Control device for a bicycle

Abstract

A control device for a bicycle includes a housing having a base portion and an extension portion. The base portion of the housing has an inwardly facing side and an outwardly facing side. The control device includes a lever coupled to and pivotable relative to the housing and a master cylinder portion supported by the housing. The master cylinder portion has a hollow fluid cylinder. The control device further includes a piston assembly supported by the housing. The piston assembly is movable relative to the master cylinder portion. At least a portion of the piston assembly is disposed within the master cylinder portion. The master cylinder portion is angled relative to the outwardly facing side of the base portion of the housing such that a first end of the fluid cylinder is closer to the outwardly facing side relative to a second end of the fluid cylinder.

Description

Technical Field

[0001] This disclosure generally relates to control devices for bicycles, and more specifically, to control devices for bicycle braking mechanisms and shifting mechanisms. Background Technology

[0002] Many vehicles, such as bicycles, utilize hydraulic braking systems that apply pressure to rotating components, wheels, or discs mounted on wheels. Some of these braking systems use a mechanism including a brake lever to generate pressure in a hydraulic fluid. This pressure is transmitted through hydraulic lines or conduits to the brake assembly, whereby hydraulic pressure is applied to the brake assembly's pads to compress them against the rotating components, thus imparting braking force.

[0003] The mechanism including the manual lever can be part of a control unit that also includes an electronic shift control system. The electronic shift control system also includes a shift lever positioned at least adjacent to the brake lever, a transmitter configured to wirelessly transmit shift signals, and a battery unit configured to power the transmitter. The control unit can be mounted on the bicycle handlebars, allowing the rider to activate both the brake lever and the shift lever. Summary of the Invention

[0004] In one example, a control device mountable to a bicycle handlebar includes a housing having a base portion and an extension portion. The base portion of the housing has a front end, a rear end opposite the front end, a downward-facing side, an upward-facing side, an inward-facing side, an outward-facing side, and a handlebar clamp disposed at the rear end. The control device further includes: a rod coupled to and pivotable relative to the housing; and a master cylinder portion supported by the housing. The master cylinder portion has a fluid cylinder. The fluid cylinder has a first end and a second end opposite the first end, and a cylindrical wall located between the first end and the second end. The fluid cylinder is hollow, such that an opening extends from the first end through the master cylinder portion to the second end. The control device also includes a piston assembly supported by the housing. The piston assembly is movable relative to the master cylinder portion. At least a portion of the piston assembly is disposed within the master cylinder portion. The main cylinder portion is angled relative to the outward-facing side of the base portion of the housing, such that the first end of the fluid cylinder is closer to the outward-facing side than the second end of the fluid cylinder.

[0005] In one example, the control device further includes a push rod. The rod is coupled to the piston assembly via the push rod, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion.

[0006] In one example, the master cylinder portion has a central axis extending along the length of the master cylinder portion. The control device also includes a pivot axis for pivotally connecting the rod to the housing. The pivot axis defines a pivot axis about which the rod is pivotable relative to the housing. The pivot axis is perpendicular to the central axis of the master cylinder portion, such that the rod pivots in a plane that is aligned with or parallel to the central axis of the master cylinder portion.

[0007] In one example, the pivot is positioned above the push rod relative to the downward-facing side of the base portion of the housing.

[0008] In one example, the control device further includes a fluid chamber at least partially disposed within the extension of the housing. The pivot shaft is disposed between at least a portion of the fluid chamber and the push rod.

[0009] In one example, the cylindrical wall of the fluid cylinder has at least one inner annular surface and at least one outer annular surface. The cylindrical wall of the fluid cylinder includes an opening extending from the inner annular surface of the at least one inner annular surface of the cylindrical wall through the cylindrical wall to the outer annular surface of the at least one outer annular surface.

[0010] In one example, the piston assembly includes a piston and a seal disposed around the piston. Fluid energy can be disposed within a volume between the piston and the fluid cylinder. The piston assembly is configured to translate relative to the master cylinder portion in a first direction from a first position toward a second position when the rod pivots relative to the housing in a first rotational direction, such that the seal moves toward an opening through the cylindrical wall of the fluid cylinder and ejects a portion of the fluid from the master cylinder portion to actuate the bicycle's brake calipers.

[0011] In one example, the master cylinder portion further includes a fluid port supported by the base portion of the housing, a vent supported by the extension portion of the housing, and a fluid passage within the housing. The fluid passage is between the fluid chamber and the master cylinder portion. When the piston assembly is in a first position relative to the master cylinder portion, the control device has a fluid path between the fluid port and the vent, via an opening penetrating the master cylinder portion, an opening penetrating the cylindrical wall of the fluid cylinder, a volume between the fluid cylinder and the housing, the fluid passage, and the fluid chamber.

[0012] In one example, the master cylinder portion has a central axis extending along the length of the master cylinder portion. When the control device is mounted to the handlebars of the bicycle, the central axis of the master cylinder portion extends substantially horizontally relative to the flat surface on which the bicycle is supported.

[0013] In one example, a control device mountable to a bicycle handlebar includes a housing having a base portion and an extension portion. The base portion of the housing has a front end, a rear end opposite the front end, a downward-facing side, an upward-facing side, an inward-facing side, an outward-facing side, and a handlebar clamp disposed at the rear end. The control device further includes: a rod coupled to and pivotable relative to the housing; and a master cylinder portion supported by the housing. The master cylinder portion has a fluid cylinder. The fluid cylinder has a first end and a second end opposite the first end, and a cylindrical wall located between the first end and the second end. The fluid cylinder is hollow, such that an opening extends from the first end through the master cylinder portion to the second end. The control device further includes a piston assembly supported by the housing, movable relative to the master cylinder portion, at least a portion of the piston assembly being disposed within the master cylinder portion. The control device further includes a first adjustment mechanism configured to adjust the angular position of the rod relative to the housing such that when the control device is mounted to the handlebars of the bicycle, the distance between the end of the rod and the handlebars is also adjusted. The control device also includes a second adjustment mechanism configured to adjust the initial position of the piston assembly relative to the opening through the cylindrical wall of the fluid cylinder.

[0014] In one example, the piston assembly includes a piston and a seal disposed around the piston. Fluid energy can be disposed within a volume between the piston and the fluid cylinder. The piston assembly is configured to translate relative to the master cylinder portion from a first position toward a second position in a first direction when the rod pivots relative to the housing in a first rotational direction, such that the seal moves toward the opening through the cylindrical wall of the fluid cylinder and ejects a portion of the fluid from the master cylinder portion to actuate the bicycle's brake calipers.

[0015] In one example, the control device further includes a push rod. A first end of the push rod is coupled to the rod via the first adjusting mechanism, and a second end of the push rod is coupled to the piston assembly, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion. The first adjusting mechanism includes a threaded connection between the push rod and the rod at or near the first end of the push rod. The rod is pivotally connected to the housing such that when the push rod rotates relative to the rod in a first rotational direction via the threaded connection between the push rod and the rod, an end of the rod moves toward the base portion of the housing.

[0016] In one example, the first end of the push rod is accessible via an opening through the rod and is rotatable.

[0017] In one example, the second adjustment mechanism includes a cam rotatable relative to the piston assembly. The piston assembly is biased against the cam such that the cam acts as a stop and positions the piston assembly in an initial position relative to the master cylinder portion. The cam is configured to translate the piston assembly relative to the master cylinder portion when the cam rotates relative to the piston assembly.

[0018] In one example, the master cylinder portion has a central axis extending along its length. The cam is rotatable relative to the piston assembly about a cam rotation axis. The cam rotation axis is perpendicular to the central axis of the master cylinder portion. The cam has multiple sides. Each of the multiple sides has a different height in a direction along or parallel to the central axis of the master cylinder portion.

[0019] In one example, the control device further includes: a push rod; and a push rod support, the push rod support including a receiving portion at a first end of the push rod support. The push rod support is connected to the push rod at the receiving portion. The push rod support supports the cam at or near a second end of the push rod support. The second end of the push rod support is opposite to the first end of the push rod support. The rod is coupled to the piston assembly via the push rod, the push rod support, and the cam, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion.

[0020] In one example, the second adjustment mechanism includes a hollow dial supported by the housing. The second adjustment mechanism is configured such that rotation of the hollow dial relative to the housing causes one of the piston assembly and the master cylinder portion to translate relative to the other of the piston assembly and the master cylinder portion.

[0021] In one example, the control device further includes: a push rod; and a push rod support, the push rod support including a receiving portion at a first end of the push rod support. The push rod support is connected to the push rod at the receiving portion. The second adjustment mechanism further includes a hollow adapter having an inner annular surface and an outer annular surface. A second end of the push rod support is threadedly connected to the hollow adapter at the inner annular surface of the hollow adapter, and the inner annular surface of the hollow dial is connected to the outer annular surface of the hollow adapter. The hollow adapter abuts against the piston of the piston assembly and is configured to rotate with the hollow dial, and to rotate and translate relative to the push rod support via the threaded connection between the push rod support and the hollow adapter, such that rotation of the hollow dial relative to the housing causes the hollow adapter, and consequently causes the piston assembly to translate relative to the master cylinder portion.

[0022] In one example, the control device further includes a push rod. The piston of the piston assembly includes a receiving portion located at an end of the piston. The piston is connected to the push rod at the receiving portion. The inner annular surface of the hollow dial is threadedly connected to the outer annular surface of the fluid cylinder. The hollow dial is rotatable relative to the fluid cylinder via the threaded connection between the inner annular surface of the hollow dial and the outer annular surface of the fluid cylinder, such that rotation of the hollow dial relative to the housing causes translation of the fluid cylinder relative to the piston assembly.

[0023] In one example, the control device further includes a cover attached to the housing. The cover covers at least a portion of the housing. The cover is movable relative to the housing from a first position relative to the housing to a second position relative to the housing, such that the hollow dial is accessible when the cover is in the second position relative to the housing.

[0024] In one example, the control device further includes: a shift lever coupled to and movable relative to the housing; and an electrical switch actuated by movement of the shift lever. The control device also includes a controller in communication with the electrical switch. The controller is configured to generate a shift signal in response to actuation of the electrical switch. The control device also includes a battery housing supported by the base portion of the housing. The battery housing is electrically connected to the controller such that when a battery is disposed within the battery housing, the battery is configured to supply power to the controller, the electrical switch, or a combination thereof. The control device also includes a battery cover that closes the battery housing and is removably attached to the battery housing or the housing.

[0025] In one example, the battery housing opens toward the downward-facing side or the inward-facing side of the base portion of the housing.

[0026] In one example, the battery housing is supported within the housing between the downward-facing side of the base portion of the housing and the master cylinder portion.

[0027] In one example, the extension of the housing has an inward-facing side and an outward-facing side. The outward-facing side is opposite to the inward-facing side. The electrical switch is a first switch. The control device also includes a second switch, which is supported by the extension of the housing at or near the inward-facing side of the extension.

[0028] In one example, the control device further includes an actuator that communicates with the second switch, such that the second switch can be actuated via the actuator. The actuator is supported by the inward-facing side of the extension of the housing.

[0029] In one example, the second switch is electrically connected to the controller such that when the battery is disposed within the battery housing, the battery is configured to power the second switch. Attached Figure Description

[0030] The object, features, and advantages of the present invention will become clear after reading the following description in conjunction with the accompanying drawings, in which:

[0031] Figure 1 A side view of an example bicycle that can be equipped with a control device constructed according to the teachings of this disclosure;

[0032] Figure 2 It is one implementation method of the control device and Figure 1 A first side view of a portion of the handlebars of a bicycle;

[0033] Figure 3 It was removed from the handlebars. Figure 2 First side view of the control device;

[0034] Figure 4 yes Figure 2 control device and Figure 1 An external 3D view of a portion of the handlebars of a bicycle;

[0035] Figure 5 yes Figure 2 control device and Figure 1 A second side view of a portion of the handlebars of a bicycle;

[0036] Figure 6 It was removed from the handlebars. Figure 4 An external perspective view of the control device;

[0037] Figure 7 It was removed from the handlebars. Figure 5 The second side view of the control device;

[0038] Figure 8 yes Figure 2 An exploded view of the control device, including a perspective view of the cover and auxiliary buttons removed from the housing of the control device;

[0039] Figure 9 yes Figure 2 A cross-section of a top-view perspective view of the control device;

[0040] Figure 10 yes Figure 2 An exploded perspective view of the control device;

[0041] Figure 11 yes Figure 2 control device and Figure 1 A front view of part of the handlebars of a bicycle;

[0042] Figure 12 It was removed from the handlebars. Figure 11 Front view of the control device;

[0043] Figure 13 It is along Figure 11 The axis BB is cut off Figure 11 The cross-section of the control device;

[0044] Figure 14 It is along Figure 12 The axis CC intercept Figure 12 The cross-section of the control device;

[0045] Figure 15 yes Figure 2 A side view of the housing of the control device and an exploded view of the first adjustment mechanism and piston disassembled from the housing of the control device;

[0046] Figure 16 yes Figure 15 Exploded top view of the first regulating mechanism, piston, and fluid cylinder;

[0047] Figure 17 yes Figure 16 The cross-section of the fluid cylinder, in which the first adjusting mechanism and the piston are assembled inside the fluid cylinder;

[0048] Figure 18 yes Figure 17 A three-dimensional view of the cam of the first adjustment mechanism;

[0049] Figure 19 It includes the second regulating mechanism. Figure 1 A perspective view of another embodiment of the bicycle control device;

[0050] Figure 20 yes Figure 19 The cross-section of the control device;

[0051] Figure 21 It includes the third regulatory body. Figure 1 A perspective view of another embodiment of the bicycle control device;

[0052] Figure 22 yes Figure 21 The cross-section of the control device;

[0053] Figure 23 The storage container cover has been removed. Figure 2 control device and Figure 1 A three-dimensional image of part of the handlebars of a bicycle;

[0054] Figure 24 It is intercepted along axis AA. Figure 4 The cross-section of the control device and Figure 1 Part of the handlebars of a bicycle;

[0055] Figure 25 It was removed from the handlebars. Figure 2 A bottom view of the control device;

[0056] Figure 26 The lid has been removed. Figure 1 A perspective view of another embodiment of the bicycle control device and an exploded view of the first battery assembly removed from the housing of the control device;

[0057] Figure 27 It was removed from the handlebars and assembled. Figure 26 The cross-section of the control device;

[0058] Figure 28 yes Figure 27 A close-up view of the cross-section of the first battery assembly;

[0059] Figure 29 yes Figure 26 A close-up, exploded perspective view of the battery casing and battery cover of the first battery assembly;

[0060] Figure 30 yes Figure 1 A perspective view of another embodiment of the bicycle control device and an exploded view of a second battery assembly disassembled from the housing of the control device; and

[0061] Figure 31 It is assembled. Figure 30 A close-up cross-section of the second battery assembly. Detailed Implementation

[0062] Hydraulic braking calculations for bicycles are based on the fluid volume (volume) in the lever, the fluid volume (volume) in the hose, and the fluid volume (volume) in the caliper. As the brake pads wear, fluid shifts into the caliper. The master cylinder of the control unit includes a timing port. The timing port allows fluid to flow between the caliper of the brake assembly and a reservoir within the lever body of the control unit. When the master seal passes the timing port, the seal actively displaces the fluid and builds up hydraulic pressure in the hydraulic lines leading to the brake assembly. This hydraulic pressure generates braking force, thereby slowing the bicycle and the rider. For this reason, positioning the master seal close to the timing port allows for minimal lever movement before the rider feels the brakes. Existing control units rely on positioning features formed on the lever body to position the piston assembly relative to the master cylinder, and thus the master seal.

[0063] This disclosure provides examples of a control device for a bicycle that addresses or improves upon one or more shortcomings of existing known control devices. The disclosed control device includes an adjustment mechanism for adjusting the distance between a main seal and a timing port. For example, the adjustment mechanism may include a multi-position cam for such hydraulic contact adjustment. The multi-position cam can stop and position a piston assembly including, for example, a main piston and a main seal, and can be used to adjust the position of the piston assembly relative to the timing port.

[0064] To achieve a low-cost configuration of the master cylinder and piston assembly, the master cylinder is independent of the control unit's lever body. This allows for the design and manufacture of each component using, for example, materials with the lowest cost and / or lowest weight for each part. To reduce the number of parts for cost and / or assembly purposes, multiple components and / or functions are integrated together.

[0065] The disclosed control unit also includes auxiliary buttons for additional functions and ergonomics. The auxiliary buttons are mounted inside the upper saddle section of the control unit's body (e.g., housing). The auxiliary buttons may be positioned in front of the hydraulic reservoir cover sealing surface, above the brake lever cavity. The auxiliary buttons may be connected via a cable to the shift lever paddle-shaped printed circuit board (PCB), which is laid and held on the control unit's body through a channel within the body.

[0066] The disclosed control unit also includes a remote hydraulic reservoir. This reservoir can be located above the master cylinder (e.g., within the saddle section of the control unit's body) to maximize air venting. To provide additional hydraulic reservoir fluid volume, pockets for additional fluid can be added to the blade openings for compensation. These pockets can be fitted between the lugs of the blades and surround the blade pivot.

[0067] The disclosed control device also includes a high-pivot brake lever. The lever blade is pivoted higher than the actuating crosspin and pushrod. This pivot position allows for greater mechanical gain to build up pressure and also provides finer sweep at the pushrod end, thus reducing wear on the bore, piston, and seals that may occur due to lateral loads on the main piston.

[0068] The disclosed control unit also includes a master cylinder oriented at an angle (or tilt) relative to the handlebars. This angle provides space for enclosing the master cylinder, contact adjustment elements (e.g., one or more adjustment mechanisms), and fluid ports leading to the cylinder bore. The angle of the master cylinder allows for the installation of hoses and hose clamping nuts. The lever blades can be mounted at the same angle to provide smooth lever actuation. This angle also provides a unique ergonomic experience, as the sweep of the lever blades follows the natural movement of the rider's fingers.

[0069] Upon reading this disclosure, these and other objects, features, and advantages of the disclosed control device will become apparent to those skilled in the art. Throughout the drawings, where the same reference numerals are used, the same reference numerals denote the same or substantially similar components in the various disclosed embodiments. Furthermore, specific examples of specific combinations utilizing the aspects, features, and components disclosed herein are disclosed and described. However, it is possible that each aspect, feature, and / or component disclosed herein may be used independently or in different combinations with other aspects, features, and / or components of this disclosure, in other examples not disclosed or described herein.

[0070] Now turn to the attached image. Figure 1A bicycle 50 is depicted, having a frame 52, a front wheel 54 with a fork 56 connected to the frame 52, and a rear wheel 58 with a rear top fork 60 and a rear chainstay 62 connected to the frame 52. The front wheel 54 and the rear wheel 58 support the frame 52 above a surface on which the bicycle 50 can travel in the forward direction indicated by the arrow "X". The bicycle 50 has drop bar handlebars 64 mounted to the head tube 66 of the frame 52. The bicycle 50 also has a seat 68 supported by a seatpost 70 received in the seat tube 72 of the frame 52. The bicycle 50 may have one or both of a front derailleur 74 (e.g., a front electromechanical derailleur; hereinafter referred to as a front derailleur) and a rear derailleur 76 (e.g., a rear electromechanical derailleur; hereinafter referred to as a rear derailleur) mounted to the frame 52. The bicycle 50 includes a multi-gear transmission system 78 with one or more chain links 80 driven by a crank assembly 82, the crank assembly having two crank arms 84 and two pedals 86 respectively. The chain links 80 can be connected to multiple sprockets 88 at the rear wheel 58 via a chain 90.

[0071] Reference Figures 1 to 7 In the disclosed example, the bicycle 50 has at least one bicycle control device 100 (e.g., control unit 100) that can be mounted to the handlebars 64. In this example, the control unit 100 includes a brake control element of a braking system. The brake control element includes a brake lever 102 movably connected to a cover or housing 104 of the control unit 100. The brake lever 102 operates components of the braking system of the bicycle 50. In one example, the braking system may include a connection to the front wheel 54 via, for example, a hydraulic brake line 110 (see...). Figure 1 The hydraulic front braking mechanism 106 is connected to the rear wheel 58 (see...) Figure 1 The hydraulic rear brake mechanism 108 is included. In one embodiment, the braking system is a hydraulic disc brake system that includes a hydraulic braking mechanism acting on the rotor. In an alternative embodiment, the braking system may instead be a mechanical cable-operated braking system. As described in more detail below, the control device 100 also includes a shift control element of an electronic shift control system. The shift control element includes a shift lever assembly 112 for shifting the gears of the bicycle 50.

[0072] Reference Figures 2 to 7The following describes different external views of a control device 100 constructed according to an example of the present disclosure. The control device 100 can be mounted to a handlebar 64. In one example, the housing 104 includes a clamp 120, which may include an adjustable strap extending around the handlebar 64. In one example, the bicycle 50 may include a pair of control devices 100, one on each of the left and right sides of the handlebar 64, as is well known. This pair of control devices 100 may be configured together to operate the front derailleur 74 and the rear derailleur 76 respectively, and to operate the front brake 106 and the rear brake 108 respectively. In one example, the pair of control devices 100 may be identical to each other.

[0073] In the published examples, refer to Figure 8 The control device 100 includes a cover (e.g., housing 104) that can be covered by an outer cover or outer cover 122. The housing 104 is shaped and sized for gripping by a user or cyclist's hand, and the outer cover 122 can be configured to closely conform to and cover the shape of the housing 104. The housing 104 and outer cover 122 can serve as a grip or can be configured together as a grippable portion of the control device 100. The housing 104 can be formed from any variety of materials such as, for example, metal, plastic, and / or composite materials. For example, the housing 104 can be made of glass-filled nylon or carbon (fiber)-filled nylon. The housing 104 is configured to carry, house, and / or support various components and mechanisms of the braking system and electronic shift control system, as described in more detail below. The outer cover 122 can be made from any variety of materials such as, for example, natural materials and / or synthetic elastomer materials. The outer cover 122 can be configured to have a comfortable interface for the user and reduce the tendency to become detached or moved from the outside of the housing 104. For example, the outer cover 122 can be formed from a flexible thermoplastic elastomer (TPE) such as Santoprene™. The outer cover 122 can be configured to be removably attached to and held in place on the housing 104 using any known fastening or attachment method.

[0074] In this example, refer to Figure 8 , Figure 13 and Figure 14 The brake lever 102 is pivotally or movably attached to the housing 104. The brake lever 102 may be attached to the housing 104 at or near the leading or front portion, such that the brake lever 102 is forward-separated from the handlebars 64. Therefore, the brake lever 102 may be pivotable generally forward and backward relative to the housing 104. As discussed further below, the brake lever 102 may also be pivotable toward and away from the frame 52 of the bicycle 50.

[0075] The brake lever 102 can be made of any variety of materials, such as, for example, metals (e.g., aluminum), plastics, and / or composite materials. (See reference...) Figure 10 The housing 104 may include a pivot hole or aperture 124. Pivot holes 124 may be aligned with each other and define a pivot axis P. A brake lever 102 may be attached to the housing 104 via a shaft 126 formed by, for example, a pivot pin, rod, or similar component, passing through the pivot hole 124. As discussed further below, the pivot axis P may be positioned above a push rod operably coupled to a piston supported by the housing 104. Additionally, the pivot axis P may be positioned between the push rod and at least a portion of a fluid chamber disposed within the housing 104.

[0076] In the disclosed example, the brake lever 102 may have a U-shaped recess or define a channel along at least a longitudinal portion of the grip handle. (See also...) Figures 2 to 7 The shift lever assembly 112 can be nested, at least partially, within a recess or channel, as described in more detail below. This nesting arrangement of the shift lever assembly 112 with the brake lever 102, and the U-shape of the lever body, can provide structural rigidity and protection for components housed within the channel. The shift lever assembly 112 can also be pivotally or movably attached to the housing 104, the pivoting mechanism, or the brake lever 102. The shift lever assembly 112 can be positioned behind the brake lever 102 (e.g., between the brake lever 102 and the handlebar 64 when mounted on a bicycle 50). The shift lever assembly 112 can be made of any of a variety of materials, such as, for example, plastic or composite materials. In one example, the shift lever assembly 112 can be at least partially made of a material that does not significantly inhibit the penetration of wirelessly transmitted signals.

[0077] Reference Figure 10 The shift lever assembly 112 can pivot laterally about axis S, which is generally perpendicular to the pivot axis P of the brake lever 102 about axis 126. Therefore, the shift lever assembly 112 can move relative to the bicycle 50 in the inward and outward directions while remaining nested and aligned with the brake lever 102.

