Patent Publication Number: US-11655005-B2

Title: Electronic shift control device for a bicycle derailleur

Description:
The present application is a continuation of U.S. patent application Ser. No. 17/123,751, filed Dec. 16, 2020, which is a continuation of U.S. patent application Ser. No. 15/868,550, filed Jan. 11, 2018, now U.S. Pat. No. 10,894,578, issued Jan. 19, 2021 the contents of which are incorporated herein in their entirety. 
    
    
     BACKGROUND 
     Field of the Disclosure 
     The present disclosure is generally directed to a bicycle control device, and more particularly to a bicycle control device that includes a brake lever and an electronic shift control system for mounting to a handlebar of a bicycle. 
     Description of Related Art 
     For a typical electronic shift control device for a bicycle, the battery unit for the shift control system and the jacks for connecting remote shift control buttons are packaged together on a circuit board assembly. This increases the cost and limits the placement options for these components on the device. 
     Also, the battery is received in a receptacle of the battery unit that is closed by a battery cover. The battery cover is attached to the device using multiple small threaded fasteners. The small fasteners can make removal and reinstallation of the battery cover difficult. This also requires that a user or ride has the correct tool on hand whenever the battery must be removed and replaced. 
     Further, the remote connection jacks for connecting remote shift control buttons are not typically sealed against ingress of water or other contaminants, unless a separate plug is installed. Without a plug placed in the jacks, water and other contaminants can enter and reach the battery circuit board assembly and travel through the electrical cables to the shift button circuit board assembly. These components can become damaged when exposed to water and other contaminants. 
     The battery unit is not typically sealed against ingress of water or contaminants, unless the battery cover seal is installed. In some cases, the battery cover may be compromised, which may result in ingress of water or other contaminants even if the battery cover is in place. Without a proper batter cover seal, water and other contaminants can enter the battery unit and reach the battery circuit board assembly and can travel through the electrical cables to the shift button circuit board assembly. Again, these components can become damaged when exposed to water and other contaminants. 
     Still further, an electrical cable typically connects the shift button circuit board assembly to the battery and to the remote shift button jack circuit board assembly. The cable passes through the center of the hood or housing of the bicycle control device. Thus, either the cable is required to be connected after the cable is routed through the hood of the device, or the hood must be slotted to accept the cable. Adding a slot to the hood compromises the strength of the hood. Attaching the cable after the cable is routed through the hood can also be problematic. This is because the bicycle control device needs to be built and tested independent of the brake control assembly, which is a part of the device. 
     Also, a grommet seal is typically employed at the interface between the electrical cable and the shift control circuit board in the shift lever. This requires that the multiple pin connector that is used to secure the cable to the circuit board be installed after the cable is passed through the grommet. Thus, assembly of the bicycle control device can be rendered more difficult. 
     SUMMARY 
     A bicycle control device is disclosed herein and includes a brake lever and an electronic shift control system. The control device is mounted to a handlebar of a bicycle via a main hood or housing, which includes a bracket and creates or defines a grip. In one example, the brake control of the control device is for a hydraulic brake system. However, the disclosed bicycle control device can instead be configured using a mechanical cable brake system. The electronic shift control system of the control device has a primary actuating button that is located adjacent to the brake lever. The electronic shift control system is also configured to wirelessly transmit shift signals, has a battery unit, and includes inputs or jacks for connecting to remote shift control buttons located elsewhere on the bicycle. 
     In one example, according to the teachings of the present disclosure, a control device is mountable to a bicycle handlebar. The control device includes a housing sized and shaped to be grasped by a user&#39;s hand, a shift lever coupled to and movable relative to the housing, an electrical switch that can be actuated by movement of the shift lever, and a controller in communication with the electrical switch. The controller is configured to generate a signal in response to actuation of the electrical switch. The control device also includes a communication module configured to transmit the signal, a battery receptacle on a part of the housing, and a removable battery cover closing off the battery receptacle. The battery receptacle is configured to contain a battery for providing power to the controller and the communication module. The housing has a base portion and an extension portion. The base portion includes first and second ends, a downward facing side, an upward facing side, an inward facing side, an outward facing side, and a handlebar clamp disposed at the first end. When the control device is mounted to a bicycle handlebar, the base portion extends generally horizontally, and the extension portion extends forwardly of the base portion at the second end and is angled generally upwardly from the base portion. The battery receptacle opens to the downward facing side of the base portion. 
     In one example, the battery cover can be rotatable to remove from and install over the battery receptacle. 
     In one example, the battery cover can be circular and can include a seal, such as an O-ring, around a circumference thereof. 
     In one example, the battery receptacle can be provided within a battery case that can be received in a recess in the base portion of the housing and that can be fastened or secured to the housing. 
     In one example, the battery cover can be removable from and installable on a battery case that is attached to the housing. 
     In one example, the battery cover can be removable to access the battery receptacle and can be removed and installed without use of a tool. 
     In one example, the battery cover and a battery case can be provided as a part of a shift lever assembly that also includes the shift lever. The battery case can be connected to the shift lever by an electrical wire. 
     In one example, the control device can include one or more accessory jacks that are accessible on a side of the base portion of the housing other than the downward facing side. 
     In one example, the control device can include one or more accessory jacks that are accessible on either the inward facing side or the outward facing side of the base portion of the housing. 
     In one example, the control device can include a brake lever that can be pivotally mounted to the housing and operable to operate a brake system of a bicycle. 
     In one example, the shift lever can be a part of a shift lever assembly that is mounted to a brake lever of the control device. The shift lever can pivot in concert with the brake lever about a brake pivot axis and can be movable independent of the brake lever laterally about a shift lever pivot axis oriented perpendicular to or differently from the brake lever pivot axis. 
     In one example, the control device can include a controller that can be configured to generate a signal to change a shift position of a gear shifting mechanism of a bicycle responsive to actuation of an electrical switch. 
     In one example, the controller can be configured to generate a radio frequency signal to change a shift position of a gear shift mechanism of a bicycle responsive to actuation of an electrical switch. An antenna can be in radio frequency communication with the controller to send the radio frequency signal. 
