Abstract:
A bicycle suspension system of the invention generally includes at least two bicycle suspensions and a hydraulic control assembly. The hydraulic control assembly includes a pair of fluid pumps, and a fluid responder and a fluid path for each of the bicycle suspensions. The fluid pumps are mountable to a bicycle handlebar and form part of the hydraulic control assembly. A fluid responder is mountable each of the bicycle suspensions. The fluid paths link the fluid pump to a respective fluid responder. Each fluid responder is operatively connected to one of the bicycle suspensions to operate the bicycle suspension system between first and second suspension settings in response to fluid displacement between each fluid pump and each of the fluid responders.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The invention relates to bicycle suspension systems and more particularly to a hydraulic control assembly to operate first and second bicycle suspensions between first and second suspension settings. 
       BRIEF SUMMARY OF THE INVENTION 
       [0002]    The invention provides a hydraulic control assembly for operating a bicycle suspension system including first and second bicycle suspensions. The hydraulic control assembly includes two separate fluid pumps, each of the two fluid pumps including a hydraulic cylinder and piston. Each of the bicycle suspensions includes a fluid responder. A separate fluid path communicates between each of the two hydraulic cylinders and the fluid responders. 
         [0003]    The control assembly is mountable to a bicycle handlebar. The two fluid responders are mountable to the bicycle suspensions. Each of the fluid responders is operatively connected to one of the first and second bicycle suspensions to operate between the first and second suspension settings in response to fluid displacement between the fluid pumps and the fluid responders. An actuator is operatively connected to the first piston and is configured to displace both pistons. The control assembly includes a push-push toggle mechanism. 
         [0004]    These and other features of the invention will be more fully understood from the following description of one or more embodiments of the invention, taken together with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0005]    In the drawings: 
           [0006]      FIG. 1  is a bicycle with a bicycle suspension system, including front and rear suspensions, according to one embodiment of the invention; 
           [0007]      FIG. 2  is a top perspective view of a hydraulic control assembly for operating the bicycle suspension system; 
           [0008]      FIG. 3  is a top sectional view of the hydraulic control assembly; 
           [0009]      FIG. 4  is an exploded perspective view of the hydraulic control assembly; 
           [0010]      FIG. 5  is a perspective view of a first fluid responder of a front suspension mechanism of the bicycle suspension system; 
           [0011]      FIG. 6  is sectional view of the first fluid responder; 
           [0012]      FIG. 7  is a perspective view of a second fluid responder of the bicycle suspension system; 
           [0013]      FIG. 8  is a sectional view of the fluid responder of  FIG. 7 ; 
           [0014]      FIG. 9  is a perspective view of the first piston with driving lugs and latching lugs; 
           [0015]      FIG. 10  is a perspective view of a latching ring with first and second sets of gear teeth; 
           [0016]      FIG. 11  is the latching ring assembled concentrically to the first piston, with the piston in the fully-extended position; and 
           [0017]      FIG. 12 . shows the latching ring assembled concentrically to the first piston, with the piston in the non-extended position. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]    Referring to  FIG. 1 , the present invention provides a bicycle  11  including a bicycle suspension system  13  generally including a front bicycle suspension  14  and a rear bicycle suspension  16 . A hydraulic control assembly  20  is provided in communication with the front and rear bicycle suspensions  14 ,  16 . The hydraulic control assembly  20  may be mounted to a bicycle handlebar  12  or another suitable location on the bicycle and in use causes the front suspension  14  and rear suspension  16  to change between first and second suspension settings. In one embodiment, the hydraulic control assembly  20  causes the front and rear suspensions  14 ,  16  to switch between “lock-out” and non-lock out settings. “Lock-out” refers to a condition where the suspension component is rendered relatively incompressible or substantially rigid to minimize peddling-induced bobbing of the bicycle. 