[0078] The shift lever assembly 112 includes a bracket 131 and a shift lever 132. The shift lever 132 has a proximal end 134 that is directly or indirectly pivotally attached to the bracket 131, housing 104, and / or brake lever 102 via a pivot pin (not shown). The pivot pin defines a pivot axis S of the shift lever assembly 112. The shift lever 132 also has a distal end or paddle-shaped end 138 opposite the proximal end 134 and a lever arm 140 (e.g., an elongated lever arm) connecting the proximal end 134 and the distal end 138. The lever arm 140 may be a closed, hollow body or may be U-shaped or side-opening and may include structural ribs. The shift lever 132 may be made of any variety of materials, including, for example, plastic.

[0079] The brake lever 102 and the shift lever assembly 112 are pivotally mounted to the housing 104 via a two-piece shaft 126. The two-piece shaft 126 includes a bolt 126a on one side and a nut 126b fastened to the bolt 126a on the other side. In one embodiment, at least a portion of the outer annular surface of the bolt 126a includes raised knurled features that help retain the bolt 126a within the housing of the control device 100. Two bushings 143 provide a low-friction, compliant interface between the brake lever 102 and the shaft 126.

[0080] The proximal end 134 of the shift lever 132 and / or the bracket 131 may also carry connecting components for connecting the brake lever 102 to the hydraulic braking system. These components may include a sleeve 144 carried by the bracket 131 (e.g., via an opening through the bracket 131). When the shift lever assembly 112 is assembled to the brake lever 102, the sleeve 144 is received in a set of openings 145 spaced apart from the pivot bore 124 at the proximal end of the brake lever 102. The combination of the sleeve 144 and the openings 145 engages the brake lever 102 and the shift lever assembly 112 relative to the brake lever pivot axis P. The shift lever assembly 112 is thus configured to move about the pivot axis P in conjunction with or in cooperation with the brake lever 102 when the braking system is operated, but to move independently of the brake lever 102 when the shift control system is operated. As described in more detail below, the paddle-shaped end 138 of the shift lever 132 includes an internal cavity 146 that houses the shift lever assembly 112 and electronic components of the shift control system.

[0081] Reference Figures 8 to 10 The bicycle control device 100 has at least four main components, including a housing 104, an outer cover 122, a brake lever 102, and a shift lever assembly 112. According to the teachings of this disclosure, both the shift lever assembly 112 and the housing 104 further include additional sub-components. The sub-components of the shift lever assembly 112 are located in… Figure 10 The overall example is shown in the middle, and the sub-components of housing 104 are in Figures 8 to 10 The overall example is shown in the middle.

[0082] In the published examples, refer to Figure 10 The shift lever assembly 112 is a separate electrical component. In this example, the shift lever assembly 112 includes electronic components for operating the bicycle control unit 100. Some of the electronic components in this example are housed within an internal cavity 146 in the paddle-shaped end 138 of the shift lever 132, and some electronic components are external to but electrically connected to the electronic components within the internal cavity 146 in the paddle-shaped end 138.

[0083] In this example, the paddle-shaped end 138 of the shift lever 132 has a larger surface area than the adjacent lever arm 140. Therefore, the paddle-shaped end 138 provides a convenient and ergonomic contact point for the user. The internal cavity 146 in the paddle-shaped end 138 includes a cover 148, which can be secured to the paddle-shaped end 138 by fasteners 150 (e.g., three fasteners) to seal the internal cavity 146 and prevent or exclude water and other contaminants from entering it. A seal 152 can be inserted between the internal cavity 146 and the cover 148. The seal 152 can be a rubber sealing film or layer of any suitable material used to seal the internal cavity 146 in the paddle-shaped end 138 to prevent moisture or contaminants from entering.

[0084] In one example, a printed circuit board (PCB) 154 is disposed within an internal cavity 146 in the paddle-shaped end 138. The internal cavity 146 accommodates the PCB 154 having two openings. For example, a cable is attached to the PCB 154 using a connector (e.g., a 2C board connector) and passes through the first of the two openings (not shown). The first opening of the internal cavity 146 can be sealed using, for example, a grommet or grommet. The PCB 154 is disposed within the internal cavity 146 via the second of the two openings.

[0085] Various electronic components may be mounted on or connected to PCB 154. PCB 154 may include a communication module 156 configured to transmit signals from control device 100. In one example, communication module 156 may be configured to wirelessly transmit signals in the form of electromagnetic radiation (EMR), such as radio waves or radio frequency signals. Optionally, communication module 156 may also be configured to receive signals. In one example, communication module 156 may be configured to receive signals that may be in the form of EMR, such as radio waves or radio frequency signals. Communication module 156 may include or may be a transmitter, receiver, or transceiver. PCB 154 may also include an antenna 158 operatively communicating with communication module 156 to transmit and optionally also receive EMR signals. Antenna 158 may be any device configured to transmit and / or receive electromagnetic radiation waves (e.g., TV or radio waves).

[0086] In the disclosed example, antenna 158 is positioned on PCB 154 such that it can transmit signals without significantly interfering with the structure of bicycle control unit 100 and / or the rider's hands. In another example, to help reduce or prevent interference, antenna 158 may be a wireless antenna and may be at least partially disposed in or on a portion of bicycle control unit 100 that is separate from and distanced from housing 104. For example, antenna 158 may be disposed on another portion of brake lever 102 or shift lever 132.

[0087] In one example, the bicycle control unit 100 also includes, for example, a controller (not shown) also on the PCB 154. This controller is operatively connected to the communication module 156 to perform electronic operations, such as generating signals associated with one or more of shifting, pairing, derailleur adjustment operations, power management, etc. For example, the controller may be programmable and configurable to generate signals for controlling the front derailleur 74 and the rear derailleur 76. In one example, the controller may be a microcontroller with internal memory. In another example, the communication module 156 may be programmable and configurable to send and / or receive signals for controlling the front derailleur 74 and the rear derailleur 76. In one example, the communication module 156 may be a transceiver. Any variety of microcontrollers and communication modules 156 can be utilized. Additionally, as is known in the art, auxiliary electrical and / or electronic devices and components can be used to further enhance or enable the functionality and operation of the controller, communication module 156, and related components.

[0088] In one example, the electronics of the shift lever assembly 112 may also include at least one light source (not shown) (e.g., a light-emitting diode (LED)). The LED may also be positioned on the PCB 154. The LED may convey status information to the rider, such as information related to the electronics and / or functions of the shift lever assembly 112 or the bicycle control unit 100.

[0089] In one example, the electronic components may include one or more electrical switches. For instance, when actuated, the first electrical switch 160 may cause the controller and / or communication module 156 to perform operations. Such operations may involve signal transmission or reception, pairing of derailleurs 74, 76 and control device 100, adjustment and / or shifting operations, etc. The first electrical switch 160 may generate actions and / or responses for initiating or triggering various mechanisms of the bicycle 50, such as the front derailleur 74 and / or rear derailleur 76.

[0090] In this example, the first electrical switch 160 includes a contact (not shown) located on PCB 154, below the resilient dome switch element 162 (also on PCB 154). In this example, the first electrical switch 160 is actuated from outside the internal cavity 146 in the paddle-shaped end 138 of the shift lever 132 via a seal 152. A cover 148 has a first switch opening 164, wherein both the cover 148 and the first switch opening 164 are located on the inward-facing side of the shift lever 132 (e.g., the non-actuated side of the paddle-shaped end 138). An actuator 166 is disposed in the first switch opening 164, as... Figure 5 and Figure 7 As depicted in [the text]. (Refer to...) Figure 10Actuator 166 includes a button 168 received in an eyelet 170 in the inner wall 172 of brake lever 102. A spring retainer 174 is held in a first switch opening 164 in cover 148. A spring 176 extends between the button 168 and the spring retainer 174 and biases shift lever 132 toward the outer wall 178 of brake lever 102. For example, a rider operates shift lever 132 by pushing inward against an actuating surface (e.g., the outer surface of paddle-shaped end 138) against the biasing force of spring 176. When the rider pushes against paddle-shaped end 138, button 168 eventually contacts spring retainer 174. Spring retainer 174 is pressed against resilient dome switch element 162 via seal 152, which further contacts contacts on PCB 154 to close and actuate first electrical switch 160.

[0091] As another example, the second electrical switch 180 includes a contact located on a PCB 154. The contact may be a dome-shaped switching element or a pressure-type switching contact. In this example, the second electrical switch 180 is also actuated from the outside of the internal cavity 146 and the shift lever 132 via a seal 152. A cover 148 has a second switch opening 182, wherein both the cover 148 and the second switch opening 182 are located on the inward-facing side of the shift lever 132 (e.g., the non-actuated side of the paddle end 138). A button 184 extends through and is disposed therein via the second switch opening 182 in the cover 148, as... Figure 5 and Figure 7 As depicted in the image. Button 184 may be integrally formed as part of seal 152, or may be attached to the material of seal 152. For example, a cyclist simply operates the second electrical switch 180 by pressing button 184 toward cover 148. The material layer beneath button 184 or seal 152 may have dotted contacts (not shown) on its inner end, which are pushed against seal 152 to press down and close the contacts to actuate the second electrical switch 180.

[0092] The first button 168 and the second button 184 operate through a material layer of the seal 152, thereby not compromising the integrity of the seal 152 for the internal cavity 146 in the paddle end 138. Other types of electrical switches may be used. The first electrical switch 160 may be used to operate the control device 100 on a more frequent and forceful basis, such as for initiating shifting or gear changing. The second electrical switch 180 may be an optional switch, and in this example, may be smaller and more independent. The second electrical switch 180 may be designed to be used less frequently than the first electrical switch 160. In one example, the second electrical switch 180 may be used for operations related to pairing the bicycle control device with specific bicycle components such as the front derailleur 74 and / or the rear derailleur 76, or for adjusting the front derailleur 74 and / or the rear derailleur 76. Actuation of the first electrical switch 160 and the second electrical switch 180 sends a signal via associated circuitry for the controller to act upon.

[0093] Electronic components on PCB 154 and within an internal cavity 146 in the paddle-shaped end 138 are held and sealed in place within the internal cavity 146. A seal 152 covers PCB 154 and is clamped between the paddle-shaped end 138 of the shift lever 132 and the cover 148 when the cover 148 is fastened to the shift lever 132 with, for example, three fasteners 150. The seal 152 may be, for example, a gasket. (See reference...) Figure 10 The paddle-shaped end 138 may include a recess 186 surrounding an opening leading to the internal cavity 146. Ribs on the seal 152 are positioned within the recess 186 to form a tight environmental seal when the cover 148 is secured to the paddle-shaped end 138. In one example, a second opening of the internal cavity 146 is sealed by the seal 152, which is compressed and held by the cover 148; the cover 148 is secured to the shift lever 132 with three fasteners 150 in the form of threaded screws that are directly mounted into the shift lever 132.

[0094] Cables (e.g., single-wire, double-wire (2C) cables; hereinafter referred to as wires) are electrically connected to electronic components of PCB 154 and are laid from internal cavity 146 through openings (e.g., a first opening of internal cavity 146) into lever arm 140. Wires extend along the interior of lever arm 140 and are laid around sleeve 144 and transverse openings 142 on the proximal end 134 of shift lever 132. In the disclosed example, the wires are connected to a power source (e.g., a separate battery cell 190). The separate battery cell 190 is described in more detail below.

[0095] The shift lever assembly 112 may include additional, fewer, and / or different components. For example, such as Figure 10As shown in the example, the shift lever assembly 112 may include a backing 192 that can be inserted between and sandwiched between the cover 148 and the paddle-shaped end 138 of the shift lever 132. Each of the cover 148 and the paddle-shaped end 138 of the shift lever 132 may be formed as a receiving portion, such as a recess 194, defining an edge that captures the backing 192. The backing 192 may form a contact point between the top of the shift lever 132 and a contact surface on the inner surface of the brake lever inner wall 172. The contact surface may include a bump or protrusion positioned to contact the backing 192. The backing 192 may be captured between the bump on the inner surface of the brake lever inner wall 172 and the recess 194 on the shift lever 132. The backing 192 may be formed of a durable material with low friction properties. In one example, the backing 192 may be made of a different material than the shift lever 132, such as Teflon, and may be attached to the shift lever 132. Therefore, the backing 192 may allow the shift lever 132 to slide laterally and easily relative to the brake lever 102 to suppress engagement and wear.

[0096] Figure 10 A chamber 196 is shown located within housing 104, where brake lever 102 is connected to components of a hydraulic braking system. Chamber 196 can accommodate components of control device 100 and provide access to those components for maintenance or adjustment. When cover 122 is attached to housing 104, chamber 196 can be covered, concealed, and protected from environmental influences.

[0097] Reference Figure 8 The housing 104 has a base portion 200, an extension portion 202 extending away from the base portion 200 (e.g., a saddle head), an inwardly facing side portion 204, and an outwardly facing side portion 206 opposite to the inwardly facing side portion 204. The base portion 200 of the housing 104 has a front end 208, a rear end 210 opposite to the front end 208, an upwardly facing side portion 212, and a downwardly facing side portion 214. The base portion 200 of the housing 104 may include more, fewer, and / or different sides.

[0098] A portion (e.g., the upward-facing portion) of the extension 202 of the housing 104 can be accessed via the removable cover 216. The removable cover 216 can be secured to the housing 104 by any variety of fastening devices, including, for example, screws or other fasteners, snap-fit ​​connectors, adhesives, or other types of fastening devices. Figure 8 In the example shown, the removable cover 216 is secured to the housing 104 with three screws 218. In other examples, the removable cover 216 may be secured to the housing 104 with more or fewer screws 218 and / or other fastening devices.

[0099] Reference Figure 9 and Figure 10 The extension 202 of the housing 104, accessible via a removable cover 216, accommodates multiple components of the control device 100. For example, a chamber 222 in the upward-facing portion of the extension 202 of the housing 104 (see...) Figure 9 A compliant or flexible diaphragm 220 is disposed on the open side of the chamber 222 to close the chamber 222 and thus provide a defined fluid chamber (e.g., a hydraulic reservoir) with a variable volume. The flexible diaphragm 220 may be positioned between the removable cover 216 and the open side of the chamber 222. The fluid chamber, at least partially defined by the flexible diaphragm 220, is at least partially filled with a fluid such as, for example, hydraulic braking fluid (e.g., an incompressible fluid). In one embodiment, the flexible diaphragm 220 is a bladder.

[0100] Reference Figure 8 and Figure 9 The extension 202 of housing 104 (e.g., a portion accessible via a removable cover 216) also accommodates an auxiliary button unit 230. The auxiliary button unit 230 is mounted to the inward-facing side 204 (e.g., the inner side) of the extension 202 of housing 104 (e.g., when viewed from the inward-facing side 204 of housing 104, above chamber 222, in front of the hydraulic reservoir cover sealing surface, overlapping with the hydraulic release plug assembly and the hydraulic reservoir). The auxiliary button unit 230 is attached to housing 104 in any of a variety of ways, including, for example, screws, tape, glue, epoxy resin, snap-fit ​​features, press-fit features, and / or other fasteners or fixing devices. The auxiliary button unit 230 is connected via, for example, a cable 232 (e.g., a two-conductor cable) to a PCB 154 within an internal cavity 146 in the paddle end 138 of shift lever 132. Cable 232 can be laid and held on top of and / or inside housing 104 through channel 234 at the inward-facing side 204 of housing 104 (e.g., the base portion 200 and / or extension portion 202 of housing 104).

[0101] The auxiliary button unit 230 includes multiple components. (See reference...) Figure 8 and Figure 9 The auxiliary button unit 230 includes, for example, an inner housing 236, an outer housing 238, a button actuator 240, a flexible sealing element 242 (e.g., a gasket) for the button actuator 240, a PCB 244 that supports and is electrically connected to the electrical switch 246, and a cable 232 (see [link to documentation]). Figure 9The inner housing 236 has a first opening 248 through which a PCB 244 with an electrical switch 246 is assembled. The inner housing 236 also has a second opening 250 through which a cable 232 passes. The second opening 250 is sealed (e.g., around the cable 232) to prevent, for example, the ingress of water and contaminants. The second opening 250 can be sealed in any number of ways, including, for example, with adhesive, epoxy resin, flexible grommets, or another sealant. For example, as... Figure 9 As shown in the example, the second opening 250 can be sealed with a grommet 251.

[0102] Cable 232 is coupled to PCB 244 to transmit signals from the electrical switch 246 of auxiliary button unit 230 to PCB 154 located within an internal cavity 146 in the paddle-shaped end 138 of shift lever 132. Housing 238 is coupled to inner housing 236 and has a recess 252 for assembling button actuator 240 therein. The joint or seam between inner housing 236 and housing 238 is sealed to prevent ingress of, for example, water and contaminants. The joint or seam between inner housing 236 and housing 238 can be sealed in any of a variety of ways, including, for example, by plastic welding, flexible sealing elements (e.g., gaskets), or other seals.

[0103] The housing 238 has an opening 254 through which a button actuator 240 extends and translates when pressed by a rider to actuate an electrical switch 246. For example, the opening 254 can be sealed to prevent the ingress of water and contaminants. The opening 254 can be sealed in any number of ways, including, for example, with a gasket, an overmolded elastomer, an O-ring, or another seal.

[0104] exist Figure 8 and Figure 9 In the example shown, the push-button actuator 240 is mounted on a washer 242 positioned between the push-button actuator 240 and the electrical switch 246. In one embodiment, the push-button actuator 240 is mounted directly on the electrical switch 246.

[0105] The auxiliary button unit 230 is covered by the outer cover 122. The electric switch 246 can be activated by the rider, for example, by pressing the button actuator 240 using the outer cover 122. (See reference...) Figure 9 The outer cover 122 may have an external feature 256 (e.g., a dome or rectangle with a raised or recessed shape) indicating the location of the auxiliary button unit 230.

[0106] The activation of electrical switch 246 can control one or more components of bicycle 50 that are the same as and / or different from those controlled by the first electrical switch 160 and / or the second electrical switch 180. For example, the activation assist button unit 230 can initiate the generation of signals (e.g., via a controller on PCB 154) related to shifting, pairing, derailleur adjustment, power management, one or more other actions on bicycle 50, or any combination thereof. In one embodiment, for example, the activation assist button unit 230 controls the front derailleur 74 and / or the rear derailleur 76. For example, the controller on PCB 154 can be configured to generate signals for controlling the front derailleur 74 and / or the rear derailleur 76 in response to a signal received from electrical switch 246 when activated by the rider. The assist button unit 230, due to its location at the extension 202 of housing 104, provides ergonomic options for controlling one or more components of bicycle 50.

[0107] Reference Figure 13 and Figure 14 The housing 104 may generally include a housing bore 300, into which a master cylinder sleeve 302 (e.g., a fluid cylinder or hydraulic cylinder) is inserted and configured to function as a master cylinder for a braking system. The master cylinder sleeve 302 can be of any number of sizes and / or shapes. For example, as... Figure 10 , Figure 13 and Figure 14 As shown, the master cylinder liner 302 can be cylindrical and hollow. The master cylinder liner 302 can be made of any variety of materials, including, for example, aluminum, aluminum alloys, stainless steel, plastics, composite materials, another material, or any combination thereof. In one example, the housing 104 is made of a first material (e.g., glass-filled nylon), and the master cylinder liner 302 is made of a second material different from the first material (e.g., aluminum). In another example, the first and second materials are the same material. The housing bore 300, and thus the master cylinder liner 302 (when mounted within the housing bore 300), can be horizontal relative to the flat surface on which the bicycle 50 is supported, although other orientations are possible.

[0108] To create a lighter weight configuration and reduce the number of parts in the master cylinder sleeve 302 and piston 304 (e.g., a piston assembly comprising one or more parts), the master cylinder sleeve 302 can be independent of the housing 104. This allows each component (e.g., housing 104 and master cylinder sleeve 302) to be designed and manufactured using the most reliable and / or lowest weight materials for each component.

[0109] At least a portion of piston 304 resides within and moves relative to master cylinder liner 302. (See reference...) Figure 13 and Figure 14The piston 304 has a first end 306 and a second end 308 opposite to the first end 306. The piston 304 is connected to the brake lever 102 via a push rod 310 adjacent to the second end 308 of the piston 304 (e.g., at a position closer to the second end 308 of the piston 304 than the first end 306 of the piston 304), and can be operated by movement of the brake lever 102, as is known in the art. For example, rotation of the brake lever 102 causes translation (e.g., rotation) of the push rod 310, which causes translation of the piston 304 relative to the master cylinder sleeve 302. Figure 10 , Figure 13 and Figure 14 In the example shown, push rod 310 can be connected to piston 304 via an adjustment mechanism, as will be described in more detail below.

[0110] Reference Figure 13 and Figure 14 The push rod 310 has a first end 312 and a second end 314 opposite to the first end 312. The first end 312 of the push rod 310 includes a body 316 that can be disposed within a portion of an adjusting mechanism 318. For example, the adjusting mechanism 318 includes a push rod support 320 (e.g., a push rod slot) having a receiving portion 322 at the first end 324 of the push rod support 320. The push rod 310 is connected to the push rod support 320 via the body 316 of the push rod 310 disposed within the receiving portion 322 at the first end 324 of the push rod support 320.

[0111] The push rod support 320 is hollow at and near its first end 324 to form a receiving portion 322. The receiving portion 322 is formed by one or more inner surfaces 326 (e.g., inner annular surfaces, at least one of which is angled or inclined relative to a central axis along the length of the push rod support 320), the size and shape of which are designed to facilitate the positioning of the body 316 of the push rod 310 within the receiving portion 322 of the push rod support 320 and the rotation of the body 316 of the push rod 310 relative to the push rod support 320. For example, one or more inner surfaces 326 of the push rod support 320 extend outward at or near its first end 324, and the body 316 of the push rod 310 can abut against one or more inner surfaces 326 of the push rod support 320. The base portion of the receiving part 322 can be rounded to facilitate the rotation of the main body 316 of the push rod 310 within the receiving part 322.

[0112] The adjusting mechanism 318 also includes a cam 330 supported by a push rod support 320 at or near the second end 328 of the push rod support 320. The second end 328 of the push rod support 320 is opposite to the first end 324 of the push rod support 320.

[0113] Reference Figure 10 and Figure 14 A first spring 332 (e.g., a return spring) is disposed within the master cylinder sleeve 302. The return spring 332 extends from a position at or near the first end 306 of the piston 304 toward the rear end 210 of the base portion 200 of the housing 104. The return spring 332 may be, for example, a compression spring, and may act on the piston 304 at or near the first end 306 of the piston 304 such that the second end 308 of the piston 304 is pressed into contact with the cam 330 of the adjusting mechanism 318. In one embodiment, the return spring 332 is disposed around a portion of the piston 304 (e.g., disposed at and / or near the first end 306 of the piston 304).

[0114] The control device 100 may include one or more components and / or features to prevent the return spring 332 from pushing the piston 304 and the adjusting mechanism 318 out of the master cylinder sleeve 302. For example, the brake lever 102 may include an extension 334 extending toward the extension 202 of the housing 104. When viewed from the inward-facing side 204 of the housing 104, the contact between the extension 334 and the extension 202 of the housing 104 can act as a stop for the brake lever 102 to rotate clockwise relative to the housing 104 via the shaft 126. Since the brake lever 102 is connected to the adjusting mechanism 318 via the push rod 310, when the brake lever 102 cannot rotate further clockwise relative to the housing 104 (e.g., when viewed from the inward-facing side 204 of the housing 104), the adjusting mechanism 318 cannot translate further relative to the master cylinder sleeve 302 (e.g., move out of the master cylinder sleeve 302). Therefore, the cam 330 acts as a stop for the piston 304. Figure 10 In the example shown, control device 100 also includes a brake lever biasing spring 336 disposed around shaft 126. Brake lever biasing spring 336 can be configured to bias brake lever 102 toward the body 316 of push rod 310 within a receiving portion 322 of push rod support 320 (e.g., in contact with at least one surface of one or more inner surfaces 326 of push rod support 320). In one embodiment, receiving portion 322 is a snap-fit ​​slot, and the body 316 of push rod 310 is held within the snap-fit ​​slot. Control device 100 may include more, fewer, and / or different components and / or features to retain piston 304 within master cylinder liner 302.

[0115] The shaft 126 can be positioned in any number of locations relative to the components supported by the housing 104. For example, the shaft 126 can be located between at least a portion of the chamber 222 and the push rod 310. In other embodiments, other positioning of the shaft 126 relative to the chamber 222, the push rod 310, and / or other components supported by the housing 104 can be provided.

[0116] When a force is applied to the brake lever 102, the applied force is partially transmitted to the piston 304 via the push rod 310 (e.g., the body 316 of the push rod 310) and the adjusting mechanism 318 (e.g., the push rod support 320 and the cam 330). This transmitted force can cause the piston 304 to move (e.g., translate) relative to the master cylinder sleeve 302 toward the rear end 210 of the base portion 200 of the housing 104, and the return spring 332 is compressed. When the brake lever 102 is released and no force is applied, the return spring 332 maintains contact between the second end 308 of the piston 304 and the cam 330, and returns the piston 304 and the brake lever 102 to their respective rest positions (e.g., relative to the master cylinder sleeve 302).