     In one example, the control device can include an electrical switch, a controller, and an antenna, each of which can be a part of a shift lever assembly and can be carried on a portion of the shift lever. 
     In one example, the control device can include a shift lever assembly, which further includes a printed circuit board carried within a portion of the shift lever. An electrical switch, a controller, and an antenna can each be carried, at least in part, by a printed circuit board within the shift lever. 
     In one example, the battery receptacle can be provided within a battery case that is received in a recess in the base portion of the housing. The battery case can include a second cavity disposed opposite the battery receptacle on the battery case. The second cavity can face toward a recess in the housing. 
     In one example, the control device can further include a positive contact with a contact portion exposed within the battery receptacle and a connector portion exposed within the second cavity, a negative contact with a contact portion exposed within the battery receptacle and a connector portion exposed within the second cavity, and electrical wires connected to the connector portions of the first and second contacts exposed within the second cavity. The second cavity can be filled with an epoxy material, which can cover the electrical wires and the connector portions of the first and second contacts. 
     In one example, the communication module can be a wireless communication module configured to wirelessly transmit the signal. 
     In one example according to the teachings of the present disclosure, a control device for a bicycle includes a housing mountable to the bicycle and sized and shaped to be grasped by a user&#39;s hand, a battery receptacle positioned on the housing, and at least one accessory jack accessible on an exterior of the housing. The at least one accessory jack is configured to receive an electrical connector of a remote accessory spaced from the control device on the bicycle. The housing has a base portion and an extension portion. The base portion includes first and second ends, a downward facing side, an upward facing side, in inward facing side, an outward facing side, and a handlebar clamp disposed at the first end. When the control device is mounted to a bicycle handlebar, the base portion extends generally horizontally, and the extension portion extends forwardly of the base portion at the second end and is angled generally upwardly from the base portion. The battery receptacle is positioned on a first side selected from the downward, upward, inward, and outward facing sides of the base portion of the housing. The at least one accessory jack is positioned on a second side different than the first side and selected from the downward, upward, inward, and outward facing sides of the base portion of the housing. 
     In one example, the control device can include a shift lever assembly attached to the housing. The shift lever assembly can include a battery case attached to the first side of the housing. The battery receptacle can be defined within the battery case and can open to an exterior of the housing. A shift lever can be coupled to and movable relative to the housing. Movement of the shift lever can actuate an electrical switch. A controller can be in wireless communication with the electrical switch and can be connected to the battery case by a first electrical wire. The at least one accessory jack can be connected to the controller by a second electrical wire. 
     In one example, the housing can be configured to provide a first wire path whereby a first electrical wire is directed from a controller to the position of the battery receptacle and to provide a second wire path whereby a second electrical wire is directed from the controller to the position of the at least one accessory jack. 
     In one example, the control device can include a brake lever pivotally connected to and movable relative to the housing. 
     In one example, the control device can include a shift lever assembly with a shift lever that can be mounted to the brake lever. The shift lever can pivot in concert with the brake lever about a brake pivot axis and can be movable independent of the brake lever laterally about a shift lever pivot axis that is different from the brake lever pivot axis. 
     In one example, the control device can include a shift lever assembly that can include a printed circuit board housed within a cavity in a paddle end of a shift lever. 
     In one example, the at least one accessory jack can include a plurality of accessory jacks. The plurality of accessory jacks can each be connected to a controller of a shift lever assembly by a corresponding plurality of second electrical wires. 
     In one example, the control device can include a controller that can be configured to generate a signal to change a shift position of a gear shifting mechanism of a bicycle responsive to actuation of an electrical switch. 
     In one example, the battery receptacle can be positioned on the downward facing side of the base portion of the housing. 
     In one example, the at least one accessory jack can be positioned on the inward facing side or the outward facing side of the base portion of the housing. 
     In one example according to the teachings of the present disclosure, a control device is configured for operating an electromechanical gear shifting mechanism of a bicycle. The control device includes a housing mountable to a bicycle and a brake lever coupled to and pivotally movable relative to the housing. The brake lever has a contact surface on a part thereof, a shift lever movable in concert with the brake lever and movable relative to the housing and relative to the brake lever, and a backer provided on a receiving portion of the shift lever. The contact surface of the brake lever is disposed in contact with the backer. 
     In one example, the receiving portion can be a pocket provided on the shift lever. 
     In one example, the backer can be seated in a pocket on the shift lever and can have a friction reducing surface exposed to and in contact with the contact surface of the brake lever. 
     In one example, the backer can be seated in a pocket on the shift lever. 
     In one example, the backer can be captured between the contact surface of the brake lever and the receiving portion on the shift lever. 
     In one example, the backer can be made from a material different from the shift lever and can be attached to the shift lever. 
     In one example, the backer can be formed from a Teflon material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Objects, features, and advantages of the present invention will become apparent upon reading the following description in conjunction with the drawing figures, in which: 
         FIG.  1    shows a side view of a bicycle including a bicycle control device according to the present disclosure. 
         FIG.  2    shows a rear and outside perspective view of the bicycle control device and a portion of the handlebar of the bicycle depicted in  FIG.  1   . 
         FIG.  3    shows a front view of the bicycle control device of  FIG.  2   . 
         FIG.  4    shows an outside view of the bicycle control device of  FIG.  2   . 
         FIG.  5    shows a top view of the bicycle control device of  FIG.  2   . 
         FIG.  6    shows an inside bottom perspective view of the bicycle control device of  FIG.  2   . 
         FIG.  7    shows the bicycle control device of  FIG.  6   , but with an outer cover removed. 
         FIG.  8    shows an outside bottom perspective view of the bicycle control device of  FIG.  7   . 
         FIG.  9    shows a cross section taken along line  9 - 9  of the brake lever and shift lever assembly of the bicycle control device of  FIG.  3   . 
         FIG.  10    shows a cross section taken along line  10 - 10  of the brake lever and shift lever assembly of the bicycle control device of  FIG.  9   . 
         FIG.  11    shows a partial exploded view of the bicycle control device of  FIGS.  7  and  8   . 
         FIG.  12    shows a further exploded view of the bicycle control device of  FIGS.  7  and  8   . 
