Bicycle pedal crank, intermediate product and method for manufacturing such a pedal crank

Information

  • Patent Application
  • 20070199403
  • Publication Number
    20070199403
  • Date Filed
    August 09, 2006
    17 years ago
  • Date Published
    August 30, 2007
    16 years ago
Abstract
A bicycle pedal crank has an elongated body and a first end portion with a first seat for coupling with a bottom bracket of the bicycle, a second end portion with a second seat for coupling with a pedal, and an intermediate portion extending between the first end portion and said second end portion and having an inner portion substantially without structural strength and a first reinforcement structure. The first reinforcement structure has a tubular structure arranged around said inner portion and extending longitudinally not longer than the longitudinal extension of the intermediate portion. The extension of the tubular element is limited to the intermediate portion of the pedal crank. The crank may be manufactured in a simple, quick way in a completely automated manner, using a filling material molded under high pressure.
Description

BRIEF DESCRIPTION OF THE DRAWING(S)

Further characteristics and advantages of the pedal crank of the present invention shall become clearer from the following description of some preferred embodiments thereof, made hereafter, for indicating and not limiting purposes, with reference to the attached drawings. In such drawings:



FIG. 1 is a perspective view partially in section of a left pedal crank according to the present invention;



FIG. 2 is a perspective view of a core for manufacturing the pedal crank of FIG. 1;



FIG. 3 is a perspective view that illustrates a preparation step of a preferred embodiment of an intermediate product for manufacturing the pedal crank of FIG. 1;



FIG. 4 is a perspective view of a preferred embodiment of an intermediate product for manufacturing the pedal crank of FIG. 1;



FIG. 5 is a cross section view along the line V-V of the intermediate product of FIG. 4;



FIG. 6 is a cross section view along the line VI-VI of the pedal crank of FIG. 1;



FIGS. 7 and 7
a are perspective views of alternative embodiments of the core of FIG. 2;



FIG. 8 is a perspective view of a core for manufacturing a right pedal crank according to the invention;



FIG. 8
a is a top view of a preferred embodiment of the core of FIG. 8;



FIG. 8
b is a view of a detail of the core of FIG. 8a;



FIG. 9 is a perspective view that illustrates a preparation step of a preferred embodiment of an intermediate product for manufacturing a right pedal crank according to the invention;



FIG. 10 is a longitudinal section view of a right pedal crank manufactured with the core of FIG. 8; and



FIG. 11 is a section view of a mold for manufacturing the pedal crank of FIG. 1, having the intermediate product of FIG. 4 in its cavity.