[0117] Reference Figures 15 to 17 The piston 304 includes a flange 338 extending around and away from an outer surface 340 (e.g., an outer annular surface) of the piston 304. The flange 338 may be disposed adjacent to a first end 306 of the piston 304 (e.g., closer to the first end 306 than to a second end 308 of the piston 304). One or more components may be disposed between the flange 338 of the piston 304 and an end cap 342 of the piston 304. For example, a seal 344 (e.g., a cup seal) may be disposed around the piston 304 between the end cap 342 and the flange 338. In one embodiment, a ring (e.g., a support ring) may also be disposed around the piston 304 between the end cap 342 and the flange 338. The seal 344 may be made of any number of materials, including, for example, polyurethane or rubber. The seal 344 may be any number of shapes and sizes. For example, the seal 344 may be a hollow cylinder with a U-shaped or V-shaped cross-section. The seal 344 can be supported by a support ring, allowing the seal 344 to withstand high pressure. This support ring can be made of any variety of materials, including, for example, metals.

[0118] The piston assembly may include any number of components, such as piston 304 (e.g., having end cap 342), push rod 310, return spring 332, seal 344, one or more other seals (e.g., seal 358), support ring, or any combination thereof. The piston assembly may include additional, fewer, and / or different components.

[0119] Reference Figure 13 and Figure 14The housing bore 300 may include a first end 346 and a second end 348 opposite to the first end 346. The first end 346 of the housing bore 300 may be located at the rear end 210 of the base portion 200 of the housing 104. The housing bore 300 extends through the housing 104. The master cylinder liner 302 may be completely disposed within the housing bore 300. In another embodiment, less than all of the master cylinder liners 302 (i.e., not all of the master cylinder liners 302) are disposed within the housing bore 300. The adjusting mechanism 318 and the push rod 310 (e.g., when the brake lever 102 is depressed) may extend through the second end 348 of the housing bore 300.

[0120] Additional components of the hydraulic braking system may be provided at the second end 348 of the housing bore 300 and / or its vicinity for sealing and component retention. For example, refer to... Figure 10 and Figures 15 to 17 The retaining plate 350 (e.g., cylinder head) can be attached to the housing 104 at the second end 348 of the housing bore 300. The retaining plate 350 can be attached to the housing 104 at the second end 348 of the housing bore 300 in any number of ways, including (e.g., via a corresponding threaded opening in the housing 104) for example by attaching one or more connectors 351 (e.g., three screws) to the housing 104.

[0121] The cylinder head 350 can retain the master cylinder liner 302 within the housing bore 300 (e.g., trapped within the housing bore 300). For example, refer to... Figure 10 The cylinder head 350 may include an opening 352 through which the pushrod support 320 can translate. However, the opening 352 through the cylinder head 350 may be smaller than the outer diameter of the master cylinder sleeve 302, so that the master cylinder sleeve 302 cannot move through the opening 352 of the cylinder head 350.

[0122] The size and shape of the pushrod support 320 can also be designed such that only a portion of the pushrod support 320 can translate through the opening 352 through the cylinder head 350. The pushrod support 320 may include a ridge or extension 354 adjacent to the second end 328 of the pushrod support 320. The ridge or extension 354 extends away from the outer surface 356 of the body 357 of the pushrod support 320. The size and shape of the opening 352 through the cylinder head 350 can be designed such that only the body 357 of the pushrod support 320 can translate through the opening 352 through the cylinder head 350, because at the ridge or extension 354 the diameter of the pushrod support 320 is too large to pass through the opening 352. In other words, the ridge or extension 354 can retain at least a portion of the cam 330 within the housing bore 300.

[0123] Reference Figure 10 and Figures 13 to 17A seal 358 (e.g., a cup seal) may be disposed around the piston 304, adjacent to the second end 308 of the piston 304 (e.g., at a position closer to the second end 308 of the piston 304 than the first end 306 of the piston 304). See reference. Figure 17 The piston 304 may include a groove 360 ​​adjacent to the second end 308 of the piston 304, and a seal 358 may be disposed within the groove 360. The seal 358 may be made of any variety of materials, including, for example, polyurethane or rubber. The seal 358 may be any number of shapes and sizes. For example, the seal 358 may be a hollow cylinder with a U-shaped or V-shaped cross-section. The seal 358 protects components of the hydraulic braking system within the piston 304 from environmental influences.

[0124] Reference Figure 10 , Figure 13 and Figure 14 The extension 202 of housing 104 includes an opening 362 (e.g., a vent) extending from the front end 364 of the extension 202 of housing 104 into the chamber 222. A vent plug assembly 368, including at least a vent plug 370 (e.g., a vent screw), is removably connectable to or attached to the vent 362 via, for example, a threaded bushing 372 corresponding to the vent 362, such that hydraulic fluid of the braking system can be filled, capped (or filled), or vented through the chamber 222. The vent plug 370 can be of any shape and size and can be made of any material. In one example, the vent plug 370 is made of the same material as the master cylinder sleeve 302. For example, the vent plug 370 can be made of aluminum, which may be a different material than that used to make housing 104. Alternatively, the vent plug 370 can be made of the same material as housing 104. When the vent plug 370 is removed, the chamber 222 (e.g., serving as a brake fluid chamber for the braking system) is accessible or accessible.

[0125] As discussed above, chamber 222 is at least partially located within extension 202 of housing 104. Hydraulic braking calculations are based on lever fluid volume / volume, hose fluid volume / volume, and caliper fluid volume / volume. As the bushings wear, fluid shifts into the caliper. (Refer to...) Figure 10 To provide a larger reservoir fluid volume, chamber 222 includes a recess 373 in the rod blade opening for additional fluid used for compensation. The recess 373 is fitted between the lugs of brake lever 102 and surrounds shaft 126.

[0126] Reference Figure 16 and Figure 17 The master cylinder liner 302 has one or more outer annular surfaces 374 and one or more inner annular surfaces 376 (see...). Figure 17 ).exist Figure 17In the example shown, the master cylinder sleeve 302 has at least eleven outer annular surfaces 374, each having a plurality of different diameters to provide, for example, a seal 378 (e.g., an O-ring) around the master cylinder sleeve 302. The master cylinder sleeve 302 may have more or fewer outer annular surfaces 374. Figure 17 In the example shown, the master cylinder liner 302 has four inner annular surfaces 376. The master cylinder liner 302 may have more or fewer inner annular surfaces 376.

[0127] Reference Figure 17 The master cylinder sleeve 302 includes one or more first openings 380 (e.g., a plurality of first openings; five first openings arranged around the circumference of the master cylinder sleeve 302) and one or more second openings 382 (e.g., a plurality of second openings; five second openings arranged around the circumference of the master cylinder sleeve 302). The plurality of first openings 380 and the plurality of second openings 382 extend, for example, through at least one of one or more outer annular surfaces 374 through the master cylinder sleeve 302 (e.g., through the cylindrical wall of the master cylinder sleeve 302) to at least one of one or more inner annular surfaces 376. In other words, the plurality of first openings 380 and the plurality of second openings 382 extend radially through the master cylinder sleeve 302.

[0128] A plurality of first openings 380 are spaced apart from each other in the circumferential direction, and a plurality of second openings 382 are spaced apart from each other in the circumferential direction. The plurality of second openings 382 are positioned at a certain distance relative to the plurality of first openings 380 along the length of the main cylinder sleeve 302. In other words, the plurality of second openings 382 are spaced apart from the plurality of first openings 380 in the direction along the length of the main cylinder sleeve 302. Figure 17 In the example shown, the plurality of first openings 380 are closer to the first end 384 of the master cylinder sleeve 302 than the plurality of second openings 382. In other words, the plurality of second openings 382 are closer to the second end 386 of the master cylinder sleeve 302 than the plurality of first openings 380. The second end 386 of the master cylinder sleeve 302 is opposite to the first end 384 of the master cylinder sleeve 302.

[0129] In one example, a plurality of first openings 380 are timing ports (hereinafter referred to as timing ports), and a plurality of second openings 382 are compensation ports (hereinafter referred to as compensation ports). The plurality of timing ports 380 and the plurality of compensation ports 382 can be of any number and shape and size. For example, the plurality of timing ports 380 and the plurality of compensation ports 382 can be circular openings. In one example, since the flow through the plurality of compensation ports 382 will be less controlled than the flow through the plurality of timing ports 380, the plurality of compensation ports 382 can be larger (e.g., in terms of diameter) than the plurality of timing ports 380.

[0130] Reference Figure 17 As discussed above, when the brake lever 102 is not actuated, the second end 308 of the piston 304 is biased against the cam 330 of the adjusting mechanism 318. The surface of the cam 330 acts as a stop and positions the piston 304 relative to the initial position of the master cylinder sleeve 302. This also positions the seal 344 disposed around the piston 304 relative to the master cylinder sleeve 302. More specifically, the seal 344 disposed around the piston 304 is positioned relative to a plurality of timing ports 380 extending through the master cylinder sleeve 302. Figure 17 In the example shown, when the brake lever 102 is not pulled (e.g., the initial position of the piston assembly), the seal 344 is positioned adjacent to a plurality of timing ports 380.

[0131] When the piston assembly is in the initial position and the drain plug 370 is removed, the control device 100 has a fluid path between a drain port 362 exposed to the environment when the drain plug 370 is removed and a fluid port 388 supported by the housing 104 (e.g., at and / or adjacent to the first end 384 of the master cylinder sleeve 302). The fluid port 388 is fluidly connected to a hydraulic line 390 (see...). Figure 11 The hydraulic line 390 leads to, for example, a hydraulic front brake mechanism 106 or a hydraulic rear brake mechanism 108. The fluid port 388 may be rotatable relative to the housing 104, for example.

[0132] In one embodiment, fluid port 388 is connected via hose connector 391 (e.g., via SRAM). ® The olive-shaped oil needle valve assembly is fluidly connected to the hydraulic line 390. A hose connector 391 can be integrated into the master cylinder (e.g., master cylinder sleeve 302), which is a component independent of the housing 104. For example, the Stealthamajig valve assembly 391 is an assembly including a valve and a spring (e.g., a return spring 332). When the hydraulic line 390 is disconnected, the force of the spring closes the master cylinder sleeve 302 using, for example, an O-ring on the valve.

[0133] The fluid path between the vent 362 and the fluid port 388 passes through the chamber 222 and through the housing 104 (e.g., the base portion 200 of the housing 104; see also...). Figure 13 The passage 392, between the volume 394 and the chamber 222 in the housing bore 300, between the housing 104 and the master cylinder liner 302, at least one of the plurality of first openings 380 and the volume 396 in the master cylinder liner 302, extends between the piston 304 and the rear end 210 of the base portion 200 of the housing 104.

[0134] Chamber 222 is located above housing bore 300 and master cylinder liner 302, and channel 392 (e.g., a connecting port) can be used to fill volume 394 (e.g., annular volume) within housing bore 300 between housing 104 and master cylinder liner 302, and flush volume 396 within master cylinder liner 302 to provide fluid for pressurization. Channel 392 can be drilled into housing 104 (e.g., base portion 200 of housing 104) and forms flow between chamber 222 and housing bore 300 in which master cylinder liner 302 is mounted. Drain port 362 is located at the top of extension 202 of housing 104 (e.g., saddle head), and thus at the top of chamber 222. The opening of drain port 362 can be oriented to allow drilling through channel 392. This location maximizes air venting.

[0135] For example, air in the fluid path between vent 362 and fluid port 388 and / or in hydraulic line 390 can cause inefficiency in the hydraulic braking system and may result in spongy or loose brake lever 102. Air may be introduced into the fluid path via leaks, old seals, damaged hydraulic lines, and / or other causes. Air in the fluid path can be purged from vent 362 (when vent plug 370 is removed) or from fluid port 388 or hydraulic line 390 in either direction.

[0136] When the rider pulls the brake lever 102 and the brake lever 102 rotates relative to the housing 104 (e.g., in the first rotational direction), a push rod 310 connected to the brake lever 102 (e.g., via the adjusting mechanism 318) and the piston 304 pushes the piston 304, causing the piston 304 to translate in a direction toward the rear end 210 of the base portion 200 of the housing 104 (e.g., in the first direction). This translation of the piston 304 also causes a seal 344, which is disposed around the piston 304 and abuts against the flange 338 of the piston 304, to translate in the first direction. In other words, the translation of the piston 304 in the first direction causes the seal 344 to move toward a plurality of timing ports 380. The movement of the seal 344 across the plurality of timing ports 380 pushes a portion of the fluid in the chamber 222 out of the volume 396 within the master cylinder sleeve 302 and into the hydraulic line 390 via the fluid port 388. This actuates the hydraulic front braking mechanism 106 or the hydraulic rear braking mechanism 108.

[0137] As the seal 344 passes the multiple timing ports 380, it actively displaces fluid and eventually builds pressure, thereby slowing, for example, the front wheel 54 or rear wheel 58 and the rider. The seal 344 can be positioned as close as possible to the multiple timing ports 380 to achieve performance that allows minimal movement of the brake lever 102 before the rider feels the brakes (e.g., “dead throw”, “wake-up”, “dead zone”). An adjustment mechanism 318 (e.g., including a cam 330) allows adjustment of the position between the seal 344 and the master cylinder sleeve 302 (e.g., contact adjustment). A piston assembly (e.g., including a piston 304 and the seal 344) slides axially to adjust the amount of dead throw (e.g., the sway of the brake lever 102 before pressure builds up). Movement of the piston assembly can be achieved by rotation of the cam 330 relative to, for example, the piston 304 and the pushrod support 320.

[0138] Reference Figure 17 The master cylinder sleeve 302 has a central axis C extending along the length of the master cylinder sleeve 302. The cam 330 rotates relative to the piston 304 (e.g., piston assembly) via a cam rotation axis M, for example. For example, the cam rotation axis M is perpendicular to the central axis C extending along the length of the master cylinder sleeve 302.

[0139] Reference Figures 13 to 19 The cam 330 is supported by the pushrod support 320 at the second end 328 of the pushrod support 320 and / or its vicinity. (See reference...) Figure 10 and Figure 16The push rod support 320 may include a recess 400 at and / or adjacent to the second end 328 of the push rod support 320. The cam 330 can be pressed into the recess 400 of the push rod support 320 by means of the piston 304 biased in a direction away from the rear end 210 of the base portion 200 of the housing 104 and toward the cam 330.

[0140] Reference Figure 18 The cam 330 includes a body 402, which may have four different sides 404a-404d (e.g., configured) having four different heights relative to the centerline of the cam 330 (e.g., the cam rotation axis M). In other words, when the respective sides 404a-404d contact the second end 308 of the piston 304, each of the four different sides 404a-404d has a different height in a direction along or parallel to the central axis C extending along the length of the master cylinder sleeve 302. In other embodiments, the cam 330 may include more or fewer sides 404 having different heights relative to the centerline (e.g., six sides 404 having different heights relative to the centerline).

[0141] The cam 330 also includes a tool interface 406. The tool interface 406 may be formed by, for example, cylindrical extensions 408 extending to opposite sides of the body 402 of the cam 330, respectively. One or both of the cylindrical extensions 408 of the tool interface 406 each include one or more slots (e.g., hexagonal slots) through which a tool can be used to rotate the cam 330 relative to the push rod support 320 and the piston 304. The tool interface 406 (e.g., one or more slots) can be accessed through an opening in the outer cover 122 using the outer cover 122.

[0142] The tool interface 406 may be made of the same material as the body 402 of the cam 330 (e.g., as a single component) (e.g., a metal such as aluminum). Alternatively, the tool interface 406 may be made of a different material than the body 402 of the cam 330 (e.g., plastic) (e.g., aluminum), and / or may be a separate portion attached to the body 402 of the cam 330. In one embodiment, two cylindrical extensions 408 are formed by the body 402 of the cam 330, which is disposed around and attached to the single cylindrical component, such that the body 402 separates the single cylindrical component into two extensions 408. The two cylindrical extensions 408 may be positioned in recesses 400 of the push rod support 320 (see...). Figure 16 The cam 330 is located within and supported at the opening 410 of the push rod support 320, such that the cam 330 is connected to and supported by the push rod support 320. (See reference...) Figure 17The size and shape of the body 402 of the cam 330 and the recess 400 in the push rod support 320 can be designed such that, for example, when the cam 330 rotates relative to the push rod support 320, different sides 404 of the body 402 of the cam 330 do not contact the push rod support 320 located in the recess 400.

[0143] The different heights of different sides 404 of the body 402 of the cam 330 allow for adjustment of dead travel or idle travel. For example, if the cam 330 rotates from a first position where the first side 404a of the body 402 contacts the second end 308 of the piston 304 to a second position where the second side 404b of the body 402 contacts the second end 308 of the piston 304 (see...) Figure 17 (wherein, the second side 404b of the body 402 has a greater height than the first side 404a of the body 402), then the dead travel is reduced (e.g., the seal 344 moves toward the plurality of first openings 380).

[0144] Push rod 310 is connected to brake lever 102 at or near its second end 314. (See reference...) Figure 10 and Figure 14 A portion of the push rod 310 (e.g., at the second end 314 of the push rod 310 and / or its vicinity) is attached to the brake lever 102 via a threaded connection within the sleeve 144. For example, see reference... Figure 10 In addition to the opening 145 through the brake lever 102, a sleeve 144 is also disposed within the opening 142 through the bracket 131 of the shift lever assembly 112, and a threaded (e.g., internal thread) straight rod cross pin 414 is positioned within the sleeve 144, which acts as a bushing. In other words, the straight rod cross pin 414, having, for example, internal threads and a single bushing (e.g., sleeve 144), is held and rotated within the brake lever 102. Because the threads within the straight rod cross pin 414 engage with the threads (e.g., external threads) at and / or adjacent to the second end 314 of the push rod 310, the straight rod cross pin 414 serves as an attachment point for the push rod 310.

[0145] Reference Figure 14 The adjustment mechanism 416 includes a threaded connection between a push rod 310 and a straight rod cross pin 414. The adjustment mechanism 416 is configured to adjust the angular position of the brake lever 102 relative to the housing 104, such that, for example, when the bicycle control unit 100 is mounted to the handlebar 64, the distance between the end of the brake lever 102 and the handlebar 64 is also adjusted.

[0146] Reference Figure 10The adjustment mechanism 416 also includes a tool interface 418 at the second end 314 of the push rod 310. The tool interface 418 can be any of a variety of different types of tool interfaces, including, for example, a hex wrench slot, a flathead slot, a Phillips slot, or another type of tool interface. In one embodiment, a hex wrench is used to screw the push rod 310 into and out of the straight rod cross pin 414. When a portion of the push rod support 320 is trapped within the master cylinder sleeve 302, for example, when the push rod 310 is screwed into the straight rod cross pin 414 (e.g., rotated in a first rotational direction relative to the straight rod cross pin 414), the body 316 of the push rod 310 rotates relative to the push rod support 320 within a receiving portion 322 at the first end 324 of the push rod support 320, and the end of the brake lever 102 moves, for example, closer to the handlebar 64. When the push rod 310 is unscrewed from the straight rod cross pin 414 (e.g., rotated in a second rotation direction relative to the straight rod cross pin 414, opposite to the first rotation direction relative to the straight rod cross pin 414), for example, the end of the brake lever 102 is biased away from the handlebar 64 (e.g., allowed to move away from the handlebar 64).

[0147] Tool interface 418 is accessible via an opening 420 through brake lever 102. The opening 420 through brake lever 102 allows the rider to adjust, for example, the initial distance from brake lever 102 to handlebar 64. The opening 420, and consequently tool interface 418, is accessible via a cover 422 (e.g., a hatch) attached to brake lever 102 (e.g., the front side of brake lever 102). Cover 422 can be attached to brake lever 102 in any number of ways, including, for example, with one or more fasteners 424 (e.g., a screw and a corresponding threaded opening in brake lever 102).

[0148] Hydraulic braking systems may include additional, fewer, and / or different components. For example, bicycle control unit 100 can be attached to handlebar 64 in any number of ways. For example, see reference... Figure 10 The bicycle control device 100 can be attached to the clamp 120, and the clamp 120 can be attached to the handlebars 64. The bicycle control device 100 can be attached to the clamp using, for example, a nut 426 (e.g., a long nut) and a bolt 427. The bolt 427 can extend through an opening 428 through the clamp 120 and a corresponding opening (not shown) through the housing 104, and the nut 426 can secure the bicycle control device 100 to the clamp 120 via the bolt 427. A washer 429 can be disposed between the nut 426 and the housing 104.

[0149] Other implementations of the regulating mechanism may be provided. For example, refer to Figure 19 and Figure 20The adjusting mechanism 430 may not include a cam (e.g., cam 330). The push rod support 432 (e.g., push rod slot) may be connected to the piston 434 disposed in the master cylinder sleeve 436 via an adapter 438 (e.g., contact dial adapter, threaded boss), which has, for example, at least an internal thread 439 on the inner annular surface of the adapter 438.

[0150] Piston 434 has a first end 440 and a second end 442 opposite to the first end 440. Piston 434 can be biased against adapter 438 (e.g., using a spring within master cylinder sleeve 436). For example, the second end 442 of piston 434 can be biased against adapter 438.

[0151] The push rod support 432 has a first end 444 and a second end 446 opposite to the first end 444. The first end 444 of the push rod support 432 includes a receiving portion 448 extending from the first end 444 of the push rod support 432 into the push rod support 432. The push rod 450 has a first end 452 and a second end 454 opposite to the first end 452. The first end 452 of the push rod 450 is formed by a body 456 (e.g., a spherical body), and the push rod 450 is connected to the push rod support 432 via the body 456 of the push rod 450 disposed within the receiving portion 448 at the first end 444 of the push rod support 432.

[0152] The second end 446 of the push rod support 432 is formed by an extension 458. The extension 458 of the push rod support 432 may have a smaller diameter than the rest of the push rod support 432 (e.g., at the first end 444 of the push rod support 432). The extension 458 of the push rod support 432 may have an external thread 460 that can be threadedly connected to an internal thread 439 of an adapter 438. The adapter 438 may be rotatable and translational relative to the push rod support 432 via a threaded connection between the external thread 460 of the push rod support 432 and the internal thread 439 of the adapter 438.

[0153] The adjustment mechanism 430 includes a hollow dial 462 (e.g., a contact dial) supported by a housing 464 of the bicycle control unit 100. The hollow dial 462 is disposed around an adapter 438 (e.g., the outer annular surface of the adapter 438) and rotatably fixed relative to the adapter 438, such that the hollow dial 462 and the adapter 438 rotate and translate together. The hollow dial 462 and the adapter 438 can be separate components and can be rotatably fixed relative to each other in any number of ways, including, for example, using one or more connectors and / or adhesives. In one embodiment, the hollow dial 462 and the adapter 438 are formed from a single component.

[0154] The cylinder head 466 is attached to the housing 464 at its end extending through a housing bore 468 and / or adjacent to the housing 464. The cylinder head 466 can be attached to the housing 464 in any number of ways, including, for example, with one or more fasteners (e.g., snap rings, clips, and / or screws). The cylinder head 466 can, for example, retain at least the master cylinder liner 436 within the housing bore 468 and protect components (e.g., the master cylinder liner 436 and the piston 434) from environmental influences.

[0155] The pushrod support 432 is rotatably fixed relative to the cylinder head 466 and then to the housing 464, such that the pushrod support 432 cannot rotate relative to the housing 464. For example, the pushrod support 432 is bonded to the cylinder head 466 such that the pushrod support 432 can translate only relative to the cylinder head 466 and then to the housing 464.

[0156] The piston assembly, including, for example, at least a piston 434 and a seal 470 (e.g., a main seal) disposed around the piston 434, is movable relative to the master cylinder sleeve 436 (e.g., axially), and more specifically, is movable relative to a plurality of openings 472 (e.g., timing ports) extending through the master cylinder sleeve 436. The piston assembly is movable under the action of an adjusting mechanism 430 to adjust the amount of dead stroke or idle stroke (e.g., lever oscillation before pressure buildup). The piston assembly may include more, fewer, and / or different components. For example, the piston assembly may also include a seal 474 (e.g., an auxiliary seal) disposed around the piston 434 at a distance remote from the main seal 470 along the length of the piston 434.