         FIG.  13    shows a rear perspective view of the shift lever assembly of the bicycle control device of  FIG.  11   . 
         FIG.  14    shows an exploded perspective view of a portion of the shift lever assembly of  FIG.  13   . 
         FIG.  15    shows an exploded bottom perspective view of a battery unit of the shift lever assembly of  FIGS.  11 - 13   . 
         FIG.  16    shows a top perspective view of the battery unit of  FIG.  15   . 
         FIG.  17    shows a cross section taken along line  17 - 17  of the bicycle control device of  FIG.  3   . 
         FIG.  18    shows a bottom perspective view of a housing portion of the bicycle control device of  FIG.  7   . 
         FIG.  19    shows the housing portion of  FIG.  18   , but with the battery unit removed. 
         FIG.  20    shows the housing portion of  FIG.  19   , but with a battery receptacle of the battery unit installed in the housing. 
         FIG.  21    shows an inside front perspective view of the bicycle control device of  FIG.  7   . 
         FIG.  22    shows a top perspective view of the housing portion of  FIGS.  18 - 20   . 
         FIG.  23    shows the housing portion of  FIG.  22   , but with protective covers installed on parts or regions of the housing. 
         FIG.  24    shows an assembled perspective vie of the shift lever portion of the shift lever assembly of  FIG.  14   . 
         FIG.  25    shows a partial exploded view of the shift lever portion of  FIG.  24   . 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     A bicycle control device is disclosed herein that solves or improves upon one or more of the above-mentioned and/or other problems and disadvantages with prior known control devices. The disclosed bicycle control device includes a brake lever and an electronic shift control system. The control device is mounted to a handlebar of a bicycle. The brake control of the control device may be for operating a hydraulic brake system or a mechanical cable brake system. The electronic shift control system of the control device is also configured to wirelessly transmit shift signals, has a battery unit, and includes accessory ports, or jacks, for connecting to remote shift control devices or buttons located elsewhere on the bicycle. The accessory ports may be configured as input ports to receive input signals from the remote shift control devices. 
     Those having ordinary skill in the art should understand that the drawings and detailed description provided herein are for illustration only and do not limit the scope of the invention or the disclosure. The appended claims define the scope of the invention and the disclosure. The terms “first”, “second,” and the like, as well as “front”, “rear,” “left”, “right”, and the like are used for the sake of clarity. Such terms and similar terms are not used herein as terms of limitation. Further, such terms refer to bicycle mechanisms that are conventionally mounted to a bicycle and with the bicycle oriented and used in a standard manner, unless otherwise indicated. 
     Turning now to the drawings,  FIG.  1    depicts a bicycle  50  with a frame  52 , a front wheel  54  coupled to a fork  56  of the frame, and a rear wheel  58  coupled to seat stays  60  and chain stays  62  of the frame. The wheels  54 ,  58  support the frame  52  above a surface on which the bicycle  50  can travel in a forward direction indicated by the arrow ‘A’. The bicycle  50  has a drop-bar type handlebar  64  that is mounted to a head tube  66  of the frame  52 . The bicycle  50  also has a seat  68  carried by a seat post  70  received in a seat tube  72  of the frame  50 . The bicycle  50  may have one or both of a front gear changer  74  and a rear gear changer  76  mounted to the frame  52 . The gear changers  74 ,  76  may be electromechanical derailleurs, for example. The bicycle  50  includes a multiple-geared drive train  78  with one or more chainrings  80  driven by a crank assembly  82 , which has two crank arms  84  and two pedals, respectively  86 . The chainrings  80  may be connected to a plurality of sprockets  88  at the rear wheel  58  by a chain  90 . The bicycle  50  as described above is known in the art. 
     Referring to  FIGS.  1 - 5   , the bicycle  50  in the disclosed example has at least one bicycle control device  100 , hereinafter the “control device  100 ”, which can be mounted to the handlebar  64 . In this example, the control device  100  includes a brake control element of a brake system. The brake control element includes a brake lever  102  that is movably connected to a hood or housing  104  of the device. The brake lever  102  operates components of the braking system of the bicycle  50 . In one example, the brake system can include one or both of a hydraulic front brake mechanism  106  coupled to the front wheel  54  and a hydraulic rear brake mechanism  108  coupled to the rear wheel through hydraulic lines  110 . As noted above, the brake system can instead be a mechanical cable type brake system. As described in greater 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 . 
     Referring to  FIGS.  2 - 6   , various exterior views are depicted of the control device  100 , which is constructed according to one example of the present disclosure. The control device  100  is mountable to the handlebar  64 . In one example, the housing  104  can incorporate and include a known type of clamp  120 , which may be or include an adjustable band that extends around the handlebar. In one example, the bicycle  50  may include a pair of the control devices  100 , one on each of the left and right sides of the handlebar  64 , as is well known. One having ordinary skill in the art should understand that together the pair of control devices  100  may be configured to operate the respective front and rear electromechanical derailleurs  74 ,  76  and the respective front and rear brake mechanisms  106 ,  108 . In one example, the pair of control devices  100  may be identical to one another. 
     In the disclosed example, referring to  FIGS.  6 - 8   , the control device  100  includes a hood, i.e., the housing  104 , which may be covered with an exterior or outer cover  122 . The housing  104  is shaped and sized to be grasped by a hand of a user or rider and the outer cover  122  can be configured to closely follow and overlie the shape of the housing. The housing  104  and outer cover  122  can serve as a grip or can together be configured as a graspable portion of the control device  100 . The housing  104  may be formed of any suitable material, such as for example, metal, plastic, and/or composite materials. The housing  100  is constructed to carry, house, and/or support the various components and mechanisms of the control elements of the brake system and the electronic shift control system, as described in greater detail below. The outer cover  122  may be made of any suitable material, such as natural and/or synthetic elastomeric materials and may be designed to present a comfortable interface with the user and to reduce the tendency to become detached or moved from its position on the exterior of the housing  100 . For example, the outer cover  122  may be formed of a flexible thermoplastic elastomer (TPE) such as Santoprene™. The outer cover  122  may be configured to be removably attached to and held in position on the housing  104  using any known securement or attachment method. 