Claims
  • 1. Bicycle pedal crank, comprising an elongated body extending along a longitudinal axis X-X and having: a first end portion comprising a first seat for coupling with a bottom bracket of a bicycle;a second end portion comprising a second seat for coupling with a pedal;an intermediate portion extending between said first end portion and said second end portion and comprising an inner portion substantially without structural strength and a first reinforcement structure;wherein said first reinforcement structure comprises a tubular structure arranged around said inner portion and extending longitudinally for a part no longer than the longitudinal extension of said intermediate portion.
  • 2. Pedal crank according to claim 1, wherein said tubular structure comprises at least one sheet of composite material wound around said longitudinal axis X-X.
  • 3. Pedal crank according to claim 2, wherein said at least one sheet of composite material comprises at least one layer of unidirectional continuous structural fibers incorporated in a polymeric material and having a preferential direction of extension.
  • 4. Pedal crank according to claim 3, wherein said preferential direction of extension is inclined with respect to said longitudinal axis X-X by a predetermined first angle.
  • 5. Pedal crank according to claim 4, wherein said predetermined first angle is equal to about 45°.
  • 6. Pedal crank according to claim 2, wherein said sheet of composite material comprises at least two layers each comprising unidirectional continuous structural fibers incorporated in a polymeric material and having a respective preferential direction of extension.
  • 7. Pedal crank according to claim 6, wherein the preferential direction of extension of the structural fibers of a layer is inclined with respect to the preferential direction of extension of the structural fibers of at least one other layer of a predetermined second angle.
  • 8. Pedal crank according to claim 7, wherein said predetermined second angle is equal to about 90°.
  • 9. Pedal crank according to claim 1, wherein said inner portion is defined by a first cavity.
  • 10. Pedal crank according to claim 1, wherein said first and second end portions comprise a composite material comprising structural fibers arranged randomly and incorporated in a polymeric material.
  • 11. Pedal crank according to claim 1, further comprising a second reinforcement structure defined by at least one bundle of unidirectional continuous structural fibers that extends longitudinally in said elongated body.
  • 12. Pedal crank according to claim 11, wherein said second reinforcement structure is arranged, at said intermediate portion, between said inner portion and said first reinforcement structure.
  • 13. Pedal crank according to claim 11, wherein said second reinforcement structure winds in a loop around said first and second end portions and said intermediate portion.
  • 14. Pedal crank according to claim 3, wherein said structural fibers are selected from the group consisting of: carbon fibers, glass fibers, aramid fibers, boron fibers, ceramic fibers and combinations thereof.
  • 15. Pedal crank according to claim 3, wherein said polymeric material is a thermosetting material.
  • 16. Pedal crank according to claim 11, wherein said intermediate portion has a section perpendicular to said longitudinal axis X-X in which said inner portion occupies a space defined by a first area having a first surface extension and by a second area having a second surface extension and wherein said second reinforcement structure occupies a space having a surface extension equal to the difference between said first and second areas.
  • 17. Pedal crank according to claim 11, wherein the fibers of said second reinforcement structure are unidirectional continuous structural fibers extending, at said intermediate portion, substantially parallel to said longitudinal axis X-X.
  • 18. Pedal crank according to claim 9, wherein at least one of said first and second end portions comprises a second cavity extending around said coupling seat.
  • 19. Pedal crank according to claim 18, further comprising an insert housed in at least one of said first and second end portions in said coupling seat.
  • 20. Pedal crank according to claim 18, wherein said second cavity has a height at least in part shorter than a height of said first cavity.
  • 21. Pedal crank according to claim 18, wherein said first and second end portions both comprise a respective second cavity extending around the respective coupling seat.
  • 22. Pedal crank according to claim 11, wherein said pedal crank is a left pedal crank.
  • 23. Pedal crank according to claim 22, wherein said elongated body has a first face intended to face a bicycle frame and a second face opposite said first face and wherein said second reinforcement structure is arranged in said elongated body so that, at said first end portion of the pedal crank, said second reinforcement structure is closer to said first face than to said second face.
  • 24. Pedal crank according to claim 11, wherein said elongated body further comprises, at at least one of said end portions, at least one holding element of a portion of said second reinforcement structure.
  • 25. Pedal crank according to claim 24, wherein said at least one holding element is defined by a ring nut.
  • 26. Pedal crank according to claim 11, wherein said pedal crank is a right pedal crank and comprises, at said first end portion, a plurality of spokes.
  • 27. Pedal crank according to claim 26, wherein said elongated body has a first face intended to face a bicycle frame and a second face opposite said first face, wherein said second reinforcement structure is arranged in said elongated body so as to be closer to said second face than to said first face.
  • 28. Intermediate product for manufacturing a bicycle pedal crank, comprising: a core having an elongated body extending along a longitudinal axis X-X; anda sheet of composite material wound around said core and around said longitudinal axis X-X and comprising at least one layer of structural fibers, said sheet extending longitudinally for a part not longer than the longitudinal extension of said core.
  • 29. Intermediate product according to claim 28, wherein said sheet of composite material comprises unidirectional continuous structural fibers incorporated in a polymeric material.
  • 30. Intermediate product according to claim 28, further comprising at least one bundle of unidirectional continuous structural fibers arranged between said core and said sheet.
  • 31. Intermediate product according to claim 28, further comprising at least one first layer of filling material capable of flowing under pressure and arranged between said core and said sheet.
  • 32. Method for manufacturing a bicycle pedal crank, comprising the steps of: providing a core adapted to define an inner portion substantially without structural strength of a pedal crank, said core comprising an elongated body extending along a longitudinal axis X-X;providing two forming elements of opposite end portions of said pedal crank;providing an intermediate product by axially winding a first reinforcement structure comprising at least one layer of unidirectional continuous structural fibers around said core;inserting said intermediate product into a cavity of a mold together with said two forming elements and with at least one mass of filling material comprising a polymeric material and capable of flowing under pressure, said mold being equipped with a pressure element and said cavity having the shape of said pedal crank;applying a predetermined pressure to said pressure element to make said filling material flow into said cavity;heating said mold to a temperature corresponding to a cross-linking temperature of said polymeric material; andopening said mold and removing the formed pedal crank.