[0157] The piston assembly can be moved by rotating the hollow dial 462. The hollow dial 462 is a rider interface and causes the adapter 438 to rotate on the second end 446 of the pushrod support 432. The rotation of the hollow dial 462, and thus the adapter 438 (relative to the housing 464 and thus relative to the pushrod support 432 in the first rotational direction), causes the adapter 438 to move further onto the pushrod support 432 (e.g., the extension 458 of the pushrod support 432) and allows the piston assembly to be further pushed away from the plurality of openings 472 (e.g., under the action of a spring within the master cylinder liner 436), thereby extending the dead stroke or idle stroke. The rotation of the hollow dial 462 and then the adapter 438 relative to the housing 464 and then relative to the push rod support 432 in a second rotational direction (e.g., opposite to the first rotational direction) causes the adapter 438 to move further away from the push rod support 432 (e.g., the extension 458 of the push rod support 432) and pushes the piston assembly toward the plurality of openings 472, thereby shortening the dead stroke or idle stroke.

[0158] Reference Figure 19A cover 476 (e.g., corresponding to cover 122) covering at least a portion of housing 464 is movable relative to housing 464 such that the hollow dial 462 may be inaccessible when cover 476 is in a first position relative to housing 464, and may be accessible when cover 476 is in a second position relative to housing. In other words, the hollow dial 462 can be made accessible by pulling cover 476 back from the front of housing 464.

[0159] The adjustment mechanism 430 (e.g., the hollow dial 462, the adapter 438, and the threaded connection between the adapter 438 and the extension 458 of the push rod support 432) can provide any number of adjustment ranges for the dead travel. For example, the adjustment mechanism 430 can provide unlimited adjustment between 0 and 1.5 mm.

[0160] As another implementation of the regulating mechanism, refer to Figure 21 and Figure 22 The adjusting mechanism 500 can be configured, for example, to move the master cylinder sleeve 502 relative to the piston assembly 504 and housing 505 of the bicycle control unit 100. The piston assembly 504 includes at least a piston 506 and a seal 508 (e.g., a main seal) disposed around and supported by the piston 506. The piston assembly 504 may include more, fewer, and / or different components. For example, the piston assembly 504 may also include a seal 510 (e.g., an auxiliary seal) disposed around and supported by the piston 506 at a distance from the main seal 508 along the length of the piston 506.

[0161] Piston assembly 504 (e.g., piston 506, main seal 508, and auxiliary seal 510) is positioned relative to, for example, housing 505 of bicycle control unit 100. A master cylinder sleeve assembly 514, including a master cylinder sleeve 502 (e.g., having a timing port 516 extending through the master cylinder sleeve 502) and one or more O-rings 518 disposed around and supported by the master cylinder sleeve 502, translates relative to piston assembly 504 to adjust the amount of dead stroke or idle stroke (e.g., rod oscillation before pressure buildup).

[0162] The adjusting mechanism 500 includes a hollow dial 520 supported by a housing 505. The master cylinder sleeve 502 has a first end 522 and a second end 524 opposite to the first end 522. The hollow dial 520 is disposed around and connected to the master cylinder sleeve 502 at a location closer to the second end 524 than the first end 522 of the master cylinder sleeve 502. The master cylinder sleeve 502 may include an external thread 526 located adjacent to the second end 524 of the master cylinder sleeve 502 (e.g., closer to the second end 524 of the master cylinder sleeve 502 than the first end 522) on its outer annular surface 527, and the hollow dial 520 may include an internal thread 528 on its inner annular surface 530. The hollow dial 520 can be rotatably connected to the master cylinder sleeve 502 via, for example, the internal thread 528 of the hollow dial 520 and the external thread 526 of the master cylinder sleeve 502.

[0163] Piston 506 has a first end 532 and a second end 534 opposite to the first end 532. Piston 506 includes a receiving portion 536 extending from the second end 534 into piston 506. Push rod 538 has a first end 540 connected to brake lever 542 and a body 544 at the second end 546 opposite to the first end 540. Body 544 is disposed within the receiving portion 536 within piston 506.

[0164] The cylinder head 548 is attached to the housing 505 in any number of ways. For example, the cylinder head 548 is attached to the housing 505 using one or more connectors (e.g., fasteners such as screws, snap rings, and / or clips). The cylinder head 548 contacts the piston 506 to hold the piston 506 in position relative to the housing 505.

[0165] The master cylinder sleeve 502 is rotatably fixed relative to the housing 505. For example, the master cylinder sleeve 502 can be bonded to the housing 505 such that the master cylinder sleeve 502 can translate relative to the housing 505 without rotating relative to the housing 505. Therefore, the master cylinder sleeve 502 bonded to the housing 505 can prevent the master cylinder sleeve 502 from rotating with the hollow dial 520.

[0166] The master cylinder sleeve 502 can be moved relative to the housing 505 and piston 506 by rotation of the hollow dial 520. The hollow dial 520 is a rider interface and causes the master cylinder sleeve 502 to translate relative to the piston 506 and then relative to the housing 505. The hollow dial 520 can be supported by the housing 505 such that the hollow dial 520 cannot translate relative to the housing 505 and then relative to the piston 506. Due to the threaded connection between the internal thread 528 of the hollow dial 520 and the external thread 526 of the master cylinder sleeve 502, rotation of the hollow dial 520 relative to the housing 505 in a first rotational direction causes the master cylinder sleeve 502 to translate in a direction toward the rear end 550 of the housing 505 (e.g., axially relative to the housing 505 and piston 506). This translation of the master cylinder sleeve 502 causes the timing port 516 through the master cylinder sleeve 502 to move away from the main seal 508 surrounding the piston 506, thereby extending the dead stroke or idle stroke. The rotation of the hollow dial 520 relative to the housing 505 in a second rotational direction (e.g., opposite to the first rotational direction) causes the master cylinder sleeve 502 to translate in a direction away from the rear end 550 of the housing 505 (e.g., axially relative to the housing 505 and the piston 506). This translation of the master cylinder sleeve 502 causes the timing port 516 through the master cylinder sleeve 502 to move toward the main seal 508 surrounding the piston 506, thereby shortening the dead stroke or idle stroke.

[0167] Reference Figure 21 A cover 552 (e.g., corresponding to cover 122) covering at least a portion of housing 505 is movable relative to housing 505 such that the hollow dial 520 may be inaccessible when the cover 552 is in a first position relative to housing 505, and may be accessible when the cover 552 is in a second position relative to housing 505. In other words, the hollow dial 520 can be made accessible by pulling the cover 552 back from the front of housing 505.

[0168] Adjustment mechanism 500 (e.g., hollow dial 520 and the threaded connection between hollow dial 520 and master cylinder sleeve 502) can provide any number of adjustment ranges for the dead stroke. For example, adjustment mechanism 500 can provide unlimited adjustment between 0 and 1.5 mm.

[0169] The bicycle control device 100 of this embodiment uses, for example, a high-pivot brake lever. (See reference...) Figure 14 , Figure 20 and Figure 22The brake lever 102 is positioned about its rotatable pivot axis P above the push rod (e.g., push rod 310, 450, or 538) and the actuation crosspin (e.g., crosspin 414) (e.g., on the downward-facing side relative to the housing of the bicycle control unit 100), the push rod being connected to the brake lever 102 via the actuation crosspin. This position of the pivot axis P allows for a greater mechanical gain to build up pressure and also provides a finer sweep at the push rod end, thereby mitigating wear that the bore, piston, and seals may experience due to lateral loads on the piston (e.g., pistons 304, 434, and 506) within the bore.

[0170] Reference Figure 23 and Figure 24 The master cylinder sleeve 302 and the housing bore 300 therein are arranged, for example, at an angle (e.g., oriented) relative to the handlebar 64. This angle provides space for enclosing, for example, the master cylinder sleeve 302, adjustment mechanisms (e.g., adjustment mechanisms 318, 430, or 500), and hose connectors 391 (e.g., Stealthamajig valve) into the housing bore 300. This angle also allows for the installation of hoses (e.g., hydraulic lines 390) and hose clamping nuts 580. The angle between the master cylinder sleeve 302 and the handlebar 64 can be configured to allow tools to reach or approach for the installation of the hose clamping nut 580, but to remain close enough to the handlebar 64 to not affect the rider's experience or aesthetics.

[0171] Reference Figure 24 The central axis C of the master cylinder sleeve 302 is angled relative to the outward-facing side 206 of the housing 104 (e.g., and relative to a portion of the handlebar 64), such that the second end 386 of the master cylinder sleeve 302 is closer to the inward-facing side 206 of the housing 104 than the first end 384 of the master cylinder sleeve 302. In one embodiment, for example when the bicycle control unit 100 is mounted to the handlebar 64, the central axis C of the master cylinder sleeve 302 extends substantially horizontally relative to the flat surface on which the bicycle 50 is supported. Other orientations may be provided.

[0172] The brake lever 102 can be mounted to the housing 104 at the same angle as the central axis C of the master cylinder sleeve 302 relative to, for example, the outward-facing side 206 of the housing 104, thereby providing smooth lever actuation. In other words, the pivot axis P can be perpendicular to the central axis C of the master cylinder sleeve 302. This angle provides a unique ergonomic experience because the lever sweep of the brake lever 102 can follow the natural movement of the rider's fingers.

[0173] Reference Figures 25 to 29 In addition to the hydraulic braking system components discussed above, housing 104 also supports an independent battery unit 190 (e.g., a battery cell). See reference... Figure 26 The battery cell 190 includes a battery housing 600 and a first battery cover 602 (e.g., an outer battery cover). The battery housing 600 is received in a recess 604 in a housing 104 and is securely attached to the housing 104 at one or more tabs 607 (e.g., two tabs) via one or more connectors 606 (e.g., screws and corresponding threaded openings, tabs, snap-fit ​​features, tape, adhesive, epoxy resin / or press-fit features). In this example, the battery housing 600 is fastened to the housing 104 at two tabs 607 via two screws 606 and two corresponding threaded openings 608 in the housing 104. Alternatively or additionally, the battery housing 600 may be attached to the housing 104 via adhesive, other fasteners and / or another type of connector (e.g., tabs or snap-fit ​​features). More or fewer than two connectors 606 may be provided.

[0174] In one embodiment, a recess 604 of the housing 104 extends from a downward-facing side 214 of the base portion 200 of the housing 104 into the housing 104. Therefore, the independent battery unit 190 can be mounted to the housing 104 at the downward-facing side 214 of the base portion 200. However, in other embodiments, the independent battery unit 190 can be mounted to other sides and / or portions of the housing 104. For example, when viewed from the inward-facing side 204 of the bicycle control unit 100, the independent battery unit 190 can be positioned below the master cylinder sleeve 302.

[0175] The independent battery unit 190 is connected to the PCB 154 within the paddle end 138 of the shift lever 132 in any of a variety of ways. For example, the independent battery unit 190 is connected to the PCB 154 via a two-conductor cable. The two-conductor cable can be laid and held on the housing 104 through a channel 610 within at least the base portion 200 of the housing 104. The two-conductor cable can be laid on the inside or outside of the housing 104. In one embodiment, the independent battery unit 190 is also connected to the PCB 244 of the auxiliary button unit 230 to power components supported by the PCB 244 of the auxiliary button unit 230. The independent battery unit 190 can be connected to the PCB 244 of the auxiliary button unit 230 via, for example, another two-conductor cable.

[0176] The independent battery cell 190 also includes a second cover 612 (e.g., an inner battery cover) disposed between the battery housing 600 and the first battery cover 602. The battery 614 can be received within a battery receiving portion (e.g., including a first cavity or recess) defined by the outer battery cover 602 and the inner battery cover 612. The battery 614 can be any variety of different types of batteries, including, for example, conventionally replaceable button cell batteries. Alternatively, the battery 614 can be a non-replaceable and / or rechargeable battery.

[0177] Battery 614 can be configured to provide power to the controller, communication module 156, remote switch, or electrical device via an accessory jack and / or other electronic components. For example, battery 614 can be configured to provide power to the electrical switch 246 of auxiliary button unit 230 when battery 614 is disposed within battery housing 616.

[0178] The independent battery cell 190 may also include one or more seals 617 (e.g., O-rings; see also) for the outer battery cover 602 and / or the inner battery cover 612. Figure 28 ), electrical contacts 618 (e.g., two battery contacts 618), and a grommet seal. The individual battery cell 190 may include additional, fewer, and / or different components.

[0179] Reference Figure 28 The battery housing 600 has a cavity 620 (e.g., a second cavity or recess; inner cavity) with an opening inside the housing 104 and a cavity 616 (e.g., a battery receiving portion 616; outer cavity) with an opening outside the housing 104. The inner cavity 620 accommodates electrical contacts 618 that can be secured to the battery housing 600 and the terminals of wires originating from one or more cables. In one example, the electrical contacts 618 are physically attached to the battery housing 600 via heat staking, although the electrical contacts 618 can be attached to the battery housing 600 in additional and / or different ways. For example, the electrical contacts 618 can be physically attached to the battery housing 600 via snap-fit ​​features, screws, glue, epoxy resin, and / or another connector. The wires of one or more cables can be physically attached to the electrical contacts 618 in any number of ways, including, for example, via crimping features and solder.

[0180] Reference Figure 26One or more cables pass through the opening 622 leading to the internal cavity 620. In one embodiment, the opening 622 leading to the internal cavity 620 is sealed with, for example, a grommet seal to prevent the intrusion of, for example, water and contaminants. The opening 622 leading to the internal cavity 620 can be sealed in any of a variety of other ways, including, for example, with adhesive or epoxy resin. Electrical contacts 618 enter the external cavity 616 from the internal cavity 620 to interface with the battery 614.

[0181] An internal battery cover 612 may be assembled within the battery housing 600 above the electrical contacts 618 and one or more cables to conceal the electrical contacts 618 and one or more cables and protect them from damage. The internal battery cover 612 may be held within the battery housing 600 in any of a variety of ways, including, for example, by heat-fused plastic, snap-fit ​​features, and screws.

[0182] The battery 614 can be held within the outer battery cover 602 by, for example, slight interference fit, such that the battery 614 is positioned within the independent battery cell 190 by the outer battery cover 602 and can be removed from the independent battery cell 190 when the outer battery cover 602 is removed.

[0183] Reference Figure 29 The outer battery cover 602 can be held on the battery housing 600 by a set of tab features 624 extending away from the inner portion 626 of the outer battery cover 602 and a slot feature 628 at the inner portion 630 of the battery housing 600. The outer battery cover 602 can be installed and removed via the tab features 624 and the slot feature 628 by rotating the outer battery cover 602 relative to the battery housing 600. Other attachment features may be provided.

[0184] exist Figure 29 In the example shown, the tab feature 624 (e.g., a convex feature) is on the outer battery cover 602, while the groove feature 628 (e.g., a concave feature) is on the battery case 600. In another embodiment, the groove feature 628 may be on the outer battery cover 602, while the tab feature 624 may be on the battery case 600.

[0185] The tab feature 624 of the outer battery cover 602, which holds the battery 614 in the battery case 600, also aligns the outer battery cover 602 with the battery case 600 to prevent damage to, for example, one or more seals 617 and / or electrical contacts 618, when the outer battery cover 602 is being installed.

[0186] The outer battery cover 602 may also include a lever feature 632 extending away from the outer annular surface 634 of the outer battery cover 602. The lever feature 632 facilitates removal from and installation onto the battery housing 600 without tools. The lever feature 632 also rotatably aligns the outer battery cover 602 relative to the battery housing 600 and the housing 104. For example, the housing 104 may include a recess 636 at least partially formed by a wall 638 (see...). Figure 26 Furthermore, the external battery cover 602 can be oriented solely by means of the lever feature 632 being disposed within the recess 636. Otherwise, the lever feature 632 might obstruct the housing 104. See reference. Figure 25 The external battery cover 602 may also include a groove 640 (e.g., a coin slot feature) in the outer side portion 642 of the external battery cover 602 to facilitate the removal and installation of the external battery cover 602 with a tool or coin.

[0187] Other implementations of independent battery cells can be provided. For example, refer to Figure 30 and Figure 31 The independent battery unit 650 can be supported at and assembled from the inward-facing side 204 of the housing 104. For example, the independent battery unit 650 can be supported by the housing 104 between the downward-facing side 214 of the base portion 200 of the housing 104 and the housing bore 300 through the housing 104, and thus supported within the master cylinder liner 302. In other embodiments, the independent battery unit 650 can be supported at other locations within the housing 104.

[0188] In this embodiment, the outer battery cover 652 is attached to the battery housing 654 (e.g., the battery casing) via one or more connectors 656 (e.g., two screw or snap-fit ​​features) rather than a rotation-locking feature. The battery housing 654 can be attached to the housing 104 in any number of ways, including, for example, via one or more connectors 656 (e.g., via corresponding threaded openings in the housing 104), other connectors, tabs, locking features, snaps, adhesives, and / or another connector.

[0189] The seal between the outer battery cover 652 and the battery housing 654 can be achieved in any number of ways, including, for example, via a gasket or an overmolded elastomer 658 compressed between the outer battery cover 652 and the battery housing 654.

[0190] The standalone battery cell 650 also includes electrical contacts 660 (e.g., two battery contacts 660). The positive battery contact 660a is positioned on the outer portion of the battery case 654 and biases the battery 662, which is located within the standalone battery cell 650 and the outer battery cover 652, toward the inward-facing side 204 of the case 104.

[0191] The battery housing 654 has a cavity 664 (e.g., an internal cavity) outside the housing 104 with an opening 666. The internal cavity 664 accommodates electrical contacts 660 that can be secured to the battery housing 654, as well as the terminals of wires originating from one or more cables. The internal cavity 664 also accommodates a washer or overmolded elastomer 658 and at least a portion of the battery 662. In one example, the electrical contacts 660 are physically attached to the battery housing 654 via plastic heat fusion, although the electrical contacts 660 can be attached to the battery housing 654 in additional and / or different ways. For example, the electrical contacts 660 can be physically attached to the battery housing 654 via snap-fit ​​features, screws, glue, epoxy resin, and / or another connector. The wires of one or more cables can be physically attached to the electrical contacts 660 in any number of ways, including, for example, via crimp features and solder.

[0192] Reference Figure 31 One or more cables pass through the opening 666 leading to the internal cavity 664. In one embodiment, the opening 666 leading to the internal cavity 664 is sealed with, for example, a grommet seal 668 to prevent the intrusion of, for example, water and contaminants. The opening 666 leading to the internal cavity 664 can be sealed in any of a variety of other ways, including, for example, with adhesive or epoxy resin.

[0193] Although certain control devices, bicycles, and methods have been described herein in accordance with the teachings of this disclosure, the scope of this patent is not limited thereto. Rather, this patent covers all embodiments of the teachings of this disclosure that fall entirely within the scope of licenseable equivalents.

[0194] The embodiments described herein are illustrative of the general understanding of the structure of various embodiments. These illustratives are not intended to be a complete description of all elements and features of devices and systems utilizing the structures or methods described herein. Many other embodiments will become apparent to those skilled in the art upon review of this disclosure. Other embodiments may be utilized and other embodiments may be inferred from this disclosure, allowing for structural and logical substitutions and changes without departing from the scope of this disclosure. Furthermore, these illustratives are merely representative and may not be drawn to scale. Some scales within the illustratives may be enlarged, while others may be minimized. Therefore, this disclosure and the accompanying drawings are to be considered illustrative rather than restrictive.

[0195] While this specification contains numerous details, these should not be construed as limiting the scope of the invention or the scope of claims, but rather as descriptions of features specific to particular embodiments of the invention. Certain features described in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. Furthermore, although features may be described above as functioning in certain combinations and even initially claimed in this way, in some cases one or more features of a declared combination may be removed from the combination, and the declared combination may involve sub-combinations or variations thereof.

[0196] Similarly, although operations and / or actions are depicted in the accompanying drawings and described herein in a specific order, this should not be construed as requiring these operations to be performed in the specific order shown or in sequential order, or requiring all illustrated operations to be performed to achieve the desired result. In some cases, multitasking and parallel processing may be advantageous. Furthermore, the separation of various system components in the above embodiments should not be construed as requiring such separation in all embodiments, and it should be understood that any described program components and systems may be integrated together in a single software product or packaged into multiple software products.

[0197] For convenience only, the term "invention" is used independently and / or collectively to refer to one or more embodiments of this disclosure, and is not intended to actively limit the scope of this application to any particular invention or inventive concept. Furthermore, although specific embodiments have been illustrated and described herein, it should be understood that any subsequent arrangements designed to achieve the same or similar purpose may replace the specific embodiments shown. This disclosure is intended to cover any and all subsequent modifications or variations of the various embodiments. Combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those skilled in the art upon reading the specification.

[0198] This abstract of disclosure is provided to conform to 37 CFR §1.72(b) and is submitted without regard to whether it will be used to interpret or limit the scope or meaning of the claims. Additionally, in the above detailed description, various features may be combined together or described in a single embodiment for the purpose of simplifying this disclosure. This disclosure should not be construed as reflecting an intention that the claimed embodiments require more features than expressly recited in each claim. Rather, as reflected in the appended claims, the inventive subject matter may address fewer than all features of any one of the disclosed embodiments. Therefore, the following claims are incorporated into the detailed description, wherein each claim independently defines a separately claimed subject matter.

[0199] The specific embodiments described above are intended to be illustrative rather than restrictive, and it is to be understood that the following claims, including all equivalents, are intended to define the scope of the invention. The claims should not be construed as limited to the order or elements described unless otherwise stated. Therefore, all embodiments falling within the scope and spirit of the appended claims and their equivalents are protected by the invention. In one example, a control device mountable to a bicycle handlebar includes a housing having a base portion and an extension portion. The base portion of the housing has a front end, a rear end opposite the front end, a downward-facing side, an upward-facing side, an inward-facing side, an outward-facing side, and a handlebar clamp disposed at the rear end. The control device further includes: a rod coupled to and pivotable relative to the housing; and a master cylinder portion supported by the housing. The master cylinder portion has a fluid cylinder. The fluid cylinder has a first end and a second end opposite the first end, and a cylindrical wall located between the first end and the second end. The fluid cylinder is hollow, such that an opening extends from the first end through the master cylinder portion to the second end. The control device also includes a piston assembly supported by the housing. The piston assembly is movable relative to the master cylinder portion. At least a portion of the piston assembly is disposed within the master cylinder portion. The master cylinder portion is angled relative to the outward-facing side of the base portion of the housing, such that the first end of the fluid cylinder is closer to the outward-facing side than the second end of the fluid cylinder.

[0200] In one example, the control device further includes a push rod. The rod is coupled to the piston assembly via the push rod, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion.

[0201] In one example, the master cylinder portion has a central axis extending along the length of the master cylinder portion. The control device also includes a pivot axis for pivotally connecting the rod to the housing. The pivot axis defines a pivot axis about which the rod is pivotable relative to the housing. The pivot axis is perpendicular to the central axis of the master cylinder portion, such that the rod pivots in a plane that is aligned with or parallel to the central axis of the master cylinder portion.

[0202] In one example, the pivot is positioned above the push rod relative to the downward-facing side of the base portion of the housing.

[0203] In one example, the control device further includes a fluid chamber at least partially disposed within the extension of the housing. The pivot shaft is disposed between at least a portion of the fluid chamber and the push rod.

[0204] In one example, the cylindrical wall of the fluid cylinder has at least one inner annular surface and at least one outer annular surface. The cylindrical wall of the fluid cylinder includes an opening extending from the inner annular surface of the at least one inner annular surface of the cylindrical wall through the cylindrical wall to the outer annular surface of the at least one outer annular surface.

[0205] In one example, the piston assembly includes a piston and a seal disposed around the piston. Fluid energy can be disposed within a volume between the piston and the fluid cylinder. The piston assembly is configured to translate relative to the master cylinder portion in a first direction from a first position toward a second position when the rod pivots relative to the housing in a first rotational direction, such that the seal moves toward an opening through the cylindrical wall of the fluid cylinder and ejects a portion of the fluid from the master cylinder portion to actuate the bicycle's brake calipers.

[0206] In one example, the master cylinder portion further includes a fluid port supported by the base portion of the housing, a vent supported by the extension portion of the housing, and a fluid passage within the housing. The fluid passage is between the fluid chamber and the master cylinder portion. When the piston assembly is in a first position relative to the master cylinder portion, the control device has a fluid path between the fluid port and the vent, via an opening penetrating the master cylinder portion, an opening penetrating the cylindrical wall of the fluid cylinder, a volume between the fluid cylinder and the housing, the fluid passage, and the fluid chamber.

[0207] In one example, the master cylinder portion has a central axis extending along the length of the master cylinder portion. When the control device is mounted to the handlebars of the bicycle, the central axis of the master cylinder portion extends substantially horizontally relative to the flat surface on which the bicycle is supported.