     In this example, referring to  FIGS.  7 - 9    wherein the outer cover  122  has been removed, 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 part of the housing so that the brake lever is spaced forward from the handlebar  64 . The brake lever  102  may thus be pivotable relative to the housing  104  generally forward and rearward. The brake lever  102  may also be made of any suitable material such as metal, plastic, or composite materials. The brake lever  102  may include a pivot bore or holes  124  near the proximal end. The pivot holes  124  can be aligned with one another and define a pivot axis P that is oriented generally perpendicular to the lengthwise axis of a grip handle  125  of the brake lever  102 . The brake lever  102  can be attached to the housing  100  by an axle  126 , which may in the form of a pivot pin, a rod, a shaft, or the like, through the holes  124 . 
     In the disclosed example, referring to  FIG.  2   , the brake lever  102  may have a U-shaped recess or define a channel  128  along at least a lengthwise portion of the grip handle  125 . The shift lever assembly  112  may be positioned in a nested arrangement at least partially within the recess or channel  128 , as described in more detail below. This nested arrangement of the shift lever assembly  112  with the brake lever  102 , and the U-shape of the lever body, can impart some rigidity to the structure and may provide protection for components disposed within the channel. The shift lever assembly  112  may also be pivotally or movably attached to the housing  100 , to a pivot mechanism, or to the brake lever  102 . The shift lever assembly  112  may be positioned behind the brake lever  102 , i.e., between the brake lever and the handlebar  64  when installed on the bicycle  50 . The shift lever assembly  112  may also be made of any suitable materials, such as plastic or composite materials. In one example, the shift lever assembly  112  should be made, at least in part, from a material that does not significantly inhibit wirelessly transmitted signals from penetrating the material. 
       FIGS.  9  and  10    depict cross sections of the brake lever  102  and the shift lever assembly  112  in an assembled or in-use arrangement. Referring to  FIGS.  2 ,  9 , and  10   , the channel  128  of the brake lever  102  is defined between spaced apart side walls including an inside wall  130   a  and an outside wall  130   b , with reference to the orientation of the bicycle  50 , and within a front facing wall  130   c . The shift lever assembly is nested in the channel  128 . As described in further detail below, the shift lever assembly  112  can pivot laterally in a direction between the side walls  130   a ,  130   b  about an axis S that is generally perpendicular to the pivot axis P of the brake lever  102  about the axle  126 . Thus, the shift lever assembly  112  can move in inboard and outboard directions relative to the bicycle  50  while staying nested and aligned with the brake lever  102 . 
     In general, referring to  FIGS.  9 - 11   , the shift lever assembly  112  has a shift lever  132  including a proximal end  134  that is directly or indirectly pivotally attached to the housing  104  or the brake lever  102  by a pivot pin  136 , which defines the pivot axis S of the shift lever assembly. The shift lever  132  also has a distal or paddle end  138  that is opposite the proximal end and an elongate lever arm  140  connecting the proximal and distal ends. The lever arm  140  may be a closed hollow body or may be U-shaped or open sided and can include structural ribbing therein. 
     In one example, the proximal end  134  of the shift lever  132  may also have a transverse opening  142  that is positioned to accommodate the pivot axle  126  of the brake lever  102  passing through the shift lever assembly  112 . The proximal end  134  of the shift lever  132  may also carry connecting components (not described in detail herein) for connecting the brake lever  102  to the hydraulic brake system. Those components can include a sleeve  144  carried by the shift lever  132  and spaced from and parallel to the transverse opening  142 . When the shift lever assembly  112  is assembled to the brake lever  102 , the sleeve is received in a set of openings  145  at the proximal end of the brake lever  102 , which are spaced from the pivot bore  124 . The combination of the sleeve  144  and openings  145 , along with the transverse opening  142  and the axle  126 , marries the brake lever  102  and the shift lever assembly  112  together relative to the brake lever pivot axis P. The shift lever assembly  112  is thus configured to move in concert with the brake lever  102  about the pivot axis P when the brake system is operated, but moves independent of the brake lever when the shift control system is operated. As describe in more detail below, the paddle end  138  of the shift lever  132  includes an interior cavity  146  that houses electronic components of the shift lever assembly  112  and the shift control system. 
     Referring to  FIGS.  11  and  12   , the bicycle control device  100  has four primary parts including the housing  104 , the outer cover  122  (not shown, see  FIG.  6   ), the brake lever  102 , and the shift lever assembly  112 . The shift lever assembly  112  and the housing  104  each further include additional sub-components according to the teachings of the present invention and as illustrated generally in  FIG.  12   . 
     In the disclosed example, referring to  FIGS.  11 - 14   , the shift lever assembly  112  is a self-contained electrical assembly, which provides several advantages and improvements, as described below, over prior known bicycle control devices of this type. In this example, the shift lever assembly  112  includes electronic componentry for operating the bicycle control device  100 . Some of the electronic componentry in this example is housed within the interior cavity  146  in the paddle end  138  of the shift lever  132  and some of the componentry is external to but electrically connected with the componentry within the cavity. 
     The paddle end  138  of the shift lever  132  in this example has a larger surface area than the adjoining lever arm  140 . The paddle end  138  thus provides a convenient and ergonomic contact point for a user. The interior cavity  146  includes a cover  148 , which can be secured by fasteners  150  to the paddle end  138  to close off the cavity and exclude water and other contaminants from entry into the cavity. A seal  152  may be interposed between the interior cavity  146  and the cover  148 . The seal  152  may be a rubber seal membrane or layer or any suitable material that satisfactorily seals the cavity  146  to prevent ingress of moisture or contaminants. 
