Claims
- 1. A frame for a wheeled vehicle comprising:
a front structural element having a top beam, having a first end and a second end, a down beam having a first end and a second end, the down beam first end being joined to the top beam first end, a seat beam having a first end and a second end, the seat beam first end being joined to the top beam second end, and the seat beam second end being joined to the down beam second end; an upper rear structural element having a left seat stay beam having a first end and a second end, a right seat stay beam having a first end and a second end, and a mounting portion configured for mounting to the front structural element, the mounting portion being formed by a joining of the left seat stay first end and the right seat stay first end; and a lower rear structural element having a left chain beam having a first end and a second end, a right chain beam having a first end and a second end, and a mounting portion configured for mounting to the frame, the mounting portion being formed by a joining of the left chain stay first end and the right chain stay first end; wherein the upper rear structural element is positioned closer to the top beam than is the lower structural element; wherein the upper rear structural element left seat stay second end is joined to the lower rear structural element left chain stay second end; wherein the upper rear structural element right seat stay second end is joined to the lower rear structural element chain stay second end; and wherein the upper rear structural element is mounted to the front structural element by a shock absorption mechanism.
- 2. A frame as recited in claim 1, wherein the upper and lower rear structural elements are joined at wheel drop outs.
- 3. A frame as recited in claim 1, wherein at least one of the front structural element and the rear structural element comprise a resin matrix and reinforcing fiber.
- 4. A frame as recited in claim 1, wherein at least one of the front structural element and the rear structural element comprises a filament wound composite.
- 5. A frame as recited in claim 1, further comprising:
a head tube, and a head cap, the head cap having a body portion and mounting protrusions extending from the body portion, the head cap body portion extending around the head tube, the head cap mounting protrusions being mounted to the right side of the front structural element, and being mounted to the left side of the front structural element.
- 6. A frame as recited in claim 1, further comprising:
a seat tube, and a seat cap, the seat cap having a body portion and mounting protrusions extending from the body portion, the seat cap body portion extending around the seat tube, the seat cap mounting protrusions being mounted to the right side of the front structural element, and the seat cap mounting protrusions being mounted to the left side of the front structural element.
- 7. A frame as recited in claim 1, further comprising:
a bottom bracket tube adjacent the juncture of the chain stay first ends and the seat beam, and a bottom bracket cap, the bottom bracket cap having a body portion and mounting protrusions extending from the body portion, the bottom bracket cap body portion extending around the bottom bracket tube, the bottom bracket cap mounting protrusions being mounted to the right side of the front structural element, to the left side of the front structural element, to the right side of the chain stay, and to the left side of the chain stay.
- 8. A frame as recited in claim 1, further comprising a reinforcing side element mounted to a side of the front structural element.
- 9. A frame as recited in claim 1, further comprising: a channel in a side of the front structural element.
- 10. A frame as recited in claim 8, further comprising:
a reinforcing side element installed in the channel.
- 11. A frame as recited in claim 1, further comprising:
a channel in a side of the rear structural element.
- 12. A frame as recited in claim 11, further comprising:
a reinforcing side element installed in the channel.
- 13. A frame as recited in claim 1, further comprising:
a left seat beam channel on the left side of the seat beam; an elongate reinforcing member installed in the left seat beam channel; a left top beam channel on the left side of the top beam; an elongate reinforcing member installed in the left top beam channel; a left down beam channel on the left side of the down beam; an elongate reinforcing member installed in the left down beam channel; a left seat stay channel on the left side of the seat stay; an elongate reinforcing member installed in the left seat stay channel; a left chain stay channel on the left side of the chain stay; an elongate reinforcing member installed in the left chain stay channel; a right seat beam channel on the right side of the seat beam; an elongate reinforcing member installed in the right seat beam channel; a right top beam channel on the right side of the top beam; an elongate reinforcing member installed in the right top beam channel; a right down beam channel on the right side of the down beam; an elongate reinforcing member installed in the right down beam channel; a right seat stay channel on the right side of the seat stay; an elongate reinforcing member installed in the right seat stay channel; a right chain stay channel on the right side of the chain stay; and an elongate reinforcing member installed in the right chain stay channel.