[0208] In one example, a control device mountable to a bicycle handlebar includes a housing having a base portion and an extension portion. The base portion of the housing has a front end, a rear end opposite the front end, a downward-facing side, an upward-facing side, an inward-facing side, an outward-facing side, and a handlebar clamp disposed at the rear end. The control device further includes: a rod coupled to and pivotable relative to the housing; and a master cylinder portion supported by the housing. The master cylinder portion has a fluid cylinder. The fluid cylinder has a first end and a second end opposite the first end, and a cylindrical wall located between the first end and the second end. The fluid cylinder is hollow, such that an opening extends from the first end through the master cylinder portion to the second end. The control device further includes a piston assembly supported by the housing, movable relative to the master cylinder portion, at least a portion of the piston assembly being disposed within the master cylinder portion. The control device further includes a first adjustment mechanism configured to adjust the angular position of the rod relative to the housing such that when the control device is mounted to the handlebars of the bicycle, the distance between the end of the rod and the handlebars is also adjusted. The control device also includes a second adjustment mechanism configured to adjust the initial position of the piston assembly relative to the opening through the cylindrical wall of the fluid cylinder.

[0209] In one example, the piston assembly includes a piston and a seal disposed around the piston. Fluid energy can be disposed within a volume between the piston and the fluid cylinder. The piston assembly is configured to translate relative to the master cylinder portion from a first position toward a second position in a first direction when the rod pivots relative to the housing in a first rotational direction, such that the seal moves toward the opening through the cylindrical wall of the fluid cylinder and ejects a portion of the fluid from the master cylinder portion to actuate the bicycle's brake calipers.

[0210] In one example, the control device further includes a push rod. A first end of the push rod is coupled to the rod via the first adjusting mechanism, and a second end of the push rod is coupled to the piston assembly, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion. The first adjusting mechanism includes a threaded connection between the push rod and the rod at or near the first end of the push rod. The rod is pivotally connected to the housing such that when the push rod rotates relative to the rod in a first rotational direction via the threaded connection between the push rod and the rod, an end of the rod moves toward the base portion of the housing.

[0211] In one example, the first end of the push rod is accessible via an opening through the rod and is rotatable.

[0212] In one example, the second adjustment mechanism includes a cam rotatable relative to the piston assembly. The piston assembly is biased against the cam such that the cam acts as a stop and positions the piston assembly in an initial position relative to the master cylinder portion. The cam is configured to translate the piston assembly relative to the master cylinder portion when the cam rotates relative to the piston assembly.

[0213] In one example, the master cylinder portion has a central axis extending along its length. The cam is rotatable relative to the piston assembly about a cam rotation axis. The cam rotation axis is perpendicular to the central axis of the master cylinder portion. The cam has multiple sides. Each of the multiple sides has a different height in a direction along or parallel to the central axis of the master cylinder portion.

[0214] In one example, the control device further includes: a push rod; and a push rod support, the push rod support including a receiving portion at a first end of the push rod support. The push rod support is connected to the push rod at the receiving portion. The push rod support supports the cam at or near a second end of the push rod support. The second end of the push rod support is opposite to the first end of the push rod support. The rod is coupled to the piston assembly via the push rod, the push rod support, and the cam, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion.

[0215] In one example, the second adjustment mechanism includes a hollow dial supported by the housing. The second adjustment mechanism is configured such that rotation of the hollow dial relative to the housing causes one of the piston assembly and the master cylinder portion to translate relative to the other of the piston assembly and the master cylinder portion.

[0216] In one example, the control device further includes: a push rod; and a push rod support, the push rod support including a receiving portion at a first end of the push rod support. The push rod support is connected to the push rod at the receiving portion. The second adjustment mechanism further includes a hollow adapter having an inner annular surface and an outer annular surface. A second end of the push rod support is threadedly connected to the hollow adapter at the inner annular surface of the hollow adapter, and the inner annular surface of the hollow dial is connected to the outer annular surface of the hollow adapter. The hollow adapter abuts against the piston of the piston assembly and is configured to rotate with the hollow dial, and to rotate and translate relative to the push rod support via the threaded connection between the push rod support and the hollow adapter, such that rotation of the hollow dial relative to the housing causes the hollow adapter, and consequently causes the piston assembly to translate relative to the master cylinder portion.

[0217] In one example, the control device further includes a push rod. The piston of the piston assembly includes a receiving portion located at an end of the piston. The piston is connected to the push rod at the receiving portion. The inner annular surface of the hollow dial is threadedly connected to the outer annular surface of the fluid cylinder. The hollow dial is rotatable relative to the fluid cylinder via the threaded connection between the inner annular surface of the hollow dial and the outer annular surface of the fluid cylinder, such that rotation of the hollow dial relative to the housing causes translation of the fluid cylinder relative to the piston assembly.

[0218] In one example, the control device further includes a cover attached to the housing. The cover covers at least a portion of the housing. The cover is movable relative to the housing from a first position relative to the housing to a second position relative to the housing, such that the hollow dial is accessible when the cover is in the second position relative to the housing.

[0219] In one example, the control device further includes: a shift lever coupled to and movable relative to the housing; and an electrical switch actuated by movement of the shift lever. The control device also includes a controller in communication with the electrical switch. The controller is configured to generate a shift signal in response to actuation of the electrical switch. The control device also includes a battery housing supported by the base portion of the housing. The battery housing is electrically connected to the controller such that when a battery is disposed within the battery housing, the battery is configured to supply power to the controller, the electrical switch, or a combination thereof. The control device also includes a battery cover that closes the battery housing and is removably attached to the battery housing or the housing.

[0220] In one example, the battery housing opens toward the downward-facing side or the inward-facing side of the base portion of the housing.

[0221] In one example, the battery housing is supported within the housing between the downward-facing side of the base portion of the housing and the master cylinder portion.

[0222] In one example, the extension of the housing has an inward-facing side and an outward-facing side. The outward-facing side is opposite to the inward-facing side. The electrical switch is a first switch. The control device also includes a second switch, which is supported by the extension of the housing at or near the inward-facing side of the extension.

[0223] In one example, the control device further includes an actuator that communicates with the second switch, such that the second switch can be actuated via the actuator. The actuator is supported by the inward-facing side of the extension of the housing.

[0224] In one example, the second switch is electrically connected to the controller such that when the battery is disposed within the battery housing, the battery is configured to power the second switch.

[0225] Attached Figure

[0226] The object, features, and advantages of the present invention will become clear after reading the following description in conjunction with the accompanying drawings, in which:

[0227] Figure 1 A side view of an example bicycle that can be equipped with a control device constructed according to the teachings of this disclosure;

[0228] Figure 2 It is one implementation method of the control device and Figure 1 A first side view of a portion of the handlebars of a bicycle;

[0229] Figure 3 It was removed from the handlebars. Figure 2 First side view of the control device;

[0230] Figure 4 yes Figure 2 control device and Figure 1 An external 3D view of a portion of the handlebars of a bicycle;

[0231] Figure 5 yes Figure 2 control device and Figure 1 A second side view of a portion of the handlebars of a bicycle;

[0232] Figure 6 It was removed from the handlebars. Figure 4 An external perspective view of the control device;

[0233] Figure 7 It was removed from the handlebars. Figure 5 The second side view of the control device;

[0234] Figure 8 yes Figure 2 An exploded view of the control device, including a perspective view of the cover and auxiliary buttons removed from the housing of the control device;

[0235] Figure 9 yes Figure 2 A cross-section of a top-view perspective view of the control device;

[0236] Figure 10 yes Figure 2 An exploded perspective view of the control device;

[0237] Figure 11 yes Figure 2 control device and Figure 1 A front view of part of the handlebars of a bicycle;

[0238] Figure 12 It was removed from the handlebars. Figure 11 Front view of the control device;

[0239] Figure 13 It is along Figure 11 The axis BB is cut off Figure 11 The cross-section of the control device;

[0240] Figure 14 It is along Figure 12 The axis CC intercept Figure 12 The cross-section of the control device;

[0241] Figure 15 yes Figure 2 A side view of the housing of the control device and an exploded view of the first adjustment mechanism and piston disassembled from the housing of the control device;

[0242] Figure 16 yes Figure 15 Exploded top view of the first regulating mechanism, piston, and fluid cylinder;

[0243] Figure 17 yes Figure 16 The cross-section of the fluid cylinder, in which the first adjusting mechanism and the piston are assembled inside the fluid cylinder;

[0244] Figure 18 yes Figure 17 A three-dimensional view of the cam of the first adjustment mechanism;

[0245] Figure 19 It includes the second regulating mechanism. Figure 1 A perspective view of another embodiment of the bicycle control device;

[0246] Figure 20 yes Figure 19 The cross-section of the control device;

[0247] Figure 21 It includes the third regulatory body. Figure 1 A perspective view of another embodiment of the bicycle control device;

[0248] Figure 22 yes Figure 21 The cross-section of the control device;

[0249] Figure 23 The storage container cover has been removed. Figure 2 control device and Figure 1 A three-dimensional image of part of the handlebars of a bicycle;

[0250] Figure 24 It is intercepted along axis AA. Figure 4 The cross-section of the control device and Figure 1 Part of the handlebars of a bicycle;

[0251] Figure 25 It was removed from the handlebars. Figure 2 A bottom view of the control device;

[0252] Figure 26 The lid has been removed. Figure 1 A perspective view of another embodiment of the bicycle control device and an exploded view of the first battery assembly removed from the housing of the control device;

[0253] Figure 27 It was removed from the handlebars and assembled. Figure 26 The cross-section of the control device;

[0254] Figure 28 yes Figure 27 A close-up view of the cross-section of the first battery assembly;

[0255] Figure 29 yes Figure 26 A close-up, exploded perspective view of the battery casing and battery cover of the first battery assembly;

[0256] Figure 30 yes Figure 1 A perspective view of another embodiment of the bicycle control device and an exploded view of a second battery assembly disassembled from the housing of the control device; and

[0257] Figure 31 It is assembled. Figure 30 A close-up cross-section of the second battery assembly.

[0258] Implementation

[0259] Hydraulic braking calculations for bicycles are based on the fluid volume (volume) in the lever, the fluid volume (volume) in the hose, and the fluid volume (volume) in the caliper. As the brake pads wear, fluid shifts into the caliper. The master cylinder of the control unit includes a timing port. The timing port allows fluid to flow between the caliper of the brake assembly and a reservoir within the lever body of the control unit. When the master seal passes the timing port, the seal actively displaces the fluid and builds up hydraulic pressure in the hydraulic lines leading to the brake assembly. This hydraulic pressure generates braking force, thereby slowing the bicycle and the rider. For this reason, positioning the master seal close to the timing port allows for minimal lever movement before the rider feels the brakes. Existing control units rely on positioning features formed on the lever body to position the piston assembly relative to the master cylinder, and thus the master seal.

[0260] This disclosure provides examples of a control device for a bicycle that addresses or improves upon one or more shortcomings of existing known control devices. The disclosed control device includes an adjustment mechanism for adjusting the distance between a main seal and a timing port. For example, the adjustment mechanism may include a multi-position cam for such hydraulic contact adjustment. The multi-position cam can stop and position a piston assembly including, for example, a main piston and a main seal, and can be used to adjust the position of the piston assembly relative to the timing port.

[0261] To achieve a low-cost configuration of the master cylinder and piston assembly, the master cylinder is independent of the control unit's lever body. This allows for the design and manufacture of each component using, for example, materials with the lowest cost and / or lowest weight for each part. To reduce the number of parts for cost and / or assembly purposes, multiple components and / or functions are integrated together.

[0262] The disclosed control unit also includes auxiliary buttons for additional functions and ergonomics. The auxiliary buttons are mounted inside the upper saddle section of the control unit's body (e.g., housing). The auxiliary buttons may be positioned in front of the hydraulic reservoir cover sealing surface, above the brake lever cavity. The auxiliary buttons may be connected via a cable to the shift lever paddle-shaped printed circuit board (PCB), which is laid and held on the control unit's body through a channel within the body.

[0263] The disclosed control unit also includes a remote hydraulic reservoir. This reservoir can be located above the master cylinder (e.g., within the saddle section of the control unit's body) to maximize air venting. To provide additional hydraulic reservoir fluid volume, pockets for additional fluid can be added to the blade openings for compensation. These pockets can be fitted between the lugs of the blades and surround the blade pivot.

[0264] The disclosed control device also includes a high-pivot brake lever. The lever blade is pivoted higher than the actuating crosspin and pushrod. This pivot position allows for greater mechanical gain to build up pressure and also provides finer sweep at the pushrod end, thus reducing wear on the bore, piston, and seals that may occur due to lateral loads on the main piston.

[0265] The disclosed control unit also includes a master cylinder oriented at an angle (or tilt) relative to the handlebars. This angle provides space for enclosing the master cylinder, contact adjustment elements (e.g., one or more adjustment mechanisms), and fluid ports leading to the cylinder bore. The angle of the master cylinder allows for the installation of hoses and hose clamping nuts. The lever blades can be mounted at the same angle to provide smooth lever actuation. This angle also provides a unique ergonomic experience, as the sweep of the lever blades follows the natural movement of the rider's fingers.

[0266] Upon reading this disclosure, these and other objects, features, and advantages of the disclosed control device will become apparent to those skilled in the art. Throughout the drawings, where the same reference numerals are used, the same reference numerals denote the same or substantially similar components in the various disclosed embodiments. Furthermore, specific examples of specific combinations utilizing the aspects, features, and components disclosed herein are disclosed and described. However, it is possible that each aspect, feature, and / or component disclosed herein may be used independently or in different combinations with other aspects, features, and / or components of this disclosure, in other examples not disclosed or described herein.

[0267] Now turn to the attached image. Figure 1A bicycle 50 is depicted, having a frame 52, a front wheel 54 with a fork 56 connected to the frame 52, and a rear wheel 58 with a rear top fork 60 and a rear chainstay 62 connected to the frame 52. The front wheel 54 and the rear wheel 58 support the frame 52 above a surface on which the bicycle 50 can travel in the forward direction indicated by the arrow "X". The bicycle 50 has drop bar handlebars 64 mounted to the head tube 66 of the frame 52. The bicycle 50 also has a seat 68 supported by a seatpost 70 received in the seat tube 72 of the frame 52. The bicycle 50 may have one or both of a front derailleur 74 (e.g., a front electromechanical derailleur; hereinafter referred to as a front derailleur) and a rear derailleur 76 (e.g., a rear electromechanical derailleur; hereinafter referred to as a rear derailleur) mounted to the frame 52. The bicycle 50 includes a multi-gear transmission system 78 with one or more chain links 80 driven by a crank assembly 82, the crank assembly having two crank arms 84 and two pedals 86 respectively. The chain links 80 can be connected to multiple sprockets 88 at the rear wheel 58 via a chain 90.

[0268] Reference Figures 1 to 7 In the disclosed example, the bicycle 50 has at least one bicycle control device 100 (e.g., control unit 100) that can be mounted to the handlebars 64. In this example, the control unit 100 includes a brake control element of a braking system. The brake control element includes a brake lever 102 movably connected to a cover or housing 104 of the control unit 100. The brake lever 102 operates components of the braking system of the bicycle 50. In one example, the braking system may include a connection to the front wheel 54 via, for example, a hydraulic brake line 110 (see...). Figure 1 The hydraulic front braking mechanism 106 is connected to the rear wheel 58 (see...) Figure 1 The hydraulic rear brake mechanism 108 is included. In one embodiment, the braking system is a hydraulic disc brake system that includes a hydraulic braking mechanism acting on the rotor. In an alternative embodiment, the braking system may instead be a mechanical cable-operated braking system. As described in more detail below, the control device 100 also includes a shift control element of an electronic shift control system. The shift control element includes a shift lever assembly 112 for shifting the gears of the bicycle 50.

[0269] Reference Figures 2 to 7The following describes different external views of a control device 100 constructed according to an example of the present disclosure. The control device 100 can be mounted to a handlebar 64. In one example, the housing 104 includes a clamp 120, which may include an adjustable strap extending around the handlebar 64. In one example, the bicycle 50 may include a pair of control devices 100, one on each of the left and right sides of the handlebar 64, as is well known. This pair of control devices 100 may be configured together to operate the front derailleur 74 and the rear derailleur 76 respectively, and to operate the front brake 106 and the rear brake 108 respectively. In one example, the pair of control devices 100 may be identical to each other.

[0270] In the published examples, refer to Figure 8 The control device 100 includes a cover (e.g., housing 104) that can be covered by an outer cover or outer cover 122. The housing 104 is shaped and sized for gripping by a user or cyclist's hand, and the outer cover 122 can be configured to closely conform to and cover the shape of the housing 104. The housing 104 and outer cover 122 can serve as a grip or can be configured together as a grippable portion of the control device 100. The housing 104 can be formed from any variety of materials such as, for example, metal, plastic, and / or composite materials. For example, the housing 104 can be made of glass-filled nylon or carbon (fiber)-filled nylon. The housing 104 is configured to carry, house, and / or support various components and mechanisms of the braking system and electronic shift control system, as described in more detail below. The outer cover 122 can be made from any variety of materials such as, for example, natural materials and / or synthetic elastomer materials. The outer cover 122 can be configured to have a comfortable interface for the user and reduce the tendency to become detached or moved from the outside of the housing 104. For example, the outer cover 122 can be formed from a flexible thermoplastic elastomer (TPE) such as Santoprene™. The outer cover 122 can be configured to be removably attached to and held in place on the housing 104 using any known fastening or attachment method.

[0271] In this example, refer to Figure 8 , Figure 13 and Figure 14 The brake lever 102 is pivotally or movably attached to the housing 104. The brake lever 102 may be attached to the housing 104 at or near the leading or front portion, such that the brake lever 102 is forward-separated from the handlebars 64. Therefore, the brake lever 102 may be pivotable generally forward and backward relative to the housing 104. As discussed further below, the brake lever 102 may also be pivotable toward and away from the frame 52 of the bicycle 50.

[0272] The brake lever 102 can be made of any variety of materials, such as, for example, metals (e.g., aluminum), plastics, and / or composite materials. (See reference...) Figure 10 The housing 104 may include a pivot hole or aperture 124. Pivot holes 124 may be aligned with each other and define a pivot axis P. A brake lever 102 may be attached to the housing 104 via a shaft 126 formed by, for example, a pivot pin, rod, or similar component, passing through the pivot hole 124. As discussed further below, the pivot axis P may be positioned above a push rod operably coupled to a piston supported by the housing 104. Additionally, the pivot axis P may be positioned between the push rod and at least a portion of a fluid chamber disposed within the housing 104.

[0273] In the disclosed example, the brake lever 102 may have a U-shaped recess or define a channel along at least a longitudinal portion of the grip handle. (See also...) Figures 2 to 7 The shift lever assembly 112 can be nested, at least partially, within a recess or channel, as described in more detail below. This nesting arrangement of the shift lever assembly 112 with the brake lever 102, and the U-shape of the lever body, can provide structural rigidity and protection for components housed within the channel. The shift lever assembly 112 can also be pivotally or movably attached to the housing 104, the pivoting mechanism, or the brake lever 102. The shift lever assembly 112 can be positioned behind the brake lever 102 (e.g., between the brake lever 102 and the handlebar 64 when mounted on a bicycle 50). The shift lever assembly 112 can be made of any of a variety of materials, such as, for example, plastic or composite materials. In one example, the shift lever assembly 112 can be at least partially made of a material that does not significantly inhibit the penetration of wirelessly transmitted signals.

[0274] Reference Figure 10 The shift lever assembly 112 can pivot laterally about axis S, which is generally perpendicular to the pivot axis P of the brake lever 102 about axis 126. Therefore, the shift lever assembly 112 can move relative to the bicycle 50 in the inward and outward directions while remaining nested and aligned with the brake lever 102.

[0275] The shift lever assembly 112 includes a bracket 131 and a shift lever 132. The shift lever 132 has a proximal end 134 that is directly or indirectly pivotally attached to the bracket 131, housing 104, and / or brake lever 102 via a pivot pin (not shown). The pivot pin defines a pivot axis S of the shift lever assembly 112. The shift lever 132 also has a distal end or paddle-shaped end 138 opposite the proximal end 134 and a lever arm 140 (e.g., an elongated lever arm) connecting the proximal end 134 and the distal end 138. The lever arm 140 may be a closed, hollow body or may be U-shaped or side-opening and may include structural ribs. The shift lever 132 may be made of any variety of materials, including, for example, plastic.

[0276] The brake lever 102 and the shift lever assembly 112 are pivotally mounted to the housing 104 via a two-piece shaft 126. The two-piece shaft 126 includes a bolt 126a on one side and a nut 126b fastened to the bolt 126a on the other side. In one embodiment, at least a portion of the outer annular surface of the bolt 126a includes raised knurled features that help retain the bolt 126a within the housing of the control device 100. Two bushings 143 provide a low-friction, compliant interface between the brake lever 102 and the shaft 126.

[0277] The proximal end 134 of the shift lever 132 and / or the bracket 131 may also carry connecting components for connecting the brake lever 102 to the hydraulic braking system. These components may include a sleeve 144 carried by the bracket 131 (e.g., via an opening through the bracket 131). When the shift lever assembly 112 is assembled to the brake lever 102, the sleeve 144 is received in a set of openings 145 spaced apart from the pivot bore 124 at the proximal end of the brake lever 102. The combination of the sleeve 144 and the openings 145 engages the brake lever 102 and the shift lever assembly 112 relative to the brake lever pivot axis P. The shift lever assembly 112 is thus configured to move about the pivot axis P in conjunction with or in cooperation with the brake lever 102 when the braking system is operated, but to move independently of the brake lever 102 when the shift control system is operated. As described in more detail below, the paddle-shaped end 138 of the shift lever 132 includes an internal cavity 146 that houses the shift lever assembly 112 and electronic components of the shift control system.

[0278] Reference Figures 8 to 10 The bicycle control device 100 has at least four main components, including a housing 104, an outer cover 122, a brake lever 102, and a shift lever assembly 112. According to the teachings of this disclosure, both the shift lever assembly 112 and the housing 104 further include additional sub-components. The sub-components of the shift lever assembly 112 are located in… Figure 10 The overall example is shown in the middle, and the sub-components of housing 104 are in Figures 8 to 10 The overall example is shown in the middle.

[0279] In the published examples, refer to Figure 10 The shift lever assembly 112 is a separate electrical component. In this example, the shift lever assembly 112 includes electronic components for operating the bicycle control unit 100. Some of the electronic components in this example are housed within an internal cavity 146 in the paddle-shaped end 138 of the shift lever 132, and some electronic components are external to but electrically connected to the electronic components within the internal cavity 146 in the paddle-shaped end 138.

[0280] In this example, the paddle-shaped end 138 of the shift lever 132 has a larger surface area than the adjacent lever arm 140. Therefore, the paddle-shaped end 138 provides a convenient and ergonomic contact point for the user. The internal cavity 146 in the paddle-shaped end 138 includes a cover 148, which can be secured to the paddle-shaped end 138 by fasteners 150 (e.g., three fasteners) to seal the internal cavity 146 and prevent or exclude water and other contaminants from entering it. A seal 152 can be inserted between the internal cavity 146 and the cover 148. The seal 152 can be a rubber sealing film or layer of any suitable material used to seal the internal cavity 146 in the paddle-shaped end 138 to prevent moisture or contaminants from entering.

[0281] In one example, a printed circuit board (PCB) 154 is disposed within an internal cavity 146 in the paddle-shaped end 138. The internal cavity 146 accommodates the PCB 154 having two openings. For example, a cable is attached to the PCB 154 using a connector (e.g., a 2C board connector) and passes through the first of the two openings (not shown). The first opening of the internal cavity 146 can be sealed using, for example, a grommet or grommet. The PCB 154 is disposed within the internal cavity 146 via the second of the two openings.

[0282] Various electronic components may be mounted on or connected to PCB 154. PCB 154 may include a communication module 156 configured to transmit signals from control device 100. In one example, communication module 156 may be configured to wirelessly transmit signals in the form of electromagnetic radiation (EMR), such as radio waves or radio frequency signals. Optionally, communication module 156 may also be configured to receive signals. In one example, communication module 156 may be configured to receive signals that may be in the form of EMR, such as radio waves or radio frequency signals. Communication module 156 may include or may be a transmitter, receiver, or transceiver. PCB 154 may also include an antenna 158 operatively communicating with communication module 156 to transmit and optionally also receive EMR signals. Antenna 158 may be any device configured to transmit and / or receive electromagnetic radiation waves (e.g., TV or radio waves).

[0283] In the disclosed example, antenna 158 is positioned on PCB 154 such that it can transmit signals without significantly interfering with the structure of bicycle control unit 100 and / or the rider's hands. In another example, to help reduce or prevent interference, antenna 158 may be a wireless antenna and may be at least partially disposed in or on a portion of bicycle control unit 100 that is separate from and distanced from housing 104. For example, antenna 158 may be disposed on another portion of brake lever 102 or shift lever 132.