  • 33. Method according to claim 32, wherein said step of providing an intermediate product comprises the step of winding at least one bundle of unidirectional continuous structural fibers in a loop around said two forming elements and around said core.
  • 34. Method according to claims 32, wherein said core consists of a metallic material having a low melting point, said method further comprising, after said step of heating said mold, the steps of: forming at least one hole on a surface of said pedal crank; andheating said pedal crank up to the melting point of said metallic material having a low melting point to allow it to flow out.
  • 35. Method according to claim 34, wherein said melting point is higher than the cross-linking temperature of said polymeric material by a value ΔT of between about 1° C. and about 25° C.
  • 36. Method according to claim 35, wherein said melting point is higher than the cross-linking temperature of said polymeric material by a value ΔT equal to about 5° C.
  • 37. Method according to claims 32, wherein said cross-linking temperature is between about 60° C. and about 180° C.
  • 38. Method according to claim 32, further comprising, before said step of inserting said intermediate product or after said step of inserting said intermediate product and before said step of applying a predetermined pressure, the step of preheating said intermediate product and said at least one mass of filling material bringing it to a predetermined preheating temperature for a predetermined preheating time.
  • 39. Method according to claim 38, wherein said preheating temperature is between about 60° C. and about 100° C.
  • 40. Method according to claim 38, wherein said predetermined preheating time is between about 5 and about 70 minutes.
  • 41. Method according to claim 32, wherein said predetermined pressure is between 5 and 400 bar.
  • 42. Method according to claim 33, wherein said bundle of fibers is housed in a pair of housing seats formed on opposite longitudinal sides of said core.
  • 43. Method according to claim 42, wherein each housing seat is defined by a side surface of said core and by a projecting surface that projects laterally from said side surface and said intermediate product is inserted into said cavity of said mold so that said pressure element acts upon a first portion of said bundle of fibers through said projecting surface.
  • 44. Method according to claim 43, further comprising the step of providing a holding element of a second portion of said bundle of fibers on at least one of said forming elements in such a way that said holding element acts upon said bundle of fibers on the opposite side to said projecting surface of said core.
  • 45. Bicycle pedal crank, having an elongated body extending along a longitudinal axis X-X comprising: a first end portion comprising a first seat for coupling with a bottom bracket of a bicycle;a second end portion comprising a second seat for coupling with a pedal;an intermediate portion extending between said first end portion and said second end portion and comprising an inner portion and a first reinforcement structure;wherein said first reinforcement structure comprises a tubular structure arranged around said inner portion and extending longitudinally no longer than the longitudinal extension of said intermediate portion,said inner portion is defined by a first cavity, andsaid first and second end portions comprise a composite material comprising structural fibers arranged randomly and incorporated in a polymeric material.
  • 46. Pedal crank according to claim 45, further comprising a second reinforcement structure defined by at least one bundle of unidirectional continuous structural fibers that extends longitudinally in said elongated body.
  • 47. Pedal crank according to claim 45, further comprising a second reinforcement structure defined by at least one bundle of unidirectional continuous structural fibers that extends longitudinally in said elongated body, wherein said pedal crank is a left pedal crank, andsaid elongated body has a first face intended to face a bicycle frame and a second face opposite said first face and wherein said second reinforcement structure is arranged in said elongated body so that, at said first end portion of the pedal crank, said second reinforcement structure is closer to said first face than to said second face.
  • 48. Bicycle pedal crank, having an elongated body extending along a longitudinal axis X-X comprising: a first end portion comprising a first seat for coupling with a bottom bracket of a bicycle;a second end portion comprising a second seat for coupling with a pedal;an intermediate portion extending between said first end portion and said second end portion and comprising an inner portion and a first reinforcement structure;wherein said first reinforcement structure comprises a tubular structure arranged around said inner portion and extending longitudinally no longer than the longitudinal extension of said intermediate portion,said inner portion is defined by a first cavity,said first and second end portions comprise a composite material comprising structural fibers arranged randomly and incorporated in a polymeric material, andsaid tubular structure comprises at least a layer of unidirectional or/and woven structural fibres.
  • 49. Bicycle pedal crank, having an elongated body extending along a longitudinal axis X-X comprising: a first end portion comprising a first seat for coupling with a bottom bracket of a bicycle;a second end portion comprising a second seat for coupling with a pedal;an intermediate portion extending between said first end portion and said second end portion and comprising an inner portion and a first reinforcement structure;wherein said first reinforcement structure comprises a tubular structure arranged around said inner portion and extending longitudinally no longer than the longitudinal extension of said intermediate portion,said inner portion is defined by a first cavity,said first and second end portions comprise a composite material comprising structural fibers arranged randomly and incorporated in a polymeric materialsaid tubular structure comprises at least a layer of unidirectional or/and woven structural fibres, andsaid unidirectional fibres are inclined with respect to the longitudinal axis of the pedal crank.
  • 50. Bicycle pedal crank, having an elongated body extending along a longitudinal axis X-X comprising: a first end portion comprising a first seat for coupling with a bottom bracket of a bicycle;a second end portion comprising a second seat for coupling with a pedal;an intermediate portion extending between said first end portion and said second end portion and comprising an inner portion and a first reinforcement structure;wherein said first reinforcement structure comprises a tubular structure arranged around said inner portion and extending longitudinally no longer than the longitudinal extension of said intermediate portion,said inner portion is defined by a first cavity.
  • 51. Bicycle pedal crank, having an elongated body extending along a longitudinal axis X-X comprising: a first end portion comprising a first seat for coupling with a bottom bracket of a bicycle;a second end portion comprising a second seat for coupling with a pedal;an intermediate portion extending between said first end portion and said second end portion and comprising an inner portion and a first reinforcement structure;wherein said first reinforcement structure comprises a tubular structure arranged around said inner portion and extending longitudinally no longer than the longitudinal extension of said intermediate portion,said first and second end portions comprise a composite material comprising structural fibers arranged randomly and incorporated in a polymeric material.
Priority Claims (1)
Number Date Country Kind
06425087.1 Feb 2006 EP regional