     In one example, a printed circuit board (PCB)  154  is disposed within the sealed cavity  146 . Various electronic componentry may be mounted on or connected to the PCB  154 . The PCB  154  may include a communication module  156  configured to transmit signals from the control device  100 . In one example, the communication module  156  may be configured for wireless transmission of signals in the form of electromagnetic radiation (EMR), such as radio waves or radio frequency signals. Optionally, the communication module  156  may also be configured to receive signals. In one example, the communication module  156  may be configured to receive signals, which may be in the form of EMR such as radio waves or radio frequency signals. The communications module  156  can include or can be a transmitter or a transceiver. The PCB  154  may also include an antenna  158  that is in operative communication with the communication module  156  to send and optionally also receive EMR signals. The antenna  158  may be any device designed to transmit and/or receive electromagnetic radiation (e.g. TV or radio) waves. 
     In the disclosed example, the antenna  158  is on the PCB  154  in a position where it will be able to send signals without significant interference from the structure of the bicycle control device  100  and/or from a user&#39;s hand. In another example, to help reduce or prevent interference, the antenna  158  may be a wireless antenna and may be positioned, at least in part, in or on a portion of the bicycle control device  100  that is separate and remote or spaced from the housing  104 . The antenna  158  may be positioned on another part of the brake lever  102  or the shift lever  132 , for example. 
     The bicycle control device  100  also includes a controller  160 , which in this example is also on the PCB  154 . The controller  160  is operatively connected to the communication module  156  to perform electronic operations such as generating the signals related to one or more of shifting, pairing, derailleur trim operations, power management, and the like. The controller  160  may be programmable and configurable to generate signals to control the front and rear derailleurs  74 ,  76 , for example. In one example, the controller  160  may be an Atmel ATmega324PA microcontroller with an internal EEPROM memory. The communication module  156  may also be programmable and configurable to likewise to transmit and/or receive signals to control the front and rear derailleurs  74 ,  76 . In one example, the communication module  156  may be an Atmel AT86RF231 2.4 GHz transceiver utilizing AES encryption and DSS spread spectrum technology supporting  16  channels and the IEEE 802.15.4 communication protocol. However, other suitable microcontrollers  160  and communications modules  156  may be utilized. Additionally, ancillary electrical and/or electronic devices and components may be used, as is well known in the art, to further enhance or enable the function and operation of the controller  160  and the communications module  156  and related components. 
     In one example, the bicycle control device  100  may include at least one light emitting diode (LED)  162 , which may also be positioned on the PCB  154 . The LED  162  may convey status information to a user or a rider relating to the electronic componentry and function of the shift lever assembly  112  or bicycle control device  100 . The LED  162  in this example is visible through a transparent part  164  of the seal  152  and a window or opening  166  in the cover  148  of the cavity  146 . In one example, the entire seal  152  may be transparent. Alternatively, only the part  164  of the seal material is configured to permits light through the seal. 
     Further, the electronic componentry may include one or more electrical switches  170 ,  172 . The electrical switches  170 ,  172 , when actuated, may cause operations to be carried out by the controller  160 . Such operations may relate to signal transmission or reception, derailleur, and control device  100  pairing, trim and/or shift operations, and the like. The switches  170 ,  172  may generate signals to initiate or elicit an action and/or response from various mechanisms of the bicycle  50 , such as the front and rear electromechanical derailleurs  74 ,  76 . 
     In this example, the first electrical switch  170  includes a contact (not shown) on the PCB  154  underlying a resilient dome switch element  174 , also on the PCB. In this example, the first electrical switch  170  is actuated through the seal  152  from outside the cavity  146  and the shift lever  132 . The cover  148  has a first switch opening  176 , where both the cover and the opening are on the inward facing side of the shift lever  132 , i.e., the non-actuation side of the paddle end  138 . An actuator  178  is seated in the first switch opening  176 , as depicted in  FIGS.  6 ,  10 , and  12   . The actuator  178  includes a button  180  that is received in a hole  182  in the inside wall  130   a  of the brake lever  102 . A spring retainer  184  is retained in the first switch opening  176  in the cover  148 . A spring  186  extends between the button  180  and the retainer  184  and biases the shift lever toward the outside wall  130   b  of the brake lever  102 , as depicted in  FIG.  10   . A user or rider operates the shift lever  132  by pushing inward on the actuation surface, i.e., outside surface of the paddle end  138  against the bias force of the spring  186 . As the rider pushes on the paddle end  138 , the button  180  will eventually contact the spring retainer  184 . Through the seal  152 , the spring retainer  184  will push against the domed switch element  174 , which will further touch the contact on the PCB  154  to close and actuate the first electrical switch  170 . 
     The second electrical switch  172  includes a contact  190  on the PCB  154 . The contact  190  may be a domed switch element or a pressure type switch contact. In this example, the second electrical switch  172  is also actuated through the seal  152  from outside the cavity  146  and the shift lever  132 . The cover  148  has a second switch opening  192 , where both the cover and the opening are again on the inward facing side of the shift lever  132 , i.e., the non-actuation side of the paddle end  138 . A button  194  extends through and is seated in the second switch opening  192  in the cover  148 , as depicted in  FIG.  6   . The button  194  may be integrally formed as a part of the seal  152  or may be attached to the seal material. A user or rider operates the second electrical switch  172  simply by depressing the button  194  toward the cover  148 . The button  194  or the underlying material layer of the seal  152 , may have a point contact (not shown) on the inside end, which pushes against the seal  152  to depress and close the contact  190  to actuate the second electrical switch  172 . 
     The buttons  180  and  194  operate through the material layer of the seal  152 , whereby the integrity of the seal for the cavity  146  is not compromised. Other types of electrical switches may be used. The first electrical switch  170  may be used for operating the bicycle control device  100  on a frequent and more forceful basis, such as to initiation of a gear shift or gear change. The second electrical switch  172  may be an optional switch and in this example, may be smaller and more self-contained. The second electrical switch  172  may be intended to be used less frequently than the first electrical switch  170 . In one example, the second electrical switch  172  may be used for operations related to pairing the bicycle control device with a specific bicycle component, such as the front or rear electromechanical derailleurs  74 ,  76 , or for trimming the derailleurs. 