[0284] In one example, the bicycle control unit 100 also includes, for example, a controller (not shown) also on the PCB 154. This controller is operatively connected to the communication module 156 to perform electronic operations, such as generating signals associated with one or more of shifting, pairing, derailleur adjustment operations, power management, etc. For example, the controller may be programmable and configurable to generate signals for controlling the front derailleur 74 and the rear derailleur 76. In one example, the controller may be a microcontroller with internal memory. In another example, the communication module 156 may be programmable and configurable to send and / or receive signals for controlling the front derailleur 74 and the rear derailleur 76. In one example, the communication module 156 may be a transceiver. Any variety of microcontrollers and communication modules 156 can be utilized. Additionally, as is known in the art, auxiliary electrical and / or electronic devices and components can be used to further enhance or enable the functionality and operation of the controller, communication module 156, and related components.

[0285] In one example, the electronics of the shift lever assembly 112 may also include at least one light source (not shown) (e.g., a light-emitting diode (LED)). The LED may also be positioned on the PCB 154. The LED may convey status information to the rider, such as information related to the electronics and / or functions of the shift lever assembly 112 or the bicycle control unit 100.

[0286] In one example, the electronic components may include one or more electrical switches. For instance, when actuated, the first electrical switch 160 may cause the controller and / or communication module 156 to perform operations. Such operations may involve signal transmission or reception, pairing of derailleurs 74, 76 and control device 100, adjustment and / or shifting operations, etc. The first electrical switch 160 may generate actions and / or responses for initiating or triggering various mechanisms of the bicycle 50, such as the front derailleur 74 and / or rear derailleur 76.

[0287] In this example, the first electrical switch 160 includes a contact (not shown) located on PCB 154, below the resilient dome switch element 162 (also on PCB 154). In this example, the first electrical switch 160 is actuated from outside the internal cavity 146 in the paddle-shaped end 138 of the shift lever 132 via a seal 152. A cover 148 has a first switch opening 164, wherein both the cover 148 and the first switch opening 164 are located on the inward-facing side of the shift lever 132 (e.g., the non-actuated side of the paddle-shaped end 138). An actuator 166 is disposed in the first switch opening 164, as... Figure 5 and Figure 7 As depicted in [the text]. (Refer to...) Figure 10Actuator 166 includes a button 168 received in an eyelet 170 in the inner wall 172 of brake lever 102. A spring retainer 174 is held in a first switch opening 164 in cover 148. A spring 176 extends between the button 168 and the spring retainer 174 and biases shift lever 132 toward the outer wall 178 of brake lever 102. For example, a rider operates shift lever 132 by pushing inward against an actuating surface (e.g., the outer surface of paddle-shaped end 138) against the biasing force of spring 176. When the rider pushes against paddle-shaped end 138, button 168 eventually contacts spring retainer 174. Spring retainer 174 is pressed against resilient dome switch element 162 via seal 152, which further contacts contacts on PCB 154 to close and actuate first electrical switch 160.

[0288] As another example, the second electrical switch 180 includes a contact located on a PCB 154. The contact may be a dome-shaped switching element or a pressure-type switching contact. In this example, the second electrical switch 180 is also actuated from the outside of the internal cavity 146 and the shift lever 132 via a seal 152. A cover 148 has a second switch opening 182, wherein both the cover 148 and the second switch opening 182 are located on the inward-facing side of the shift lever 132 (e.g., the non-actuated side of the paddle end 138). A button 184 extends through and is disposed therein via the second switch opening 182 in the cover 148, as... Figure 5 and Figure 7 As depicted in the image. Button 184 may be integrally formed as part of seal 152, or may be attached to the material of seal 152. For example, a cyclist simply operates the second electrical switch 180 by pressing button 184 toward cover 148. The material layer beneath button 184 or seal 152 may have dotted contacts (not shown) on its inner end, which are pushed against seal 152 to press down and close the contacts to actuate the second electrical switch 180.

[0289] The first button 168 and the second button 184 operate through a material layer of the seal 152, thereby not compromising the integrity of the seal 152 for the internal cavity 146 in the paddle end 138. Other types of electrical switches may be used. The first electrical switch 160 may be used to operate the control device 100 on a more frequent and forceful basis, such as for initiating shifting or gear changing. The second electrical switch 180 may be an optional switch, and in this example, may be smaller and more independent. The second electrical switch 180 may be designed to be used less frequently than the first electrical switch 160. In one example, the second electrical switch 180 may be used for operations related to pairing the bicycle control device with specific bicycle components such as the front derailleur 74 and / or the rear derailleur 76, or for adjusting the front derailleur 74 and / or the rear derailleur 76. Actuation of the first electrical switch 160 and the second electrical switch 180 sends a signal via associated circuitry for the controller to act upon.

[0290] Electronic components on PCB 154 and within the internal cavity 146 in the paddle-shaped end 138 are held and sealed in place within the internal cavity 146. A seal 152 covers PCB 154 and is clamped between the paddle-shaped end 138 of the shift lever 132 and the cover 148 when the cover 148 is fastened to the shift lever 132 with, for example, three fasteners 150. The seal 152 may be, for example, a gasket. (See reference...) Figure 10 The paddle-shaped end 138 may include a recess 186 surrounding an opening leading to the internal cavity 146. Ribs on the seal 152 are positioned within the recess 186 to form a tight environmental seal when the cover 148 is secured to the paddle-shaped end 138. In one example, a second opening of the internal cavity 146 is sealed by the seal 152, which is compressed and held by the cover 148; the cover 148 is secured to the shift lever 132 with three fasteners 150 in the form of threaded screws that are directly mounted into the shift lever 132.

[0291] Cables (e.g., single-wire, double-wire (2C) cables; hereinafter referred to as wires) are electrically connected to electronic components of PCB 154 and are laid from internal cavity 146 through openings (e.g., a first opening of internal cavity 146) into lever arm 140. Wires extend along the interior of lever arm 140 and are laid around sleeve 144 and transverse openings 142 on the proximal end 134 of shift lever 132. In the disclosed example, the wires are connected to a power source (e.g., a separate battery cell 190). The separate battery cell 190 is described in more detail below.

[0292] The shift lever assembly 112 may include additional, fewer, and / or different components. For example, such as Figure 10As shown in the example, the shift lever assembly 112 may include a backing 192 that can be inserted between and sandwiched between the cover 148 and the paddle-shaped end 138 of the shift lever 132. Each of the cover 148 and the paddle-shaped end 138 of the shift lever 132 may be formed as a receiving portion, such as a recess 194, defining an edge that captures the backing 192. The backing 192 may form a contact point between the top of the shift lever 132 and a contact surface on the inner surface of the brake lever inner wall 172. The contact surface may include a bump or protrusion positioned to contact the backing 192. The backing 192 may be captured between the bump on the inner surface of the brake lever inner wall 172 and the recess 194 on the shift lever 132. The backing 192 may be formed of a durable material with low friction properties. In one example, the backing 192 may be made of a different material than the shift lever 132, such as Teflon, and may be attached to the shift lever 132. Therefore, the backing 192 may allow the shift lever 132 to slide laterally and easily relative to the brake lever 102 to suppress engagement and wear.

[0293] Figure 10 A chamber 196 is shown located within housing 104, where brake lever 102 is connected to components of a hydraulic braking system. Chamber 196 can accommodate components of control device 100 and provide access to those components for maintenance or adjustment. When cover 122 is attached to housing 104, chamber 196 can be covered, concealed, and protected from environmental influences.

[0294] Reference Figure 8 The housing 104 has a base portion 200, an extension portion 202 extending away from the base portion 200 (e.g., a saddle head), an inwardly facing side portion 204, and an outwardly facing side portion 206 opposite to the inwardly facing side portion 204. The base portion 200 of the housing 104 has a front end 208, a rear end 210 opposite to the front end 208, an upwardly facing side portion 212, and a downwardly facing side portion 214. The base portion 200 of the housing 104 may include more, fewer, and / or different sides.

[0295] A portion (e.g., the upward-facing portion) of the extension 202 of the housing 104 can be accessed via the removable cover 216. The removable cover 216 can be secured to the housing 104 by any variety of fastening devices, including, for example, screws or other fasteners, snap-fit ​​connectors, adhesives, or other types of fastening devices. Figure 8 In the example shown, the removable cover 216 is secured to the housing 104 with three screws 218. In other examples, the removable cover 216 may be secured to the housing 104 with more or fewer screws 218 and / or other fastening devices.

[0296] Reference Figure 9 and Figure 10 The extension 202 of the housing 104, accessible via a removable cover 216, accommodates multiple components of the control device 100. For example, a chamber 222 in the upward-facing portion of the extension 202 of the housing 104 (see...) Figure 9 A compliant or flexible diaphragm 220 is disposed on the open side of the chamber 222 to close the chamber 222 and thus provide a defined fluid chamber (e.g., a hydraulic reservoir) with a variable volume. The flexible diaphragm 220 may be positioned between the removable cover 216 and the open side of the chamber 222. The fluid chamber, at least partially defined by the flexible diaphragm 220, is at least partially filled with a fluid such as, for example, hydraulic braking fluid (e.g., an incompressible fluid). In one embodiment, the flexible diaphragm 220 is a bladder.

[0297] Reference Figure 8 and Figure 9 The extension 202 of housing 104 (e.g., a portion accessible via a removable cover 216) also accommodates an auxiliary button unit 230. The auxiliary button unit 230 is mounted to the inward-facing side 204 (e.g., the inner side) of the extension 202 of housing 104 (e.g., when viewed from the inward-facing side 204 of housing 104, above chamber 222, in front of the hydraulic reservoir cover sealing surface, overlapping with the hydraulic release plug assembly and the hydraulic reservoir). The auxiliary button unit 230 is attached to housing 104 in any of a variety of ways, including, for example, screws, tape, glue, epoxy resin, snap-fit ​​features, press-fit features, and / or other fasteners or fixing devices. The auxiliary button unit 230 is connected via, for example, a cable 232 (e.g., a two-conductor cable) to a PCB 154 within an internal cavity 146 in the paddle end 138 of shift lever 132. Cable 232 can be laid and held on top of and / or inside housing 104 through channel 234 at the inward-facing side 204 of housing 104 (e.g., the base portion 200 and / or extension portion 202 of housing 104).

[0298] The auxiliary button unit 230 includes multiple components. (See reference...) Figure 8 and Figure 9 The auxiliary button unit 230 includes, for example, an inner housing 236, an outer housing 238, a button actuator 240, a flexible sealing element 242 (e.g., a gasket) for the button actuator 240, a PCB 244 that supports and is electrically connected to the electrical switch 246, and a cable 232 (see [link to documentation]). Figure 9The inner housing 236 has a first opening 248 through which a PCB 244 with an electrical switch 246 is assembled. The inner housing 236 also has a second opening 250 through which a cable 232 passes. The second opening 250 is sealed (e.g., around the cable 232) to prevent, for example, the ingress of water and contaminants. The second opening 250 can be sealed in any number of ways, including, for example, with adhesive, epoxy resin, flexible grommets, or another sealant. For example, as... Figure 9 As shown in the example, the second opening 250 can be sealed with a grommet 251.

[0299] Cable 232 is coupled to PCB 244 to transmit signals from the electrical switch 246 of auxiliary button unit 230 to PCB 154 located within an internal cavity 146 in the paddle-shaped end 138 of shift lever 132. Housing 238 is coupled to inner housing 236 and has a recess 252 for assembling button actuator 240 therein. The joint or seam between inner housing 236 and housing 238 is sealed to prevent ingress of, for example, water and contaminants. The joint or seam between inner housing 236 and housing 238 can be sealed in any of a variety of ways, including, for example, by plastic welding, flexible sealing elements (e.g., gaskets), or other seals.

[0300] The housing 238 has an opening 254 through which a button actuator 240 extends and translates when pressed by a rider to actuate an electrical switch 246. For example, the opening 254 can be sealed to prevent the ingress of water and contaminants. The opening 254 can be sealed in any number of ways, including, for example, with a gasket, an overmolded elastomer, an O-ring, or another seal.

[0301] exist Figure 8 and Figure 9 In the example shown, the push-button actuator 240 is mounted on a washer 242 positioned between the push-button actuator 240 and the electrical switch 246. In one embodiment, the push-button actuator 240 is mounted directly on the electrical switch 246.

[0302] The auxiliary button unit 230 is covered by the outer cover 122. The electric switch 246 can be activated by the rider, for example, by pressing the button actuator 240 using the outer cover 122. (See reference...) Figure 9 The outer cover 122 may have an external feature 256 (e.g., a dome or rectangle with a raised or recessed shape) indicating the location of the auxiliary button unit 230.

[0303] The activation of electrical switch 246 can control one or more components of bicycle 50 that are the same as and / or different from those controlled by the first electrical switch 160 and / or the second electrical switch 180. For example, the activation assist button unit 230 can initiate the generation of signals (e.g., via a controller on PCB 154) related to shifting, pairing, derailleur adjustment, power management, one or more other actions on bicycle 50, or any combination thereof. In one embodiment, for example, the activation assist button unit 230 controls the front derailleur 74 and / or the rear derailleur 76. For example, the controller on PCB 154 can be configured to generate signals for controlling the front derailleur 74 and / or the rear derailleur 76 in response to a signal received from electrical switch 246 when activated by the rider. The assist button unit 230, due to its location at the extension 202 of housing 104, provides ergonomic options for controlling one or more components of bicycle 50.

[0304] Reference Figure 13 and Figure 14 The housing 104 may generally include a housing bore 300, into which a master cylinder sleeve 302 (e.g., a fluid cylinder or hydraulic cylinder) is inserted and configured to function as a master cylinder for a braking system. The master cylinder sleeve 302 can be of any number of sizes and / or shapes. For example, as... Figure 10 , Figure 13 and Figure 14 As shown, the master cylinder liner 302 can be cylindrical and hollow. The master cylinder liner 302 can be made of any variety of materials, including, for example, aluminum, aluminum alloys, stainless steel, plastics, composite materials, another material, or any combination thereof. In one example, the housing 104 is made of a first material (e.g., glass-filled nylon), and the master cylinder liner 302 is made of a second material different from the first material (e.g., aluminum). In another example, the first and second materials are the same material. The housing bore 300, and thus the master cylinder liner 302 (when mounted within the housing bore 300), can be horizontal relative to the flat surface on which the bicycle 50 is supported, although other orientations are possible.

[0305] To create a lighter weight configuration and reduce the number of parts in the master cylinder sleeve 302 and piston 304 (e.g., a piston assembly comprising one or more parts), the master cylinder sleeve 302 can be independent of the housing 104. This allows each component (e.g., housing 104 and master cylinder sleeve 302) to be designed and manufactured using the most reliable and / or lowest weight materials for each component.

[0306] At least a portion of piston 304 resides within and moves relative to master cylinder liner 302. (See reference...) Figure 13 and Figure 14The piston 304 has a first end 306 and a second end 308 opposite to the first end 306. The piston 304 is connected to the brake lever 102 via a push rod 310 adjacent to the second end 308 of the piston 304 (e.g., at a position closer to the second end 308 of the piston 304 than the first end 306 of the piston 304), and can be operated by movement of the brake lever 102, as is known in the art. For example, rotation of the brake lever 102 causes translation (e.g., rotation) of the push rod 310, which causes translation of the piston 304 relative to the master cylinder sleeve 302. Figure 10 , Figure 13 and Figure 14 In the example shown, push rod 310 can be connected to piston 304 via an adjustment mechanism, as will be described in more detail below.

[0307] Reference Figure 13 and Figure 14 The push rod 310 has a first end 312 and a second end 314 opposite to the first end 312. The first end 312 of the push rod 310 includes a body 316 that can be disposed within a portion of an adjusting mechanism 318. For example, the adjusting mechanism 318 includes a push rod support 320 (e.g., a push rod slot) having a receiving portion 322 at the first end 324 of the push rod support 320. The push rod 310 is connected to the push rod support 320 via the body 316 of the push rod 310 disposed within the receiving portion 322 at the first end 324 of the push rod support 320.

[0308] The push rod support 320 is hollow at and near its first end 324 to form a receiving portion 322. The receiving portion 322 is formed by one or more inner surfaces 326 (e.g., inner annular surfaces, at least one of which is angled or inclined relative to a central axis along the length of the push rod support 320), the size and shape of which are designed to facilitate the positioning of the body 316 of the push rod 310 within the receiving portion 322 of the push rod support 320 and the rotation of the body 316 of the push rod 310 relative to the push rod support 320. For example, one or more inner surfaces 326 of the push rod support 320 extend outward at or near its first end 324, and the body 316 of the push rod 310 can abut against one or more inner surfaces 326 of the push rod support 320. The base portion of the receiving part 322 can be rounded to facilitate the rotation of the main body 316 of the push rod 310 within the receiving part 322.

[0309] The adjusting mechanism 318 also includes a cam 330 supported by a push rod support 320 at or near the second end 328 of the push rod support 320. The second end 328 of the push rod support 320 is opposite to the first end 324 of the push rod support 320.

[0310] Reference Figure 10 and Figure 14 A first spring 332 (e.g., a return spring) is disposed within the master cylinder sleeve 302. The return spring 332 extends from a position at or near the first end 306 of the piston 304 toward the rear end 210 of the base portion 200 of the housing 104. The return spring 332 may be, for example, a compression spring, and may act on the piston 304 at or near the first end 306 of the piston 304 such that the second end 308 of the piston 304 is pressed into contact with the cam 330 of the adjusting mechanism 318. In one embodiment, the return spring 332 is disposed around a portion of the piston 304 (e.g., disposed at and / or near the first end 306 of the piston 304).

[0311] The control device 100 may include one or more components and / or features to prevent the return spring 332 from pushing the piston 304 and the adjusting mechanism 318 out of the master cylinder sleeve 302. For example, the brake lever 102 may include an extension 334 extending toward the extension 202 of the housing 104. When viewed from the inward-facing side 204 of the housing 104, the contact between the extension 334 and the extension 202 of the housing 104 can act as a stop for the brake lever 102 to rotate clockwise relative to the housing 104 via the shaft 126. Since the brake lever 102 is connected to the adjusting mechanism 318 via the push rod 310, when the brake lever 102 cannot rotate further clockwise relative to the housing 104 (e.g., when viewed from the inward-facing side 204 of the housing 104), the adjusting mechanism 318 cannot translate further relative to the master cylinder sleeve 302 (e.g., move out of the master cylinder sleeve 302). Therefore, the cam 330 acts as a stop for the piston 304. Figure 10 In the example shown, control device 100 also includes a brake lever biasing spring 336 disposed around shaft 126. Brake lever biasing spring 336 can be configured to bias brake lever 102 toward the body 316 of push rod 310 within a receiving portion 322 of push rod support 320 (e.g., in contact with at least one surface of one or more inner surfaces 326 of push rod support 320). In one embodiment, receiving portion 322 is a snap-fit ​​slot, and the body 316 of push rod 310 is held within the snap-fit ​​slot. Control device 100 may include more, fewer, and / or different components and / or features to retain piston 304 within master cylinder liner 302.

[0312] The shaft 126 can be positioned in any number of locations relative to the components supported by the housing 104. For example, the shaft 126 can be located between at least a portion of the chamber 222 and the push rod 310. In other embodiments, other positioning of the shaft 126 relative to the chamber 222, the push rod 310, and / or other components supported by the housing 104 can be provided.

[0313] When a force is applied to the brake lever 102, the applied force is partially transmitted to the piston 304 via the push rod 310 (e.g., the body 316 of the push rod 310) and the adjusting mechanism 318 (e.g., the push rod support 320 and the cam 330). This transmitted force can cause the piston 304 to move (e.g., translate) relative to the master cylinder sleeve 302 toward the rear end 210 of the base portion 200 of the housing 104, and the return spring 332 is compressed. When the brake lever 102 is released and no force is applied, the return spring 332 maintains contact between the second end 308 of the piston 304 and the cam 330, and returns the piston 304 and the brake lever 102 to their respective rest positions (e.g., relative to the master cylinder sleeve 302).

[0314] Reference Figures 15 to 17 The piston 304 includes a flange 338 extending around and away from an outer surface 340 (e.g., an outer annular surface) of the piston 304. The flange 338 may be disposed adjacent to a first end 306 of the piston 304 (e.g., closer to the first end 306 than to a second end 308 of the piston 304). One or more components may be disposed between the flange 338 of the piston 304 and an end cap 342 of the piston 304. For example, a seal 344 (e.g., a cup seal) may be disposed around the piston 304 between the end cap 342 and the flange 338. In one embodiment, a ring (e.g., a support ring) may also be disposed around the piston 304 between the end cap 342 and the flange 338. The seal 344 may be made of any number of materials, including, for example, polyurethane or rubber. The seal 344 may be any number of shapes and sizes. For example, the seal 344 may be a hollow cylinder with a U-shaped or V-shaped cross-section. The seal 344 can be supported by a support ring, allowing the seal 344 to withstand high pressure. This support ring can be made of any variety of materials, including, for example, metals.

[0315] The piston assembly may include any number of components, such as piston 304 (e.g., having end cap 342), push rod 310, return spring 332, seal 344, one or more other seals (e.g., seal 358), support ring, or any combination thereof. The piston assembly may include additional, fewer, and / or different components.

[0316] Reference Figure 13 and Figure 14The housing bore 300 may include a first end 346 and a second end 348 opposite to the first end 346. The first end 346 of the housing bore 300 may be located at the rear end 210 of the base portion 200 of the housing 104. The housing bore 300 extends through the housing 104. The master cylinder liner 302 may be completely disposed within the housing bore 300. In another embodiment, less than all of the master cylinder liners 302 (i.e., not all of the master cylinder liners 302) are disposed within the housing bore 300. The adjusting mechanism 318 and the push rod 310 (e.g., when the brake lever 102 is depressed) may extend through the second end 348 of the housing bore 300.

[0317] Additional components of the hydraulic braking system may be provided at the second end 348 of the housing bore 300 and / or its vicinity for sealing and component retention. For example, refer to... Figure 10 and Figures 15 to 17 The retaining plate 350 (e.g., cylinder head) can be attached to the housing 104 at the second end 348 of the housing bore 300. The retaining plate 350 can be attached to the housing 104 at the second end 348 of the housing bore 300 in any number of ways, including (e.g., via a corresponding threaded opening in the housing 104) for example by attaching one or more connectors 351 (e.g., three screws) to the housing 104.

[0318] The cylinder head 350 can retain the master cylinder liner 302 within the housing bore 300 (e.g., trapped within the housing bore 300). For example, refer to... Figure 10 The cylinder head 350 may include an opening 352 through which the pushrod support 320 can translate. However, the opening 352 through the cylinder head 350 may be smaller than the outer diameter of the master cylinder sleeve 302, so that the master cylinder sleeve 302 cannot move through the opening 352 of the cylinder head 350.

[0319] The size and shape of the pushrod support 320 can also be designed such that only a portion of the pushrod support 320 can translate through the opening 352 through the cylinder head 350. The pushrod support 320 may include a ridge or extension 354 adjacent to the second end 328 of the pushrod support 320. The ridge or extension 354 extends away from the outer surface 356 of the body 357 of the pushrod support 320. The size and shape of the opening 352 through the cylinder head 350 can be designed such that only the body 357 of the pushrod support 320 can translate through the opening 352 through the cylinder head 350, because at the ridge or extension 354 the diameter of the pushrod support 320 is too large to pass through the opening 352. In other words, the ridge or extension 354 can retain at least a portion of the cam 330 within the housing bore 300.

[0320] Reference Figure 10 and Figures 13 to 17A seal 358 (e.g., a cup seal) may be disposed around the piston 304, adjacent to the second end 308 of the piston 304 (e.g., at a position closer to the second end 308 of the piston 304 than the first end 306 of the piston 304). See reference. Figure 17 The piston 304 may include a groove 360 ​​adjacent to the second end 308 of the piston 304, and a seal 358 may be disposed within the groove 360. The seal 358 may be made of any variety of materials, including, for example, polyurethane or rubber. The seal 358 may be any number of shapes and sizes. For example, the seal 358 may be a hollow cylinder with a U-shaped or V-shaped cross-section. The seal 358 protects components of the hydraulic braking system within the piston 304 from environmental influences.

[0321] Reference Figure 10 , Figure 13 and Figure 14 The extension 202 of housing 104 includes an opening 362 (e.g., a vent) extending from the front end 364 of the extension 202 of housing 104 into the chamber 222. A vent plug assembly 368, including at least a vent plug 370 (e.g., a vent screw), is removably connectable to or attached to the vent 362 via, for example, a threaded bushing 372 corresponding to the vent 362, such that hydraulic fluid of the braking system can be filled, capped (or filled), or vented through the chamber 222. The vent plug 370 can be of any shape and size and can be made of any material. In one example, the vent plug 370 is made of the same material as the master cylinder sleeve 302. For example, the vent plug 370 can be made of aluminum, which may be a different material than that used to make housing 104. Alternatively, the vent plug 370 can be made of the same material as housing 104. When the vent plug 370 is removed, the chamber 222 (e.g., serving as a brake fluid chamber for the braking system) is accessible or accessible.

