction of the first blade that decreases in the longitudinal direction over at least a portion of a length of the first blade between the proximal end and the distal end. 9. The exercise bicycle of claim 1, wherein the first blade has an incremental mass that decreases in a longitudinal direction of the first blade along at least a portion of a length of the first blade between the proximal end and the distal end. 10. Exercise bicycle, according to claim 1, characterized by the fact that the drive mechanism comprises a set of pulleys (50) supported by the frame and operatively connected to the rotor. 11. Exercise bicycle according to claim 10, characterized by the fact that the drive mechanism further comprises a set of pedals (60) operatively connected to the set of pulleys to drive the rotation of the rotor through the set of pulleys. 12. Exercise bicycle, according to claim 10, characterized by the fact that the drive mechanism further comprises a set of arms (70) operatively connected to the set of pulleys to drive the rotation of the rotor through the set of pulleys. 13. The exercise bicycle of claim 1, wherein the drive mechanism comprises a set of pedals (60) operatively connected to the rotor to drive rotation of the rotor. 14. Exercise bicycle according to claim 1, characterized in that the distal end of the first blade defines a maximum diameter of the rotor. 15. The exercise bike of claim 2, wherein the first blade has a proximal edge (15) extending between the first and second edges at the proximal end, and wherein the proximal edge is spaced from the central body of the cube between the first and second connection points. 16. Exercise bike according to claim 2, characterized by the fact that the first blade has a width (W1) defined between the first and second edges, and the width of the first blade is constant from the proximal end to the distal end. 17. Exercise bike according to claim 1, characterized by the fact that the first blade further comprises a first flange (39) connected to the body and extending from the body transversely to the upper and lower surfaces; wherein the first flange extends along the first edge of the first blade, the first flange has a first extension (41) that extends outwardly in the longitudinal direction from the proximal end of the body to form a first bezel (41) that is contiguous to the first flange, and wherein the first bezel is connected to the hub to connect the first blade to the hub. 18. The exercise bicycle according to claim 17, characterized in that the first blade further comprises a second flange (39) extending transversely to the upper and lower surfaces along the second edge of the first blade, wherein the second flange has a second extension (41) which extends outwardly in the longitudinal direction from the proximal end of the body to form a second bezel (41) which is contiguous to the second flange, and wherein the second bezel is connected to the hub for connect the first blade to the hub. 19. The exercise bicycle according to claim 17, characterized in that the first blade has a first coupling surface (98) spaced from a connection point between the first bezel and the hub, and the hub has a surface of complementary coupling (97) which couples to the first coupling surface of the first blade to resist articulation of the first blade about the connection point. 20. Exercise bike according to claim 1, characterized by the fact that a width (W1) of the first blade, measured between the first and second edges, is constant from the proximal end to the distal end. 21. Exercise bike according to claim 1, characterized by the fact that the upper portion is located in a central area of the first blade and the first lower portion is located along the first edge, and wherein the body of the first blade further comprises a second lower portion (46) extending in the longitudinal direction along the second edge, wherein the upper portion is offset vertically from the first and second lower portions, and wherein the body of the first blade further comprises a second stepped portion (47) extending downwardly from the upper portion to the second lower portion. 22. Exercise bicycle according to claim 1, characterized by the fact that the distal end of each blade is a free end. 23. Exercise bicycle according to claim 1, characterized by the fact that the connections between the hub and the plurality of blades form a single support structure for the plurality of blades. 24. Exercise bicycle according to claim 2, characterized by the fact that each blade has a first coupling surface (98) spaced from the first connection point between the respective blade and the first circular plate-like terminal portion, and the hub has a complementary mating surface (97) that couples with the first mating surface of each blade to resist articulation of the respective blade about the first connection point. 25. The exercise bicycle according to claim 24, characterized in that each blade has a second coupling surface (98) spaced from the second connection point between the respective blade and the second circular plate-like terminal portion, and the hub has a second complementary mating surface (97) that couples to the second mating surface of each blade to resist articulation of the respective blade about the second connection point. 26. The exercise bicycle of claim 2, wherein each blade has a first portion extending laterally outwardly from the first plate-like circular terminal portion and a second portion extending laterally outwardly from the second portion. circular plate-type terminal.