- 14. A frame as recited in claim 1, further comprising:
a channel in one of the structural elements, the channel having:
a main channel having a first depth, and a secondary channel having a second depth, the secondary channel being deeper than the main channel, and a reinforcing side element installed in the channel, the reinforcing side element having:
a main reinforcing member body of a first thickness, and a protrusion having a second thickness, wherein the second thickness exceeds the first thickness; wherein the reinforcing side element is installed in the channel so that the main reinforcing member body lies within and substantially covers the main channel; and wherein the protrusion lies within and substantially covers the secondary channel.
- 15. A frame as recited in claim 1, further comprising a track on the frame configured to accept a cable therein.
- 16. A frame as recited in claim 13, further comprising a track within one of the channels, the track being configured to accept a cable therein.
- 17. A frame as recited in claim 1, further comprising:
a channel in a side of the upper or lower rear structural element, a reinforcing side element installed in the channel, and a track within the channel, the track being configured to accept an elongate cable therein.
- 18. A frame as recited in claim 1, wherein one of the structural elements comprises:
a first thickness of resin matrix and reinforcing fiber, the first thickness having a first side and a second side, a second thickness of structural foam, the second thickness of structural foam having a first side and a second side, the first side of the second thickness being in contact with the second side of the first thickness, and a third thickness of resin matrix and reinforcing fiber, the third thickness having a first side and a second side, the first side of the third thickness being in contact with the second side of the second thickness.
- 19. A frame as recited in claim 1, wherein one of the structural elements comprises:
a first thickness of resin matrix and reinforcing fiber, a second thickness of structural foam, and a third thickness of resin matrix and reinforcing fiber; wherein the second thickness is disposed between the first thickness and the third thickness.
- 20. A frame as recited in claim 19, wherein one of the structural elements further comprises:
a channel in the second thickness of structural foam, and a reinforcing side element installed in the channel.
- 21. A frame as recited in claim 20, further comprising:
a track within the channel, the track being configured to accept an elongate cable therein.
- 22. A frame as recited in claim 19, wherein one of the structural elements further comprises:
a channel in the second thickness of structural foam, the channel having: a main channel having a first depth, and a secondary channel having a second depth, the secondary channel being deeper than the main channel, and a reinforcing side element installed in the channel, the reinforcing side element having:
a main reinforcing member body of a first thickness, and a protrusion having a second thickness, wherein the second thickness exceeds the first thickness; wherein the reinforcing side element is installed in the channel so that the main reinforcing member body lies within and substantially covers the main channel; and wherein the protrusion lies within and substantially covers the secondary channel.
- 23. A frame as recited in claim 22, wherein the first thickness of resin matrix and reinforcing fiber is a filament wound thickness; and
wherein the second thickness of resin matrix and reinforcing fiber is a filament wound thickness.
- 24 A structural element having a top, a bottom, a first flank and a second flank, the structural element comprising:
a first thickness comprising resin matrix and reinforcing fiber, the first thickness having a first side and a second side; a second thickness of structural foam, the second thickness of structural foam having a first side and a second side, the first side of the second thickness being in contact with the second side of the first thickness; a third thickness comprising resin matrix and reinforcing fiber, the third thickness having a first side and a second side, the first side of the third thickness being in contact with the second side of the second thickness; and a reinforcing side element installed on the first flank.
- 25. A process for manufacturing structural elements, the process comprising:
(a) selecting a mandrel of a desired shape, (b) filament winding reinforcing fiber with a resin matrix onto the mandrel resulting in a length of uncured filament wound component stock on the mandrel, (c) curing the length of filament wound component stock, (d) removing the mandrel from the component stock, and (e) forming a plurality of structural elements from the component stock.
- 26. A process for manufacturing structural elements, the process comprising:
(a) selecting a mandrel of a desired shape, (b) filament winding a first thickness of reinforcing fiber with a resin matrix onto the mandrel, (c) placing a thickness of structural foam onto the first filament wound thickness, (d) filament winding a second thickness of reinforcing fiber with a resin matrix onto the mandrel resulting in a length of uncured filament wound component stock on the mandrel, the component stock having a first filament wound thickness, a second filament wound thickness, and a structural foam thickness disposed between the first and the second filament wound thicknesses, (e) curing the length of filament wound component stock, (f) removing the mandrel from the component stock, and (g) forming a plurality of structural elements from the component stock.