[0322] As discussed above, chamber 222 is at least partially located within extension 202 of housing 104. Hydraulic braking calculations are based on lever fluid volume / volume, hose fluid volume / volume, and caliper fluid volume / volume. As the bushings wear, fluid shifts into the caliper. (Refer to...) Figure 10 To provide a larger reservoir fluid volume, chamber 222 includes a recess 373 in the rod blade opening for additional fluid used for compensation. The recess 373 is fitted between the lugs of brake lever 102 and surrounds shaft 126.

[0323] Reference Figure 16 and Figure 17 The master cylinder liner 302 has one or more outer annular surfaces 374 and one or more inner annular surfaces 376 (see...). Figure 17 ).exist Figure 17In the example shown, the master cylinder sleeve 302 has at least eleven outer annular surfaces 374, each having a plurality of different diameters to provide, for example, a seal 378 (e.g., an O-ring) around the master cylinder sleeve 302. The master cylinder sleeve 302 may have more or fewer outer annular surfaces 374. Figure 17 In the example shown, the master cylinder liner 302 has four inner annular surfaces 376. The master cylinder liner 302 may have more or fewer inner annular surfaces 376.

[0324] Reference Figure 17 The master cylinder sleeve 302 includes one or more first openings 380 (e.g., a plurality of first openings; five first openings arranged around the circumference of the master cylinder sleeve 302) and one or more second openings 382 (e.g., a plurality of second openings; five second openings arranged around the circumference of the master cylinder sleeve 302). The plurality of first openings 380 and the plurality of second openings 382 extend, for example, through at least one of one or more outer annular surfaces 374 through the master cylinder sleeve 302 (e.g., through the cylindrical wall of the master cylinder sleeve 302) to at least one of one or more inner annular surfaces 376. In other words, the plurality of first openings 380 and the plurality of second openings 382 extend radially through the master cylinder sleeve 302.

[0325] A plurality of first openings 380 are spaced apart from each other in the circumferential direction, and a plurality of second openings 382 are spaced apart from each other in the circumferential direction. The plurality of second openings 382 are positioned at a certain distance relative to the plurality of first openings 380 along the length of the main cylinder sleeve 302. In other words, the plurality of second openings 382 are spaced apart from the plurality of first openings 380 in the direction along the length of the main cylinder sleeve 302. Figure 17 In the example shown, the plurality of first openings 380 are closer to the first end 384 of the master cylinder sleeve 302 than the plurality of second openings 382. In other words, the plurality of second openings 382 are closer to the second end 386 of the master cylinder sleeve 302 than the plurality of first openings 380. The second end 386 of the master cylinder sleeve 302 is opposite to the first end 384 of the master cylinder sleeve 302.

[0326] In one example, a plurality of first openings 380 are timing ports (hereinafter referred to as timing ports), and a plurality of second openings 382 are compensation ports (hereinafter referred to as compensation ports). The plurality of timing ports 380 and the plurality of compensation ports 382 can be of any number and shape and size. For example, the plurality of timing ports 380 and the plurality of compensation ports 382 can be circular openings. In one example, since the flow through the plurality of compensation ports 382 will be less controlled than the flow through the plurality of timing ports 380, the plurality of compensation ports 382 can be larger (e.g., in terms of diameter) than the plurality of timing ports 380.

[0327] Reference Figure 17 As discussed above, when the brake lever 102 is not actuated, the second end 308 of the piston 304 is biased against the cam 330 of the adjusting mechanism 318. The surface of the cam 330 acts as a stop and positions the piston 304 relative to the initial position of the master cylinder sleeve 302. This also positions the seal 344 disposed around the piston 304 relative to the master cylinder sleeve 302. More specifically, the seal 344 disposed around the piston 304 is positioned relative to a plurality of timing ports 380 extending through the master cylinder sleeve 302. Figure 17 In the example shown, when the brake lever 102 is not pulled (e.g., the initial position of the piston assembly), the seal 344 is positioned adjacent to a plurality of timing ports 380.

[0328] When the piston assembly is in the initial position and the drain plug 370 is removed, the control device 100 has a fluid path between a drain port 362 exposed to the environment when the drain plug 370 is removed and a fluid port 388 supported by the housing 104 (e.g., at and / or adjacent to the first end 384 of the master cylinder sleeve 302). The fluid port 388 is fluidly connected to a hydraulic line 390 (see...). Figure 11 The hydraulic line 390 leads to, for example, a hydraulic front brake mechanism 106 or a hydraulic rear brake mechanism 108. The fluid port 388 may be rotatable relative to the housing 104, for example.

[0329] In one embodiment, fluid port 388 is connected via hose connector 391 (e.g., via SRAM). ® The olive-shaped oil needle valve assembly is fluidly connected to the hydraulic line 390. A hose connector 391 can be integrated into the master cylinder (e.g., master cylinder sleeve 302), which is a component independent of the housing 104. For example, the Stealthamajig valve assembly 391 is an assembly including a valve and a spring (e.g., a return spring 332). When the hydraulic line 390 is disconnected, the force of the spring closes the master cylinder sleeve 302 using, for example, an O-ring on the valve.

[0330] The fluid path between the vent 362 and the fluid port 388 passes through the chamber 222 and through the housing 104 (e.g., the base portion 200 of the housing 104; see also...). Figure 13 The passage 392, between the volume 394 and the chamber 222 in the housing bore 300, between the housing 104 and the master cylinder liner 302, at least one of the plurality of first openings 380 and the volume 396 in the master cylinder liner 302, extends between the piston 304 and the rear end 210 of the base portion 200 of the housing 104.

[0331] Chamber 222 is located above housing bore 300 and master cylinder liner 302, and channel 392 (e.g., a connecting port) can be used to fill volume 394 (e.g., annular volume) within housing bore 300 between housing 104 and master cylinder liner 302, and flush volume 396 within master cylinder liner 302 to provide fluid for pressurization. Channel 392 can be drilled into housing 104 (e.g., base portion 200 of housing 104) and forms flow between chamber 222 and housing bore 300 in which master cylinder liner 302 is mounted. Drain port 362 is located at the top of extension 202 of housing 104 (e.g., saddle head), and thus at the top of chamber 222. The opening of drain port 362 can be oriented to allow drilling through channel 392. This location maximizes air venting.

[0332] For example, air in the fluid path between vent 362 and fluid port 388 and / or in hydraulic line 390 can cause inefficiency in the hydraulic braking system and may result in spongy or loose brake lever 102. Air may be introduced into the fluid path via leaks, old seals, damaged hydraulic lines, and / or other causes. Air in the fluid path can be purged from vent 362 (when vent plug 370 is removed) or from fluid port 388 or hydraulic line 390 in either direction.

[0333] When the rider pulls the brake lever 102 and the brake lever 102 rotates relative to the housing 104 (e.g., in the first rotational direction), a push rod 310 connected to the brake lever 102 (e.g., via the adjusting mechanism 318) and the piston 304 pushes the piston 304, causing the piston 304 to translate in a direction toward the rear end 210 of the base portion 200 of the housing 104 (e.g., in the first direction). This translation of the piston 304 also causes a seal 344, which is disposed around the piston 304 and abuts against the flange 338 of the piston 304, to translate in the first direction. In other words, the translation of the piston 304 in the first direction causes the seal 344 to move toward a plurality of timing ports 380. The movement of the seal 344 across the plurality of timing ports 380 pushes a portion of the fluid in the chamber 222 out of the volume 396 within the master cylinder sleeve 302 and into the hydraulic line 390 via the fluid port 388. This actuates the hydraulic front braking mechanism 106 or the hydraulic rear braking mechanism 108.

[0334] As the seal 344 passes the multiple timing ports 380, it actively displaces fluid and eventually builds pressure, thereby slowing, for example, the front wheel 54 or rear wheel 58 and the rider. The seal 344 can be positioned as close as possible to the multiple timing ports 380 to achieve performance that allows minimal movement of the brake lever 102 before the rider feels the brakes (e.g., “dead throw”, “wake-up”, “dead zone”). An adjustment mechanism 318 (e.g., including a cam 330) allows adjustment of the position between the seal 344 and the master cylinder sleeve 302 (e.g., contact adjustment). A piston assembly (e.g., including a piston 304 and the seal 344) slides axially to adjust the amount of dead throw (e.g., the sway of the brake lever 102 before pressure builds up). Movement of the piston assembly can be achieved by rotation of the cam 330 relative to, for example, the piston 304 and the pushrod support 320.

[0335] Reference Figure 17 The master cylinder sleeve 302 has a central axis C extending along the length of the master cylinder sleeve 302. The cam 330 rotates relative to the piston 304 (e.g., piston assembly) via a cam rotation axis M, for example. For example, the cam rotation axis M is perpendicular to the central axis C extending along the length of the master cylinder sleeve 302.

[0336] Reference Figures 13 to 19 The cam 330 is supported by the pushrod support 320 at the second end 328 of the pushrod support 320 and / or its vicinity. (See reference...) Figure 10 and Figure 16The push rod support 320 may include a recess 400 at and / or adjacent to the second end 328 of the push rod support 320. The cam 330 can be pressed into the recess 400 of the push rod support 320 by means of the piston 304 biased in a direction away from the rear end 210 of the base portion 200 of the housing 104 and toward the cam 330.

[0337] Reference Figure 18 The cam 330 includes a body 402, which may have four different sides 404a-404d (e.g., configured) having four different heights relative to the centerline of the cam 330 (e.g., the cam rotation axis M). In other words, when the respective sides 404a-404d contact the second end 308 of the piston 304, each of the four different sides 404a-404d has a different height in a direction along or parallel to the central axis C extending along the length of the master cylinder sleeve 302. In other embodiments, the cam 330 may include more or fewer sides 404 having different heights relative to the centerline (e.g., six sides 404 having different heights relative to the centerline).

[0338] The cam 330 also includes a tool interface 406. The tool interface 406 may be formed by, for example, cylindrical extensions 408 extending to opposite sides of the body 402 of the cam 330, respectively. One or both of the cylindrical extensions 408 of the tool interface 406 each include one or more slots (e.g., hexagonal slots) through which a tool can be used to rotate the cam 330 relative to the push rod support 320 and the piston 304. The tool interface 406 (e.g., one or more slots) can be accessed through an opening in the outer cover 122 using the outer cover 122.

[0339] The tool interface 406 may be made of the same material as the body 402 of the cam 330 (e.g., as a single component) (e.g., a metal such as aluminum). Alternatively, the tool interface 406 may be made of a different material than the body 402 of the cam 330 (e.g., plastic) (e.g., aluminum), and / or may be a separate portion attached to the body 402 of the cam 330. In one embodiment, two cylindrical extensions 408 are formed by the body 402 of the cam 330, which is disposed around and attached to the single cylindrical component, such that the body 402 separates the single cylindrical component into two extensions 408. The two cylindrical extensions 408 may be positioned in recesses 400 of the push rod support 320 (see...). Figure 16 The cam 330 is located within and supported at the opening 410 of the push rod support 320, such that the cam 330 is connected to and supported by the push rod support 320. (See reference...) Figure 17The size and shape of the body 402 of the cam 330 and the recess 400 in the push rod support 320 can be designed such that, for example, when the cam 330 rotates relative to the push rod support 320, different sides 404 of the body 402 of the cam 330 do not contact the push rod support 320 located in the recess 400.

[0340] The different heights of different sides 404 of the body 402 of the cam 330 allow for adjustment of dead travel or idle travel. For example, if the cam 330 rotates from a first position where the first side 404a of the body 402 contacts the second end 308 of the piston 304 to a second position where the second side 404b of the body 402 contacts the second end 308 of the piston 304 (see...) Figure 17 (wherein, the second side 404b of the body 402 has a greater height than the first side 404a of the body 402), then the dead travel is reduced (e.g., the seal 344 moves toward the plurality of first openings 380).

[0341] Push rod 310 is connected to brake lever 102 at or near its second end 314. (See reference...) Figure 10 and Figure 14 A portion of the push rod 310 (e.g., at the second end 314 of the push rod 310 and / or its vicinity) is attached to the brake lever 102 via a threaded connection within the sleeve 144. For example, see reference... Figure 10 In addition to the opening 145 through the brake lever 102, a sleeve 144 is also disposed within the opening 142 through the bracket 131 of the shift lever assembly 112, and a threaded (e.g., internal thread) straight rod cross pin 414 is positioned within the sleeve 144, which acts as a bushing. In other words, the straight rod cross pin 414, having, for example, internal threads and a single bushing (e.g., sleeve 144), is held and rotated within the brake lever 102. Because the threads within the straight rod cross pin 414 engage with the threads (e.g., external threads) at and / or adjacent to the second end 314 of the push rod 310, the straight rod cross pin 414 serves as an attachment point for the push rod 310.

[0342] Reference Figure 14 The adjustment mechanism 416 includes a threaded connection between a push rod 310 and a straight rod cross pin 414. The adjustment mechanism 416 is configured to adjust the angular position of the brake lever 102 relative to the housing 104, such that, for example, when the bicycle control unit 100 is mounted to the handlebar 64, the distance between the end of the brake lever 102 and the handlebar 64 is also adjusted.

[0343] Reference Figure 10The adjustment mechanism 416 also includes a tool interface 418 at the second end 314 of the push rod 310. The tool interface 418 can be any of a variety of different types of tool interfaces, including, for example, a hex wrench slot, a flathead slot, a Phillips slot, or another type of tool interface. In one embodiment, a hex wrench is used to screw the push rod 310 into and out of the straight rod cross pin 414. When a portion of the push rod support 320 is trapped within the master cylinder sleeve 302, for example, when the push rod 310 is screwed into the straight rod cross pin 414 (e.g., rotated in a first rotational direction relative to the straight rod cross pin 414), the body 316 of the push rod 310 rotates relative to the push rod support 320 within a receiving portion 322 at the first end 324 of the push rod support 320, and the end of the brake lever 102 moves, for example, closer to the handlebar 64. When the push rod 310 is unscrewed from the straight rod cross pin 414 (e.g., rotated in a second rotation direction relative to the straight rod cross pin 414, opposite to the first rotation direction relative to the straight rod cross pin 414), for example, the end of the brake lever 102 is biased away from the handlebar 64 (e.g., allowed to move away from the handlebar 64).

[0344] Tool interface 418 is accessible via an opening 420 through brake lever 102. The opening 420 through brake lever 102 allows the rider to adjust, for example, the initial distance from brake lever 102 to handlebar 64. The opening 420, and consequently tool interface 418, is accessible via a cover 422 (e.g., a hatch) attached to brake lever 102 (e.g., the front side of brake lever 102). Cover 422 can be attached to brake lever 102 in any number of ways, including, for example, with one or more fasteners 424 (e.g., a screw and a corresponding threaded opening in brake lever 102).

[0345] Hydraulic braking systems may include additional, fewer, and / or different components. For example, bicycle control unit 100 can be attached to handlebar 64 in any number of ways. For example, see reference... Figure 10 The bicycle control device 100 can be attached to the clamp 120, and the clamp 120 can be attached to the handlebars 64. The bicycle control device 100 can be attached to the clamp using, for example, a nut 426 (e.g., a long nut) and a bolt 427. The bolt 427 can extend through an opening 428 through the clamp 120 and a corresponding opening (not shown) through the housing 104, and the nut 426 can secure the bicycle control device 100 to the clamp 120 via the bolt 427. A washer 429 can be disposed between the nut 426 and the housing 104.

[0346] Other implementations of the regulating mechanism may be provided. For example, refer to Figure 19 and Figure 20The adjusting mechanism 430 may not include a cam (e.g., cam 330). The push rod support 432 (e.g., push rod slot) may be connected to the piston 434 disposed in the master cylinder sleeve 436 via an adapter 438 (e.g., contact dial adapter, threaded boss), which has, for example, at least an internal thread 439 on the inner annular surface of the adapter 438.

[0347] Piston 434 has a first end 440 and a second end 442 opposite to the first end 440. Piston 434 can be biased against adapter 438 (e.g., using a spring within master cylinder sleeve 436). For example, the second end 442 of piston 434 can be biased against adapter 438.

[0348] The push rod support 432 has a first end 444 and a second end 446 opposite to the first end 444. The first end 444 of the push rod support 432 includes a receiving portion 448 extending from the first end 444 of the push rod support 432 into the push rod support 432. The push rod 450 has a first end 452 and a second end 454 opposite to the first end 452. The first end 452 of the push rod 450 is formed by a body 456 (e.g., a spherical body), and the push rod 450 is connected to the push rod support 432 via the body 456 of the push rod 450 disposed within the receiving portion 448 at the first end 444 of the push rod support 432.

[0349] The second end 446 of the push rod support 432 is formed by an extension 458. The extension 458 of the push rod support 432 may have a smaller diameter than the rest of the push rod support 432 (e.g., at the first end 444 of the push rod support 432). The extension 458 of the push rod support 432 may have an external thread 460 that can be threadedly connected to an internal thread 439 of an adapter 438. The adapter 438 may be rotatable and translational relative to the push rod support 432 via a threaded connection between the external thread 460 of the push rod support 432 and the internal thread 439 of the adapter 438.

[0350] The adjustment mechanism 430 includes a hollow dial 462 (e.g., a contact dial) supported by a housing 464 of the bicycle control unit 100. The hollow dial 462 is disposed around an adapter 438 (e.g., the outer annular surface of the adapter 438) and rotatably fixed relative to the adapter 438, such that the hollow dial 462 and the adapter 438 rotate and translate together. The hollow dial 462 and the adapter 438 can be separate components and can be rotatably fixed relative to each other in any number of ways, including, for example, using one or more connectors and / or adhesives. In one embodiment, the hollow dial 462 and the adapter 438 are formed from a single component.

[0351] The cylinder head 466 is attached to the housing 464 at its end extending through a housing bore 468 and / or adjacent to the housing 464. The cylinder head 466 can be attached to the housing 464 in any number of ways, including, for example, with one or more fasteners (e.g., snap rings, clips, and / or screws). The cylinder head 466 can, for example, retain at least the master cylinder liner 436 within the housing bore 468 and protect components (e.g., the master cylinder liner 436 and the piston 434) from environmental influences.

[0352] The pushrod support 432 is rotatably fixed relative to the cylinder head 466 and then to the housing 464, such that the pushrod support 432 cannot rotate relative to the housing 464. For example, the pushrod support 432 is bonded to the cylinder head 466 such that the pushrod support 432 can translate only relative to the cylinder head 466 and then to the housing 464.

[0353] The piston assembly, including, for example, at least a piston 434 and a seal 470 (e.g., a main seal) disposed around the piston 434, is movable relative to the master cylinder sleeve 436 (e.g., axially), and more specifically, is movable relative to a plurality of openings 472 (e.g., timing ports) extending through the master cylinder sleeve 436. The piston assembly is movable under the action of an adjusting mechanism 430 to adjust the amount of dead stroke or idle stroke (e.g., lever oscillation before pressure buildup). The piston assembly may include more, fewer, and / or different components. For example, the piston assembly may also include a seal 474 (e.g., an auxiliary seal) disposed around the piston 434 at a distance remote from the main seal 470 along the length of the piston 434.

[0354] The piston assembly can be moved by rotating the hollow dial 462. The hollow dial 462 is a rider interface and causes the adapter 438 to rotate on the second end 446 of the pushrod support 432. The rotation of the hollow dial 462, and thus the adapter 438 (relative to the housing 464 and thus relative to the pushrod support 432 in the first rotational direction), causes the adapter 438 to move further onto the pushrod support 432 (e.g., the extension 458 of the pushrod support 432) and allows the piston assembly to be further pushed away from the plurality of openings 472 (e.g., under the action of a spring within the master cylinder liner 436), thereby extending the dead stroke or idle stroke. The rotation of the hollow dial 462 and then the adapter 438 relative to the housing 464 and then relative to the push rod support 432 in a second rotational direction (e.g., opposite to the first rotational direction) causes the adapter 438 to move further away from the push rod support 432 (e.g., the extension 458 of the push rod support 432) and pushes the piston assembly toward the plurality of openings 472, thereby shortening the dead stroke or idle stroke.

[0355] Reference Figure 19A cover 476 (e.g., corresponding to cover 122) covering at least a portion of housing 464 is movable relative to housing 464 such that the hollow dial 462 may be inaccessible when cover 476 is in a first position relative to housing 464, and may be accessible when cover 476 is in a second position relative to housing. In other words, the hollow dial 462 can be made accessible by pulling cover 476 back from the front of housing 464.

[0356] The adjustment mechanism 430 (e.g., the hollow dial 462, the adapter 438, and the threaded connection between the adapter 438 and the extension 458 of the push rod support 432) can provide any number of adjustment ranges for the dead travel. For example, the adjustment mechanism 430 can provide unlimited adjustment between 0 and 1.5 mm.

[0357] As another implementation of the regulating mechanism, refer to Figure 21 and Figure 22 The adjusting mechanism 500 can be configured, for example, to move the master cylinder sleeve 502 relative to the piston assembly 504 and housing 505 of the bicycle control unit 100. The piston assembly 504 includes at least a piston 506 and a seal 508 (e.g., a main seal) disposed around and supported by the piston 506. The piston assembly 504 may include more, fewer, and / or different components. For example, the piston assembly 504 may also include a seal 510 (e.g., an auxiliary seal) disposed around and supported by the piston 506 at a distance from the main seal 508 along the length of the piston 506.

[0358] Piston assembly 504 (e.g., piston 506, main seal 508, and auxiliary seal 510) is positioned relative to, for example, housing 505 of bicycle control unit 100. A master cylinder sleeve assembly 514, including a master cylinder sleeve 502 (e.g., having a timing port 516 extending through the master cylinder sleeve 502) and one or more O-rings 518 disposed around and supported by the master cylinder sleeve 502, translates relative to piston assembly 504 to adjust the amount of dead stroke or idle stroke (e.g., rod oscillation before pressure buildup).

[0359] The adjusting mechanism 500 includes a hollow dial 520 supported by a housing 505. The master cylinder sleeve 502 has a first end 522 and a second end 524 opposite to the first end 522. The hollow dial 520 is disposed around and connected to the master cylinder sleeve 502 at a location closer to the second end 524 than the first end 522 of the master cylinder sleeve 502. The master cylinder sleeve 502 may include an external thread 526 located adjacent to the second end 524 of the master cylinder sleeve 502 (e.g., closer to the second end 524 of the master cylinder sleeve 502 than the first end 522) on its outer annular surface 527, and the hollow dial 520 may include an internal thread 528 on its inner annular surface 530. The hollow dial 520 can be rotatably connected to the master cylinder sleeve 502 via, for example, the internal thread 528 of the hollow dial 520 and the external thread 526 of the master cylinder sleeve 502.

[0360] Piston 506 has a first end 532 and a second end 534 opposite to the first end 532. Piston 506 includes a receiving portion 536 extending from the second end 534 into piston 506. Push rod 538 has a first end 540 connected to brake lever 542 and a body 544 at the second end 546 opposite to the first end 540. Body 544 is disposed within the receiving portion 536 within piston 506.

[0361] The cylinder head 548 is attached to the housing 505 in any number of ways. For example, the cylinder head 548 is attached to the housing 505 using one or more connectors (e.g., fasteners such as screws, snap rings, and / or clips). The cylinder head 548 contacts the piston 506 to hold the piston 506 in position relative to the housing 505.

[0362] The master cylinder sleeve 502 is rotatably fixed relative to the housing 505. For example, the master cylinder sleeve 502 can be bonded to the housing 505 such that the master cylinder sleeve 502 can translate relative to the housing 505 without rotating relative to the housing 505. Therefore, the master cylinder sleeve 502 bonded to the housing 505 can prevent the master cylinder sleeve 502 from rotating with the hollow dial 520.

[0363] The master cylinder sleeve 502 can be moved relative to the housing 505 and piston 506 by rotation of the hollow dial 520. The hollow dial 520 is a rider interface and causes the master cylinder sleeve 502 to translate relative to the piston 506 and then relative to the housing 505. The hollow dial 520 can be supported by the housing 505 such that the hollow dial 520 cannot translate relative to the housing 505 and then relative to the piston 506. Due to the threaded connection between the internal thread 528 of the hollow dial 520 and the external thread 526 of the master cylinder sleeve 502, rotation of the hollow dial 520 relative to the housing 505 in a first rotational direction causes the master cylinder sleeve 502 to translate in a direction toward the rear end 550 of the housing 505 (e.g., axially relative to the housing 505 and piston 506). This translation of the master cylinder sleeve 502 causes the timing port 516 through the master cylinder sleeve 502 to move away from the main seal 508 surrounding the piston 506, thereby extending the dead stroke or idle stroke. The rotation of the hollow dial 520 relative to the housing 505 in a second rotational direction (e.g., opposite to the first rotational direction) causes the master cylinder sleeve 502 to translate in a direction away from the rear end 550 of the housing 505 (e.g., axially relative to the housing 505 and the piston 506). This translation of the master cylinder sleeve 502 causes the timing port 516 through the master cylinder sleeve 502 to move toward the main seal 508 surrounding the piston 506, thereby shortening the dead stroke or idle stroke.