         [0019]    Referring to  FIG. 2 , the hydraulic control assembly  20  may include a control housing  29 , an actuator  30 , a rubber boot  33 , a first fluid path  31 , and a second fluid path  32 . The actuator  30  is the interface used by a rider to operate the control assembly  20  and therefore the bicycle suspension system  13 . In one embodiment, the actuator  30  is a button or a similar manual control. The optional rubber boot  33  is a flexible, elastomeric sleeve that extends between the actuator  30  and the control housing  29  and may be in the form of an accordion so as to easily expand and contract to shield the interior of the assembly from dirt and contaminants. The fluid paths  31 ,  32  include hydraulic lines that are attached to the control housing  29  and conduct changes in fluid pressure therethrough. The hydraulic control assembly  20  may be attachable to the handlebar  12  via a standard clamp  28 , preferably in a position convenient for rider access without releasing one&#39;s grip of the handlebar. 
         [0020]    Referring to  FIG. 3 , the hydraulic control assembly  20  includes a first fluid pump  40  including a first piston  34  slidably disposed within a first fluid cavity  29   a,  a chamber or bore, typically cylindrical, formed within the control housing  29 . The hydraulic control assembly  20  includes a second fluid pump  42  including a second piston  35  slidably disposed within a second fluid cavity  29   b,  chamber or bore formed within the control housing  29 . The first and second cavities  29   a,    29   b  may be generally parallel, but are separate, i.e., not in communication with each other. 
         [0021]    Referring to  FIGS. 5 and 6 , the first cavity  29   a  is in communication with a first fluid responder  44 , which is mountable to and forms part of the front suspension  14 . The first fluid responder  44  includes a first responder housing  60  and a third piston  61 . 
         [0022]    Referring to  FIG. 6 , the third piston  61  is slidably disposed within a third fluid cavity  60   a  formed within the first responder housing  60 . The first fluid path  31 , which may include a hydraulic hose or the like, connects the first fluid cavity  29   a  to the third fluid cavity  60   a.  The third piston  61  operates the front suspension  14  between the first and second suspension setting. 
         [0023]    Referring to  FIGS. 7 and 8 , a second fluid responder  46  is mountable to the rear suspension  16  and includes a second responder housing  70  and a fourth piston  71 . In  FIG. 8 , the fourth piston  71  is slidably disposed within a fourth fluid cavity  70   a  formed within the second responder housing  70 . The second fluid path  32 , which may include a hydraulic hose or the like, connects the second fluid cavity  29   b  to the fourth fluid cavity  70   a.  The fourth piston  71  operates the rear suspension  16  between the first and second suspension settings. Fluid responders of front and rear suspension components for bicycles are well-known devices. The first fluid cavity  29   a,  the first fluid path  31  and the third fluid cavity  60   a  form a fluid circuit separate from the second fluid cavity  29   b,  second fluid path  32  and the fourth fluid cavity  70   a.    
         [0024]    Returning to  FIGS. 3 and 4 , the actuator  30  is secured to the first piston  34  by a set screw  39  or any other suitable securing means. In one embodiment, the first piston  34  is formed on a piston rod or shaft  34   a.  The shaft  34   a  may be press fit or otherwise disposed within a suitably sized opening or bore  30   b  in the actuator  30 . 
         [0025]    In one embodiment, the second piston  35  is not fixed to the actuator  30  and merely abuts the actuator. The actuator  30  has a plunger portion  30   a  that extends into the second fluid cavity  29   b.  The plunger portion  30   a  abuts and is maintained in contact with the second piston  35  by pressure in the second fluid cavity  29   b.  The first piston  34  and the second piston  35  are retained within the control housing  29  by a piston retainer  36 . The piston retainer  36  may be fixed to the control housing  29  by a fixating pin  38  that is pressed into the control housing  29 . 
         [0026]    Referring to  FIG. 3 , one embodiment of the hydraulic control assembly  20  contains a latching ring  37  located within the control housing  29  and concentrically disposed about the shaft portion of the first piston  34 . The actuator  30  is fixed to the first piston  34 ; therefore, the interaction of the first piston and the latching ring  37  allows the actuator  30  to toggle between a first extended position and a second non-extended position. The interaction of the actuator plunger  30   a  and second piston  35  allows the second piston to move between a first extended position and a second non-extended position. When the actuator  30  of the control assembly  20  is moved to the non-extended position, fluid is displaced from the first fluid cavity  29   a  to the third fluid cavity  60   a  and from the second fluid cavity  29   b  to the fourth fluid cavity  70   a.  The fluid displaced from the first fluid cavity  29   a  to the third fluid cavity  60   a  moves the third piston  61  from a first non-extended position to a second extended position. The fluid displaced from the second fluid cavity  29   b  to the fourth fluid cavity  70   a  moves the fourth piston  71  from a first non-extended position to a second extended position. 