     The electronic componentry on the PCB  154  and within the cavity  146  is retained and sealed in place in the cavity. The seal  152  overlies the PCB  154  and is sandwiched between the paddle end  138  and he cover  148  of the shift lever  132  when the cover is fastened to the shift lever. Referring to  FIGS.  10  and  14   , the seal  152  may include a perimeter rib  196  around the seal material. Likewise, the paddle end  138  may include a groove  198  around the opening into the cavity  146 . The rib  196  can seat in the groove  198  to create a tight environmental seal when the cover  148  is secured to the paddle end  138 . The material layer of the seal  152  may include raised or thickened regions  200 , which may be positioned to coincide with the electrical switches  170 ,  172 , to encourage effective force transfer from the buttons  180 ,  194  to the switches. The actuation of the electrical switches  170 ,  172  sends signals through associated circuitry, as is well known, to be acted upon by the controller  160 . 
     Referring to  FIGS.  13  and  14   , one or more wires or electrical cables  210  are electrically connected to the electronic componentry of the PCB  154  and are routed from the cavity  146  through an opening into the lever arm  140 . The wires  210  extend along the interior of the lever arm  140  and are routed around and between the sleeve  144  and the transverse opening  142  on the proximal end  134  of the shift lever  132 . In the disclosed example, the wires are connected to a power supply, i.e., a self-contained battery unit  212 . In this example, the shift lever assembly  112  also includes an accessory jack body  214  defining two accessory jacks  216 , which are also electrically connected by the wires  210  to the battery unit  212  and to the electronic componentry of the PCB  154 . In one example, the jack body  214  can be a single body defining two female accessory jacks  216  therein. Alternatively, each of the accessory jacks  216  can include its own separate body  214  element. The wires  210  thus electrically connect the power supply or battery unit  212  to the accessory jacks  216  and to the electronic componentry of the shift lever assembly  112 . 
     The accessory jacks  216  may be connected to the PCB  154  and/or to a separate accessory PCB (not shown) within the accessory jack body  214 . The accessory jack body  214 , if provided, can define one or more than two accessory jacks  216 , if desired. Connectors for optional remote actuators, buttons, or switches may be connected to the bicycle control device  100  through the accessory jacks  216 . The accessory jacks  216  can then provide power and electrical connection and operation between the remote actuator(s) and the battery unit  212  and the PCB  154 . The accessory jacks  216  may be configured to accept connectors from optional additional and/or remote electrical switches or other devices (not shown), such as optionally placed remote shift control buttons on the bicycle  50 , to the control device  100 . When no accessories are connected to the control device  100 , the accessory jacks  216  may be closed and/or sealed from moisture and contamination by inserting plugs  218  into the jacks. 
     The shift lever assembly  112  in this example is thus a self-contained electrical component of the control device  100 . The shift lever  132  and electrical componentry are capable of wirelessly transmitting shift control signals to the front and rear derailleurs  74 ,  76  according to actuation of the shift lever  132 . The battery unit  212  and each accessory jack  216  may be connected by separate wires  210  using a multiple pin connector at the PCB  154 . The battery unit  212  and jacks  216  can either have separate connection points to the PCB  154  or can use a cable assembly that starts with a single wire near the PCB and then splits to two or more wires. The battery unit  212  and jack body  214  are each connected to the housing  104  in a unique manner according to the present disclosure. 
     In this example, referring to  FIGS.  12 ,  15 , and  16   , the battery unit  212  includes a battery case  220  and a battery cover  222 . The battery case  220  is received in a recess  224  in the housing  104  and is fixedly attached to the housing via fasteners. In this example, the battery case  220  is fastened to the housing via screws  226 , but could similarly be attached to the housing via snap features, adhesive, or another suitable means. A conventional and replaceable coin cell type battery  228  may be received within a battery receptacle  230  defined by the case  220  and open to the exterior of the housing  104 . Alternatively, the battery can be a non-replaceable and/or rechargeable battery. The battery  228  may be configured to provide power for the control module  156 , the controller  160 , and to remote switches or electrical devices via the accessory jacks  216 . The cover  222  is rotatable to install over the receptacle  230  and the battery  228  and can be reverse rotated to be removed to access the battery. The cover  222  can include an elastomeric O-ring or gasket  232  around its periphery to create a moisture and contaminant proof seal against the case  220  or the housing  104  when installed. 
     Referring to  FIG.  16   , the battery receptacle  230  includes a positive contact  324  at a periphery wall  236  of the receptacle and includes a negative contact  238  at the center of the receptacle on a bottom wall  240 . Exposed contact portions of the electrical or positive and negative contacts  234 ,  238  within the battery receptacle  230  contact the corresponding two terminals of the battery  228 . Referring to  FIG.  15   , the battery case  220  also includes a second cavity  242  on a side opposite the battery receptacle  230  and which faces into the housing recess  224  when the case is installed. Portions of the electrical contacts  234  and  238  extend through holes within the case between the battery receptacle  230  and the second cavity  242 . Exposed connector portions of the electrical contacts  234 ,  238  are connected to separate wires  210  within the second cavity  242 . These connector portions can be soldered to join the wires  210  and the contacts  234 ,  238  and the wires can then be connected to the PCB  154 . Alternatively, the wires  210  can be crimped or otherwise mechanically secured to the exposed portions of the contacts  234 ,  238 . The positive and negative contacts  234 ,  238  can be secured to the case via slot features in the wall  236  and bottom  240  of the battery receptacle  230 . Alternatively, the contacts could similarly be attached to the case via staking, mechanical fasteners, adhesive, or another suitable means. 
     During assembly, the second cavity  242 , which faces into the recess  224  of the housing  104 , is filled with an epoxy that acts to both secure the contacts  234 ,  238  and wires  210  in place and to create a seal that prevents water and other contaminants from reaching the contacts, the battery  228 , the battery receptacle  230 , and the interior of the wires  210 . This epoxy seal could similarly be provided via a cover piece that is attached to the second cavity  242  via plastic welding, fasteners, adhesive, or another suitable means. 
     The battery cover  222  may be secured via conventional mechanical threads to the case  220 . However, in this example, the cover  222  is secured to the case  220  via a set of tabs  244  or keys and slots  246  or ways that engage one another when the cover is twisted into place. The O-ring  232  is compressed between the cover  222  and the case  220  or a surface of the housing  104  to provides a second seal for the battery receptacle  230  against water and other contamination. The battery cover  222  and/or the case  220  may also contain a series of recesses or depressions  250  on the exposed outer surfaces. The outer cover  122  may include protruding boss features (not shown) on the interior side of the cover that are received in these recesses or depressions  250 . When the outer cover  122  boss features are engaged with the recesses or depressions  250 , unintentional movement of the battery cover  222  may be inhibited or prevented. 