[0364] Reference Figure 21 A cover 552 (e.g., corresponding to cover 122) covering at least a portion of housing 505 is movable relative to housing 505 such that the hollow dial 520 may be inaccessible when the cover 552 is in a first position relative to housing 505, and may be accessible when the cover 552 is in a second position relative to housing 505. In other words, the hollow dial 520 can be made accessible by pulling the cover 552 back from the front of housing 505.

[0365] Adjustment mechanism 500 (e.g., hollow dial 520 and the threaded connection between hollow dial 520 and master cylinder sleeve 502) can provide any number of adjustment ranges for the dead stroke. For example, adjustment mechanism 500 can provide unlimited adjustment between 0 and 1.5 mm.

[0366] The bicycle control device 100 of this embodiment uses, for example, a high-pivot brake lever. (See reference...) Figure 14 , Figure 20 and Figure 22The brake lever 102 is positioned about its rotatable pivot axis P above the push rod (e.g., push rod 310, 450, or 538) and the actuation crosspin (e.g., crosspin 414) (e.g., on the downward-facing side relative to the housing of the bicycle control unit 100), the push rod being connected to the brake lever 102 via the actuation crosspin. This position of the pivot axis P allows for a greater mechanical gain to build up pressure and also provides a finer sweep at the push rod end, thereby mitigating wear that the bore, piston, and seals may experience due to lateral loads on the piston (e.g., pistons 304, 434, and 506) within the bore.

[0367] Reference Figure 23 and Figure 24 The master cylinder sleeve 302 and the housing bore 300 therein are arranged, for example, at an angle (e.g., oriented) relative to the handlebar 64. This angle provides space for enclosing, for example, the master cylinder sleeve 302, adjustment mechanisms (e.g., adjustment mechanisms 318, 430, or 500), and hose connectors 391 (e.g., Stealthamajig valve) into the housing bore 300. This angle also allows for the installation of hoses (e.g., hydraulic lines 390) and hose clamping nuts 580. The angle between the master cylinder sleeve 302 and the handlebar 64 can be configured to allow tools to reach or approach for the installation of the hose clamping nut 580, but to remain close enough to the handlebar 64 to not affect the rider's experience or aesthetics.

[0368] Reference Figure 24 The central axis C of the master cylinder sleeve 302 is angled relative to the outward-facing side 206 of the housing 104 (e.g., and relative to a portion of the handlebar 64), such that the second end 386 of the master cylinder sleeve 302 is closer to the inward-facing side 206 of the housing 104 than the first end 384 of the master cylinder sleeve 302. In one embodiment, for example when the bicycle control unit 100 is mounted to the handlebar 64, the central axis C of the master cylinder sleeve 302 extends substantially horizontally relative to the flat surface on which the bicycle 50 is supported. Other orientations may be provided.

[0369] The brake lever 102 can be mounted to the housing 104 at the same angle as the central axis C of the master cylinder sleeve 302 relative to, for example, the outward-facing side 206 of the housing 104, thereby providing smooth lever actuation. In other words, the pivot axis P can be perpendicular to the central axis C of the master cylinder sleeve 302. This angle provides a unique ergonomic experience because the lever sweep of the brake lever 102 can follow the natural movement of the rider's fingers.

[0370] Reference Figures 25 to 29 In addition to the hydraulic braking system components discussed above, housing 104 also supports an independent battery unit 190 (e.g., a battery cell). See reference... Figure 26 The battery cell 190 includes a battery housing 600 and a first battery cover 602 (e.g., an outer battery cover). The battery housing 600 is received in a recess 604 in a housing 104 and is securely attached to the housing 104 at one or more tabs 607 (e.g., two tabs) via one or more connectors 606 (e.g., screws and corresponding threaded openings, tabs, snap-fit ​​features, tape, adhesive, epoxy resin / or press-fit features). In this example, the battery housing 600 is fastened to the housing 104 at two tabs 607 via two screws 606 and two corresponding threaded openings 608 in the housing 104. Alternatively or additionally, the battery housing 600 may be attached to the housing 104 via adhesive, other fasteners and / or another type of connector (e.g., tabs or snap-fit ​​features). More or fewer than two connectors 606 may be provided.

[0371] In one embodiment, a recess 604 of the housing 104 extends from a downward-facing side 214 of the base portion 200 of the housing 104 into the housing 104. Therefore, the independent battery unit 190 can be mounted to the housing 104 at the downward-facing side 214 of the base portion 200. However, in other embodiments, the independent battery unit 190 can be mounted to other sides and / or portions of the housing 104. For example, when viewed from the inward-facing side 204 of the bicycle control unit 100, the independent battery unit 190 can be positioned below the master cylinder sleeve 302.

[0372] The independent battery unit 190 is connected to the PCB 154 within the paddle end 138 of the shift lever 132 in any of a variety of ways. For example, the independent battery unit 190 is connected to the PCB 154 via a two-conductor cable. The two-conductor cable can be laid and held on the housing 104 through a channel 610 within at least the base portion 200 of the housing 104. The two-conductor cable can be laid on the inside or outside of the housing 104. In one embodiment, the independent battery unit 190 is also connected to the PCB 244 of the auxiliary button unit 230 to power components supported by the PCB 244 of the auxiliary button unit 230. The independent battery unit 190 can be connected to the PCB 244 of the auxiliary button unit 230 via, for example, another two-conductor cable.

[0373] The independent battery cell 190 also includes a second cover 612 (e.g., an inner battery cover) disposed between the battery housing 600 and the first battery cover 602. The battery 614 can be received within a battery receiving portion (e.g., including a first cavity or recess) defined by the outer battery cover 602 and the inner battery cover 612. The battery 614 can be any variety of different types of batteries, including, for example, conventionally replaceable button cell batteries. Alternatively, the battery 614 can be a non-replaceable and / or rechargeable battery.

[0374] Battery 614 can be configured to provide power to the controller, communication module 156, remote switch, or electrical device via an accessory jack and / or other electronic components. For example, battery 614 can be configured to provide power to the electrical switch 246 of auxiliary button unit 230 when battery 614 is disposed within battery housing 616.

[0375] The independent battery cell 190 may also include one or more seals 617 (e.g., O-rings; see also) for the outer battery cover 602 and / or the inner battery cover 612. Figure 28 ), electrical contacts 618 (e.g., two battery contacts 618), and a grommet seal. The individual battery cell 190 may include additional, fewer, and / or different components.

[0376] Reference Figure 28 The battery housing 600 has a cavity 620 (e.g., a second cavity or recess; inner cavity) with an opening inside the housing 104 and a cavity 616 (e.g., a battery receiving portion 616; outer cavity) with an opening outside the housing 104. The inner cavity 620 accommodates electrical contacts 618 that can be secured to the battery housing 600 and the terminals of wires originating from one or more cables. In one example, the electrical contacts 618 are physically attached to the battery housing 600 via heat staking, although the electrical contacts 618 can be attached to the battery housing 600 in additional and / or different ways. For example, the electrical contacts 618 can be physically attached to the battery housing 600 via snap-fit ​​features, screws, glue, epoxy resin, and / or another connector. The wires of one or more cables can be physically attached to the electrical contacts 618 in any number of ways, including, for example, via crimping features and solder.

[0377] Reference Figure 26One or more cables pass through the opening 622 leading to the internal cavity 620. In one embodiment, the opening 622 leading to the internal cavity 620 is sealed with, for example, a grommet seal to prevent the intrusion of, for example, water and contaminants. The opening 622 leading to the internal cavity 620 can be sealed in any of a variety of other ways, including, for example, with adhesive or epoxy resin. Electrical contacts 618 enter the external cavity 616 from the internal cavity 620 to interface with the battery 614.

[0378] An internal battery cover 612 may be assembled within the battery housing 600 above the electrical contacts 618 and one or more cables to conceal the electrical contacts 618 and one or more cables and protect them from damage. The internal battery cover 612 may be held within the battery housing 600 in any of a variety of ways, including, for example, by heat-fused plastic, snap-fit ​​features, and screws.

[0379] The battery 614 can be held within the outer battery cover 602 by, for example, slight interference fit, such that the battery 614 is positioned within the independent battery cell 190 by the outer battery cover 602 and can be removed from the independent battery cell 190 when the outer battery cover 602 is removed.

[0380] Reference Figure 29 The outer battery cover 602 can be held on the battery housing 600 by a set of tab features 624 extending away from the inner portion 626 of the outer battery cover 602 and a slot feature 628 at the inner portion 630 of the battery housing 600. The outer battery cover 602 can be installed and removed via the tab features 624 and the slot feature 628 by rotating the outer battery cover 602 relative to the battery housing 600. Other attachment features may be provided.

[0381] exist Figure 29 In the example shown, the tab feature 624 (e.g., a convex feature) is on the outer battery cover 602, while the groove feature 628 (e.g., a concave feature) is on the battery case 600. In another embodiment, the groove feature 628 may be on the outer battery cover 602, while the tab feature 624 may be on the battery case 600.

[0382] The tab feature 624 of the outer battery cover 602, which holds the battery 614 in the battery case 600, also aligns the outer battery cover 602 with the battery case 600 to prevent damage to, for example, one or more seals 617 and / or electrical contacts 618, when the outer battery cover 602 is being installed.

[0383] The outer battery cover 602 may also include a lever feature 632 extending away from the outer annular surface 634 of the outer battery cover 602. The lever feature 632 facilitates removal from and installation onto the battery housing 600 without tools. The lever feature 632 also rotatably aligns the outer battery cover 602 relative to the battery housing 600 and the housing 104. For example, the housing 104 may include a recess 636 at least partially formed by a wall 638 (see...). Figure 26 Furthermore, the external battery cover 602 can be oriented solely by means of the lever feature 632 being disposed within the recess 636. Otherwise, the lever feature 632 might obstruct the housing 104. See reference. Figure 25 The external battery cover 602 may also include a groove 640 (e.g., a coin slot feature) in the outer side portion 642 of the external battery cover 602 to facilitate the removal and installation of the external battery cover 602 with a tool or coin.

[0384] Other implementations of independent battery cells can be provided. For example, refer to Figure 30 and Figure 31 The independent battery unit 650 can be supported at and assembled from the inward-facing side 204 of the housing 104. For example, the independent battery unit 650 can be supported by the housing 104 between the downward-facing side 214 of the base portion 200 of the housing 104 and the housing bore 300 through the housing 104, and thus supported within the master cylinder liner 302. In other embodiments, the independent battery unit 650 can be supported at other locations within the housing 104.

[0385] In this embodiment, the outer battery cover 652 is attached to the battery housing 654 (e.g., the battery casing) via one or more connectors 656 (e.g., two screw or snap-fit ​​features) rather than a rotation-locking feature. The battery housing 654 can be attached to the housing 104 in any number of ways, including, for example, via one or more connectors 656 (e.g., via corresponding threaded openings in the housing 104), other connectors, tabs, locking features, snaps, adhesives, and / or another connector.

[0386] The seal between the outer battery cover 652 and the battery housing 654 can be achieved in any number of ways, including, for example, via a gasket or an overmolded elastomer 658 compressed between the outer battery cover 652 and the battery housing 654.

[0387] The standalone battery cell 650 also includes electrical contacts 660 (e.g., two battery contacts 660). The positive battery contact 660a is positioned on the outer portion of the battery case 654 and biases the battery 662, which is located within the standalone battery cell 650 and the outer battery cover 652, toward the inward-facing side 204 of the case 104.

[0388] The battery housing 654 has a cavity 664 (e.g., an internal cavity) outside the housing 104 with an opening 666. The internal cavity 664 accommodates electrical contacts 660 that can be secured to the battery housing 654, as well as the terminals of wires originating from one or more cables. The internal cavity 664 also accommodates a washer or overmolded elastomer 658 and at least a portion of the battery 662. In one example, the electrical contacts 660 are physically attached to the battery housing 654 via plastic heat fusion, although the electrical contacts 660 can be attached to the battery housing 654 in additional and / or different ways. For example, the electrical contacts 660 can be physically attached to the battery housing 654 via snap-fit ​​features, screws, glue, epoxy resin, and / or another connector. The wires of one or more cables can be physically attached to the electrical contacts 660 in any number of ways, including, for example, via crimp features and solder.

[0389] Reference Figure 31 One or more cables pass through the opening 666 leading to the internal cavity 664. In one embodiment, the opening 666 leading to the internal cavity 664 is sealed with, for example, a grommet seal 668 to prevent the intrusion of, for example, water and contaminants. The opening 666 leading to the internal cavity 664 can be sealed in any of a variety of other ways, including, for example, with adhesive or epoxy resin.

[0390] Although certain control devices, bicycles, and methods have been described herein in accordance with the teachings of this disclosure, the scope of this patent is not limited thereto. Rather, this patent covers all embodiments of the teachings of this disclosure that fall entirely within the scope of licenseable equivalents.

[0391] The embodiments described herein are illustrative of the general understanding of the structure of various embodiments. These illustratives are not intended to be a complete description of all elements and features of devices and systems utilizing the structures or methods described herein. Many other embodiments will become apparent to those skilled in the art upon review of this disclosure. Other embodiments may be utilized and other embodiments may be inferred from this disclosure, allowing for structural and logical substitutions and changes without departing from the scope of this disclosure. Furthermore, these illustratives are merely representative and may not be drawn to scale. Some scales within the illustratives may be enlarged, while others may be minimized. Therefore, this disclosure and the accompanying drawings are to be considered illustrative rather than restrictive.

[0392] While this specification contains numerous details, these should not be construed as limiting the scope of the invention or the scope of claims, but rather as descriptions of features specific to particular embodiments of the invention. Certain features described in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. Furthermore, although features may be described above as functioning in certain combinations and even initially claimed in this way, in some cases one or more features of a declared combination may be removed from the combination, and the declared combination may involve sub-combinations or variations thereof.

[0393] Similarly, although operations and / or actions are depicted in the accompanying drawings and described herein in a specific order, this should not be construed as requiring these operations to be performed in the specific order shown or in sequential order, or requiring all illustrated operations to be performed to achieve the desired result. In some cases, multitasking and parallel processing may be advantageous. Furthermore, the separation of various system components in the above embodiments should not be construed as requiring such separation in all embodiments, and it should be understood that any described program components and systems may be integrated together in a single software product or packaged into multiple software products.

[0394] For convenience only, the term "invention" is used independently and / or collectively to refer to one or more embodiments of this disclosure, and is not intended to actively limit the scope of this application to any particular invention or inventive concept. Furthermore, although specific embodiments have been illustrated and described herein, it should be understood that any subsequent arrangements designed to achieve the same or similar purpose may replace the specific embodiments shown. This disclosure is intended to cover any and all subsequent modifications or variations of the various embodiments. Combinations of the above embodiments, as well as other embodiments not specifically described herein, will be apparent to those skilled in the art upon reading the specification.

[0395] This abstract of disclosure is provided to conform to 37 CFR §1.72(b) and is submitted without regard to whether it will be used to interpret or limit the scope or meaning of the claims. Additionally, in the above detailed description, various features may be combined together or described in a single embodiment for the purpose of simplifying this disclosure. This disclosure should not be construed as reflecting an intention that the claimed embodiments require more features than expressly recited in each claim. Rather, as reflected in the appended claims, the inventive subject matter may address fewer than all features of any one of the disclosed embodiments. Therefore, the following claims are incorporated into the detailed description, wherein each claim independently defines a separately claimed subject matter.

[0396] The specific embodiments described above are intended to be illustrative rather than restrictive, and it should be understood that the following claims, including all equivalents, are intended to define the scope of the invention. The claims should not be construed as limited to the described order or elements unless otherwise stated. Therefore, all embodiments falling within the scope and spirit of the appended claims and their equivalents are protected by this invention.

Claims

1. A control device that can be mounted on the handlebars of a bicycle, the control device comprising: A housing having a base portion and an extension portion, the base portion of the housing having a front end, a rear end opposite to the front end, a downward-facing side, an upward-facing side, an inward-facing side, an outward-facing side, and a handlebar clamp disposed at the rear end; A rod, which is connected to the housing and is pivotable relative to the housing; The main cylinder portion is supported by the housing and has a fluid cylinder having a first end and a second end opposite to the first end, and a cylindrical wall located between the first end and the second end. The fluid cylinder is hollow, such that an opening extends from the first end through the main cylinder portion to the second end. as well as A piston assembly supported by the housing, the piston assembly being movable relative to the master cylinder portion, at least a portion of the piston assembly being disposed within the master cylinder portion. The main cylinder portion is angled relative to the outward-facing side of the base portion of the housing, such that the second end of the fluid cylinder is closer to the outward-facing side than the first end of the fluid cylinder.

2. The control device according to claim 1, further comprising a push rod, in, The rod is connected to the piston assembly via the push rod, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion. The master cylinder portion has a central axis extending along its length. The control device further includes a pivot axis that pivotally connects the lever to the housing, the pivot axis defining a pivot line, and the lever pivoting relative to the housing about the pivot line. The pivot axis is perpendicular to the central axis of the master cylinder section, such that the rod pivots in a plane that is consistent with or parallel to the central axis of the master cylinder section.

3. The control device according to claim 2, wherein, The pivot is positioned above the push rod relative to the downward-facing side of the base portion of the housing.

4. The control device according to claim 3, further comprising a fluid chamber at least partially disposed within the extension of the housing, the pivot shaft being disposed between at least a portion of the fluid chamber and the push rod.

5. The control device according to claim 4, wherein, The cylindrical wall of the fluid cylinder has at least one inner annular surface and at least one outer annular surface, and The cylindrical wall of the fluid cylinder includes an opening that extends from an inner annular surface of at least one inner annular surface of the cylindrical wall through the cylindrical wall to an outer annular surface of at least one outer annular surface.

6. The control device according to claim 5, in, The piston assembly includes a piston and a seal disposed around the piston. The fluid can be arranged within the volume between the piston and the fluid chamber, and The piston assembly is configured to translate relative to the master cylinder portion from a first position toward a second position in a first direction when the rod pivots relative to the housing in a first rotational direction, such that the seal moves toward the opening through the cylindrical wall of the fluid cylinder and ejects a portion of the fluid from the master cylinder portion to activate the bicycle's brake caliper.

7. The control device according to claim 1, wherein, The master cylinder portion has a central axis extending along the length of the master cylinder portion, and When the control device is mounted on the handlebars of the bicycle, the central axis of the master cylinder portion extends substantially horizontally relative to the flat surface on which the bicycle is supported.

8. A control device that can be mounted on the handlebars of a bicycle, the control device comprising: A housing having a base portion and an extension portion, the base portion of the housing having a front end, a rear end opposite to the front end, a downward-facing side, an upward-facing side, an inward-facing side, an outward-facing side, and a handlebar clamp disposed at the rear end; A rod, which is connected to the housing and is pivotable relative to the housing; The main cylinder portion is supported by the housing and has a fluid cylinder having a first end and a second end opposite to the first end, and a cylindrical wall located between the first end and the second end. The fluid cylinder is hollow, such that an opening extends from the first end through the main cylinder portion to the second end. and A piston assembly supported by the housing, the piston assembly being movable relative to the master cylinder portion, at least a portion of the piston assembly being disposed within the master cylinder portion; A first adjustment mechanism is configured to adjust the angular position of the rod relative to the housing, such that when the control device is mounted on the handlebars of the bicycle, the distance between the end of the rod and the handlebars is also adjusted. as well as A second adjustment mechanism is configured to adjust the initial position of the piston assembly relative to the opening through the cylindrical wall of the fluid cylinder. The main cylinder portion is angled relative to the outward-facing side of the base portion of the housing, such that the second end of the fluid cylinder is closer to the outward-facing side than the first end of the fluid cylinder.

9. The control device according to claim 8, wherein, The piston assembly includes a piston and a seal disposed around the piston. The fluid can be arranged within the volume between the piston and the fluid cylinder. The piston assembly is configured to translate relative to the master cylinder portion from a first position toward a second position in a first direction when the rod pivots relative to the housing in a first rotational direction, such that the seal moves toward the opening through the cylindrical wall of the fluid cylinder and ejects a portion of the fluid from the master cylinder portion to activate the bicycle's brake caliper.

10. The control device of claim 9, further comprising a push rod, a first end of which is connected to the rod via the first adjusting mechanism, and a second end of which is connected to the piston assembly, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion. in, The first adjusting mechanism includes a threaded connection between the push rod and the rod at or near the first end of the push rod, and The rod is pivotally connected to the housing such that when the push rod rotates relative to the rod in a first rotational direction via the threaded connection between the push rod and the rod, the end of the rod moves toward the base portion of the housing.

11. The control device according to claim 10, wherein, The first end of the push rod is accessible via an opening through the rod and is rotatable.

12. The control device according to claim 8, wherein, The second adjustment mechanism includes a cam that can rotate relative to the piston assembly. The piston assembly is biased against the cam, such that the cam acts as a stop and positions the piston assembly relative to the master cylinder portion at its initial position. The cam is configured to cause the piston assembly to translate relative to the master cylinder portion when the cam rotates relative to the piston assembly.

13. The control device according to claim 12, wherein, The master cylinder portion has a central axis extending along the length of the master cylinder portion. The cam is rotatable relative to the piston assembly about a cam rotation axis, the cam rotation axis being perpendicular to the central axis of the master cylinder portion. The cam has multiple sides, each of which has a different height in a direction along or parallel to the central axis of the master cylinder portion.

14. The control device according to claim 13, further comprising: Putter; as well as A push rod support member, the push rod support member including a receiving portion located at a first end of the push rod support member, the push rod support member being connected to the push rod at the receiving portion. Wherein, the push rod support member supports the cam at or near the second end of the push rod support member, and the second end of the push rod support member is opposite to the first end of the push rod support member, and The rod is connected to the piston assembly via the push rod, the push rod support and the cam, such that rotation of the rod relative to the housing causes translation of the piston assembly relative to the master cylinder portion.

15. The control device according to claim 8, wherein, The second adjustment mechanism includes a hollow dial supported by the housing, and The second adjustment mechanism is configured such that rotation of the hollow dial relative to the housing causes one of the piston assembly and the master cylinder portion to translate relative to the other of the piston assembly and the master cylinder portion.

16. The control device according to claim 15, further comprising: Putter; as well as A push rod support member, the push rod support member including a receiving portion located at a first end of the push rod support member, the push rod support member being connected to the push rod at the receiving portion. The second adjustment mechanism further includes a hollow adapter having an inner annular surface and an outer annular surface. The second end of the push rod support is threadedly connected to the hollow adapter at the inner annular surface of the hollow adapter, and the inner annular surface of the hollow dial is connected to the outer annular surface of the hollow adapter. The hollow adapter abuts against the piston of the piston assembly and is configured to rotate with the hollow dial. The hollow adapter rotates and translates relative to the push rod support via the threaded connection between the push rod support and the hollow adapter, such that the rotation of the hollow dial relative to the housing causes the hollow adapter and, consequently, the piston assembly to translate relative to the master cylinder portion.

17. The control device according to claim 15, further comprising a push rod, in, The piston assembly includes a receiving portion located at an end of the piston, at which the piston is connected to the push rod. The inner annular surface of the hollow dial is threadedly connected to the outer annular surface of the fluid cylinder, and The hollow dial is rotatable relative to the fluid cylinder via a threaded connection between the inner annular surface of the hollow dial and the outer annular surface of the fluid cylinder, such that the rotation of the hollow dial relative to the housing causes the fluid cylinder to translate relative to the piston assembly.

18. The control device according to claim 8, further comprising: A gear shift lever, which is connected to the housing and movable relative to the housing; An electrical switch that can be actuated by movement of the shift lever; A controller, which communicates with the electrical switch, is configured to generate a shift signal in response to actuation of the electrical switch. A battery housing, supported by the base portion of the housing, is electrically connected to the controller such that when the battery is disposed within the battery housing, the battery is configured to power the controller, the electrical switch, or a combination thereof. A battery cover that closes the battery housing and is removably attached to the battery housing or the housing.

19. The control device according to claim 18, wherein, The battery housing opens toward the downward-facing side or the inward-facing side of the base portion of the housing, and wherein the battery housing is supported within the housing between the downward-facing side of the base portion of the housing and the master cylinder portion.

20. The control device according to claim 18, wherein, The extension of the housing has an inward-facing side and an outward-facing side, the outward-facing side being opposite to the inward-facing side. The electrical switch is the first switch. The control device further includes: A second switch, the second switch being supported by the extension of the housing at or near the inward-facing side of the extension of the housing; and An actuator, which communicates with the second switch, such that the second switch can be actuated via the actuator, and The actuator is supported by the inward-facing side of the extension portion of the housing.

Images