- 27. A process for manufacturing bicycle frame components, the process comprising:
(a) manufacturing structural components according to the following steps:
(1) selecting a first mandrel of a desired shape, (2) filament winding a first filament wound thickness of reinforcing fiber with a resin matrix onto the first mandrel, (3) placing a thickness of structural foam onto the first filament wound thickness, (4) filament winding a second filament wound thickness of reinforcing fiber with a resin matrix onto the mandrel resulting in a length of uncured filament wound component stock on the first mandrel, the component stock having a first filament wound thickness, a second filament wound thickness, and a structural foam thickness disposed between the first and the second filament wound thickness, (5) curing the length of filament wound component stock, (6) removing the first mandrel from the component stock, and (7) forming a plurality of structural elements from the component stock; and (b) manufacturing cap elements according to the following steps:
(1) selecting a second mandrel of a desired shape, (2) filament winding reinforcing fiber with a resin matrix onto the second mandrel resulting in a length of uncured filament wound cap stock on the second mandrel, (3) curing the length of filament wound cap stock, (4) removing the second mandrel from the cap stock, and (5) forming a plurality of structural elements from the cap stock.
- 28. A method for constructing a frame for a vehicle having at least two wheels, the method comprising:
(a) obtaining a three-sided front structural element, the front structural element comprising a resin matrix and reinforcing fiber, (b) obtaining a rear structural element comprising a resin matrix and reinforcing fiber, (c) obtaining a head tube, a head cap, a seat tube, a seat cap, a bottom bracket tube and a bottom bracket cap, (d) joining the rear structural element to the front structural element, (e) joining the head tube to the front structural element with the head cap, (f) joining the seat tube to the front structural element with the seat cap, and (g) joining the bottom bracket tube to the front structural element and the rear structural element with the bottom bracket cap.
- 29. A method for constructing a frame for a vehicle having at least two wheels, the method comprising:
(a) filament winding a continuous front structural element having a left side and a right side, the front structural element having:
(1) a top beam having a first end and a second end, (2) a seat beam having a first end and a second end, and (3) a down beam having a first end and a second end, said top beam first end being connected to the seat beam first end, the top beam second end being connected to the down beam second end, the down beam first end being connected to the seat beam second end, and said front structural element comprising a first filament wound thickness, a second filament wound thickness, and a thickness of structural foam disposed between the first and second filament wound thicknesses; (b) filament winding a rear structural element having a right side and a left side, the rear structural element having:
(1) a seat stay having a first end and a second end, (2) a chain stay having a first end and a second end, (3) a first mounting protrusion integral with and extending from the seat stay first end, and (4) a second mounting protrusion integral with and extending from the chain stay first end, said rear structural element comprising a first filament wound thickness, a second filament wound thickness, and a thickness of structural foam disposed between the first and second filament wound thickness; (c) obtaining a head tube, a head cap, a seat tube, a seat cap, a bottom bracket tube and a bottom bracket cap; (d) joining the rear structural element to the front structural element by the first and second mounting protrusions; (e) joining the head tube to the front structural element with the head cap; (f) joining the seat tube to the front structural element with the seat cap; an (g) joining the bottom bracket tube to the front structural element and the rear structural element with the bottom bracket cap.
- 30. A method for manufacturing a bicycle fork leg element comprising:
(a) selecting a mandrel of a desired shape, (b) filament winding a thickness of reinforcing fiber with a resin matrix onto the mandrel to form a length of fork stock, (c) curing the length of filament wound fork stock, (d) removing the mandrel from the fork stock, and (e) forming a plurality of fork leg elements from the fork stock.
- 31. A method for manufacturing a fork leg element comprising:
(a) selecting a mandrel of a desired shape, (b) filament winding a first thickness of reinforcing fiber with a resin matrix onto the mandrel, (c) placing a thickness of structural foam onto the first filament wound thickness, (d) filament winding a second thickness of reinforcing fiber with a resin matrix onto the mandrel resulting in a length of uncured filament wound fork stock on the mandrel, the fork stock having a first filament wound thickness, a second filament wound thickness, and a structural foam thickness disposed between the first and the second filament wound thickness, (e) curing the length of filament wound fork stock, (f) removing the mandrel from the fork stock, and (g) cutting a plurality of fork leg elements from the fork stock.
- 32. A method for manufacturing a bicycle component comprising:
(a) selecting a mandrel of a desired shape, (b) filament winding a thickness of reinforcing fiber with a resin matrix onto the mandrel to form a length of wet component stock, (c) removing the mandrel from the wet component stock, (d) making a cut along the wet component stock, (e) placing a portion of the component stock on a mold, causing the portion to component stock to substantially conform to the shape of the mold, (f) curing the portion of component stock in place on the mold, and (g) removing the portion of component stock from the mold, resulting in a molded, cured component.