       FIG.  17    shows a cross section of the assembled control device  100 . In this example, the battery unit  212  is installed in the recess  224  in the housing  104 . The wires  210  between the battery unit  212  and the shift lever  132  are routed via a first channel  252  in the housing  104  above the recess  224 . The battery case  220  includes an upper block portion  254  that seats in the first channel  252  to help cover the channel in the assembled control device  100 . The block portion  254  also helps to align the case  220  during installation on the housing  104 . 
     In the disclosed example, the housing  104  may be described as having several sides including an inward facing side, an outward facing side, a bottom side, and a top side. In this example, the battery unit  212  is installed on the bottom side of the housing, as depicted in  FIGS.  7 ,  8 , and  17   . According to the present disclosure, though the shift lever assembly  112  includes the shift lever  132  and electronic componentry, the accessory jack body  214 , and the battery unit  212  as a self-contained assembly, the accessory jack body can be installed on a different side of the housing  104 .  FIGS.  7  and  18 - 20    show that the accessory jack body  214  is installed in a jack recess  256  on the inward facing side of the housing  104 . A second channel  258  in the housing  104  is disposed above the jack recess  256  for routing the wires  210  from the jack body  214  to the battery unit  212  and PCB  254 . 
     Referring to  FIGS.  7 ,  12 , and  18   , a jack cover  260  is removably attached to the housing  103  to cover the jack recess  256  to secure and retain the jack body  216  within the jack recess. The jack recess  256  can be shaped to compliment the shape of the jack body  216  or the separate jack bodies of the accessory jacks  216 . The accessory jacks  216  in this example are female jacks with access openings (not shown) located on and accessible from the external surface of the housing  104 . The accessory jacks  216  provide an interface between optional remote shift control button assemblies and the shift control system including the shift lever assembly  112 . In one example, two or more accessory jacks could be combined into a single assembly with a single cable assembly emanating to the battery unit  212  and PCB  154 . In this example, the jack body  214  is fixedly attached to the housing  104  via the jack cover  260  that is fastened to the housing with screws  262 . The jack body  214  could instead be attached to the housing via snap features, adhesive, or other suitable means. The jack body  214  could also be non-permanently fixed to the housing such that the jack body or accessory jacks  216  can be lifted out of the housing when not covered by the jack cover  260 . 
     Though not shown herein, the jack body  214  for each accessory jack  216  can have two cavities including an interior cavity located closer to the shift control system and separated from an external cavity, which defines a plug interface or connector receiver for receiving a connector for an accessory component. Each plug interface can function, when in use, to retain a remote shift control button connector therein and to electrically connect the connector terminal to one end of a wire or cable assembly that terminates at the PCB  154  at the other end. The terminal or terminals can extend from the external cavity to the internal cavity for each accessory jack  216  and be connected to the wire or wires. The internal cavity is filled with an epoxy, similar to the battery case second cavity  242 . The epoxy can secure the wires in place and create a seal that prevents water and other contaminants from reaching the internal cavity, the cable, or wires therein, the plug interface, and the external cavity. Such a seal could instead be provided by molding the jack body or a separate interface piece over the exterior of the wire connections and jack body. 
     Referring to  FIGS.  7 ,  11 ,  12 ,  13 , and  21    when not being used, the accessory jacks  216 , and particularly the exterior cavities, can be closed or plugged by inserting a plug  264  into each of the access openings. The plugs  264  are inserted into the jack body&#39;s external cavities. A seal can be created via an elastomeric O-ring (not shown) that is compressed between the exterior of the plug  264  and the inner wall of the externa cavities. The plug seal prevents water and contaminants from reaching the electrical interface and parts within the jack body  214 . The connectors for remote accessories can look and function similar to the plugs  264 , except that each connector would make electrical contact with a terminal or terminals within the external cavities. The plugs  264  can include an extension or tail  266  that protrudes from the accessory jacks  216  so that the plugs can be easily grasped and pulled from the jack body  214  when needed. 
     Referring to  FIGS.  17 - 21   , the housing  104  can be formed having a base portion  267  and an extension portion  268 . The base portion  267  can include first and second or rear facing and front facing ends, a downward facing side  269   a , an upward facing side  269   b , an inward facing side  269   c , an outward facing side  269   d . The handlebar clamp  120  in this example is disposed at the first or rear facing end. When the control device  100  is mounted to a bicycle handlebar  64 , the base portion  267  extends generally horizontally and the extension portion  268  extends forwardly of the base portion at the second end and is angled generally upwardly from the base portion. 
     The inward facing side  269   c  and an outward facing side  269   d , the inward facing side being closer to the center of the bicycle frame  52  when the housing  104  is mounted on the handlebar  64 . In this example, the remote shift control accessory jacks  216  are located on the inward facing side  269   c  of the base portion  267  of the housing  104 . However, the jacks could instead be positioned on the outward facing side  269   d , or on both sides. Further, in this example, the battery recess  224  in the housing, and thus the battery case  220 , are disposed on the downward facing side  269   a  on the base portion  267 . One or more electrical wires  210  extend from the top of the jack body  214  and between the accessory jacks  216  and the PCB  154 . The wires  210  are compressed into and routed via the second channel  258  in the housing  104  above the jack recess  256  toward the wires of the battery unit  212 . The wires  210  are then routed toward the PCB  154  along with the wires for the battery unit  212 . The jack cover  260  can also have a gasket or seal that creates tight seal between the cover and the housing  104  when installed. The battery case  220 , when secured to the housing  104 , also has features that secure the wires  210  by compressing the wires between the battery case and the housing. The battery case  212  also has a guide feature, i.e., the block portion  254  that guides the wires from the exterior to the interior of the housing  104 . 