         [0027]    Referring to  FIG. 9 , the first piston  34  has a generally cylindrical shaft  34   a  including two sets of lugs or extensions  34   b,    34   c  in the general shape of ridges or fins which extend outwardly from the sides of the shaft and have a longitudinal axial extent that is generally parallel to the axis A of the shaft. The lugs  34   b,    34   c  are sized, shaped and positioned on the shaft  34   a  so as to cooperatively engage with the latching ring  37  to operate the hydraulic control assembly  20  and ultimately effect desirable changes in the operation of the suspensions to which the hydraulic control assembly is attached. 
         [0028]    Referring to  FIG. 10 , the latching ring  37  in this embodiment has a center hole  37   a  that fits concentrically around the shaft  34   a  of the first piston  34 . The latching ring  37  includes a first set of gear teeth  37   b  formed at or near the top of the center hole  37   a  and a second set of gear teeth  37   c  formed at or near the bottom of the center hole. Each of the first and second set of gear teeth  37   b,    37   c  includes a plurality of gear teeth  37   d.  In the present embodiment, every other of the gear teeth  37   d  is interrupted by an axial slot  37   e.    
         [0029]    The first piston  34  moves axially within the first fluid cavity  29   a.  The latching ring  37  is installed concentrically around the first piston  34  from the proximal end. The latching ring  37  is free to rotate about the axis of the first piston  34 . Axial translation of the latching ring  37  is constrained by a ledge formed in the interior of the control housing  29  and by the piston retainer  36 . 
         [0030]    Referring to  FIG. 11 , in use, when the actuator  30  is fully extended from the control housing  29 , the upper set of lugs  34   b  (driving set) is positioned above the latching ring  37  and the lower set of lugs  34   c  (latching set) is keyed to the slots  37   e  passing through the latching ring  37 . As the first piston  34  is depressed axially into the first fluid cavity  29   a,  the latching lugs  34   c  slide out of the latching ring slots  37   e  and the driving set of lugs  34   b  engages the first set of gear teeth  37   b  of the latching ring  37  which causes the latching ring to rotate a first amount of approximately 35 degrees around the axis A of the first piston  34 . As the first piston  34  extends out of the first fluid cavity  29   a,  the latching set of lugs  34   c  engage the second set of gear teeth  37   c  of the latching ring  37 , which rotates the latching ring a second amount of an additional approximately 10 degrees, aligning the latching lugs  34   c  with a holding feature or land in the second set of gear teeth  37   c.    
         [0031]    Referring to  FIG. 12 , the engagement between the latching lugs  34   c  and the land of the second set of gear teeth  37   c  locks the first piston  34  in this second or fluid displacing position. When the first piston  34  is depressed again, the driver lugs  34   b  engage the gear teeth  37   b  of the latching ring  37 , which rotates the latching ring approximately 35 degrees again. As the first piston  34  extends, the latching lugs  34   c  engage the second set of gear teeth  37   c  of the latching ring  37  rotating it an additional 10 degrees. In this position, the latching lugs  34   c  are realigned with the slots  37   e  passing through the latching ring  37 , which allows the first piston  34  to fully extend to its initial position, which corresponds to the first or non-displaced position. 
         [0032]    The interaction of the latching ring  37  and lugs  34   b,    34   c  form a “push-push” toggle mechanism that provides two positions of the actuator  30  and therefore the first and second fluid pistons  34 ,  35  within respective first and second fluid cavities  29   a,    29   b,  the two positions corresponding to the two suspension settings. 
         [0033]    In additional embodiments (not shown), the hydraulic control assembly, including the latching ring  37  and piston  34 , may be configured to provide more than two “push-push” toggle positions, corresponding to 3 or more suspension settings. 
         [0034]    While this invention has been described by reference to a particular embodiment, it should be understood that numerous changes could be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the disclosed embodiment, but that it have the full scope permitted by the language of the following claims.