       FIGS.  22  and  23    show a top view of the housing  104  with the outer cover  122  removed.  FIG.  22    shows a chamber  270  in the housing where the brake lever  102  is connected to the hydraulic brake system components. The chamber  270  is accessible via a removable chamber cover  272 , which is depicted in  FIG.  23   . The chamber cover  272  can be secured to the housing  104  by screws  274  or other fasters, snap connections, adhesive, or other suitable securing means. Though not described in significant detail herein, the chamber  270  may house and provide access to components of the control device  100  for maintenance or adjustment. When the outer cover  122  is attached to the housing  104 , the chamber cover  272 , jack cover  260  and battery cover  222  may all be covered and hidden and be protected from the environment. 
     Referring to  FIG.  17   , the hydraulic brake system may generally include a housing bore with a master cylinder sleeve  300  inserted into the bore and configured to act as a master cylinder for the brake system. A piston  302  resides in and moves relative to the sleeve  300 . The piston  302  includes one end  304  coupled to the brake lever  102  and is operable by movement of the brake lever as is known in the art. The master cylinder sleeve  300  is in fluid communication with the chamber  270 , which can act as a brake fluid chamber for the brake system. The chamber  270  can include a bleed port  306  and a bleed screw  308  movable in the bleed port to fill, top off, or bleed hydraulic fluid of the brake system via the chamber  270 . In this example, a compliant or flexible membrane  310  may be provided over and closing off the open side of the chamber  270  to provide a defined fluid chamber having a variable volume. The membrane  310  may be positioned between the cover  272  and the open side of the chamber  270 , as depicted in  FIG.  17   . Referring to  FIGS.  11  and  21   , the housing  104  of the control device  100  may include a fluid outlet port  312  in communication with the master cylinder sleeve  300 . As force is applied to move the brake lever  102 , fluid may be forced to the fluid outlet port.  312 . The housing  104  of the control device may also include a control device fluid outlet  314  that is in fluid communication with the fluid outlet port  312 . A hydraulic brake line  110  may be connected to the control device outlet port  314  and to the front or rea brake mechanism  106  or  108  for operation as is known in the art. In one example, the chamber cover  272  may be removed to replace or repair the flexible membrane  310 . 
       FIGS.  24  and  25    show another aspect of the control device  100  according to the disclosure. In this example, a backer  280  can be inserted between and sandwiched by the cover  148  and the paddle end  138  of the shift lever  132 . Each part can be formed to define a receiving portion, such as a pocket  282 , that captures an edge of the backer  280 . The backer  280  can create a contact point between the top of the shift lever  132  and a contact surface on the inside surface of the brake lever front wall  130   c , as shown in  FIG.  9   . The contact surface can include a bump or protrusion  284  positioned to contact the backer  280 . The backer  280  is essentially captured between the bump  284  on the brake lever inside surface  130   c  and the pocket  282  on the shift lever  132 . The backer  280  can be formed from a durable material with low friction characteristics. In one example, the backer  280  can be made from a material different from the shift lever, such as Teflon, and then can be attached to the shift lever. The backer  280  can thus allow the shift lever  132  to slide laterally and easily relative to the brake lever  102  to inhibit binding and wear. 
     In the disclosed control device  100 , the interior cavity  146  of the shift lever  132  contains the shift control system PCB  154  and a separate arm cavity  290 , which extends along the lever arm  140 . The lever arm  140  can be open along a forward side that is oriented facing the brake lever front wall  130   c . The opening can open to the arm cavity  290 , guides and retains the electrical cable assembly or wires  210  extending between the PCB  154  and the battery unit  212  and accessory jacks  216 . The interior cavity  146  and the arm cavity  290  are joined via an internal hole (not shown) in the interior of the shift lever  132 . These cavities could instead be joined via a slot. The cover  148  is fastened to the paddle end  138  of the shift lever  132 , as described below, to provide a seal that prevents water and other contaminants from reaching the PCB  154 . The electrical cable assembly, which consists of one or more independent wires  210 , passes through the hole between the interior cavity  146  and the arm cavity  290 . The arm cavity  290  is also filled with epoxy during assembly to both secure the wires  210  in place and provide a seal that prevents water and other contaminants from accessing the interior of the cable assembly and wires, the PCB  154 , and the interior cavity  146 . 
     As shown in  FIG.  14   , prior to the application of epoxy to the arm cavity  290 , an epoxy blocker piece  292  can be installed at the location, i.e., the hole between the interior cavity  146  and the arm cavity  290 . The epoxy blocker piece  292  provides a temporary seal that prevents epoxy from flowing into the circuit board cavity before solidifying. Once the shift lever assembly  112  is installed with the brake lever  102 , the epoxy filled opening along the lever arm  140  faces the front wall  130   c  of the brake lever so that it would not be readily visible. 
     The disclosed control device  100  and the shift lever assembly  112  is configured such that the shift control system and battery unit are separated from the accessory jacks, even though the electronics are formed as one self-contained piece. The configuration results in several benefits. Also, the battery unit can be placed on a different side of the housing than the accessory jacks, which enables the use of a twisting battery cover with a deep coin slot. Further, the accessory jacks, battery unit, and primary shift control button assembly are all independently sealed against ingress of water or contaminants. Thus, moisture and contaminants are not able to travel from one subassembly to another within the device. Still further, no circuit board is exposed when the removable seals for the battery cover and accessory jacks are not in place. Thus, it is not possible for water or contaminants to damage the electrical shift control system when these seals are removed. 
     Another advantage is that the electrical cables or wires for the various components on the sides of the housing are routed around the exterior of the housing. This can improve the strength of the housing and can allow for complete assembly and installation of the electrical system components prior to installation on the housing. Still further, the shift control system only requires one circuit board located in the shift lever. Also, an epoxy seal is used at the interface of the electrical cables or wires and the shift control circuit board in the shift lever. This allows a multiple pin connector piece used to secure the wires to the circuit board to be installed prior to installing the cables or wires in the shift lever. 
     Although certain bicycle control device examples, features, aspects, components, and characteristics have been described herein in accordance with the teachings of the present disclosure, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the disclosure that fairly fall within the scope of permissible equivalents.