- 33. A fork for a vehicle, the fork comprising:
(a) a steer tube, the steer tube having:
(1) an elongate tubular main steer tube section having a first end, a second end, an exterior surface, and an interior passageway, the main steer tube comprising resin matrix and reinforcing fiber, (2) an upper insert having an upper portion and a lower portion, the lower portion being configured for installation into the main steer tube interior passageway so that the upper portion protrudes from the main steer tube facilitating installation of a component thereon, (b) a crown, the crown having:
(1) an upper receptacle configured for installation of the steer tube therein, and (2) a lower receptacle configured for installation of a leg member therein, and (c) a leg member having a first end and a second end, the leg member first end being installable into the lower receptacle, and the leg member second end being adapted for the installation of a wheel drop out thereon.
- 34. The fork as recited in claim 33, wherein the steer tube further comprises:
(3) a reinforcing sleeve, the reinforcing sleeve installed into the main steer tube internal passageway to reinforce the main steer tube.
- 35. The fork as recited in claim 34, wherein the main steer tube and the reinforcing sleeve are filament wound components.
- 36. The fork as recited in claim 33, wherein the leg member comprises a resin matrix and reinforcing fiber.
- 37. The fork as recited in claim 33, wherein the leg member is a filament wound component.
- 38. The fork as recited in claim 33, wherein the upper portion of the insert is threaded.
- 39. The fork as recited in claim 34, wherein a lower portion of the reinforcing sleeve is threaded.
- 40. A fork as recited in claim 33, wherein the leg member comprises:
(1) an upper half leg having a first upper half leg and a second upper half leg end, the first upper half leg end installed into the crown lower receptacle, the second upper half leg end having an opening with an internal diameter for installation of a lower half leg therein, and (2) a lower half leg having a first lower half leg end and a second lower half leg end, the second lower half leg end installed into a wheel drop out, the lower half leg first end having an external diameter, the lower half leg first end external diameter being not greater than the upper half leg second end opening internal diameter, the lower half leg first end being installed into the upper half leg second end opening.
- 41. A fork as recited in claim 40,
wherein the upper half leg is more rigid than the lower half leg, resulting in a leg member that is more rigid in the area of the leg member first end than in the area of the leg member second end.
- 42. A fork as recited in claim 41,
wherein the upper half leg has a first diameter at the upper half leg first end, and a second diameter at the upper half leg second end; and wherein the upper half leg is tapered between the upper half leg first end and the upper half leg second end so that the second diameter is smaller than the first diameter.
- 43. A fork as recited in claim 42, wherein the upper half leg second diameter approximates the lower half leg first end external diameter.
- 44. A fork as recited in claim 33, wherein the leg member comprises:
(1) an upper leg having a first upper leg end and a second upper leg end, the first upper leg end installed into the crown lower receptacle, the second upper leg end having an opening with an internal diameter adapted for installation of a mid leg therein, (2) a mid half leg having a first mid leg end and a second mid leg end, the mid leg first end having an external diameter, the mid leg first end external diameter being not greater than the upper leg second end opening internal diameter, the mid leg first end installed into the upper leg second end opening, and the mid leg second end having an opening with an internal diameter adapted for installation of a lower leg therein, and (3) a lower leg having a first lower leg end and a second lower leg end, the second lower leg end installed into a wheel drop out, the lower leg first end having an external diameter, the lower leg first end external diameter being not greater than the mid leg second end opening internal diameter, the lower leg first end being installable into the mid leg second end opening.
- 45. A fork as recited in claim 44, wherein the fork leg comprises a resin matrix and reinforcing fiber.
- 46. A fork as recited in claim 44, wherein the fork leg is a filament wound component.
- 47. A fork for a wheeled vehicle, comprising:
(a) a steer tube having a top end and a bottom end, the steer tube having a receptacle in its bottom end, (b) a first leg member having a first end and a second end, the first leg member first end terminating in a mounting protrusion and the first leg member second end being configured for joining with a wheel drop out, the first leg member comprising a resin matrix and reinforcing fiber, (c) a second leg member having a first end and a second end, the second leg member first end terminating in a mounting protrusion and the second leg member second end being configured for joining with a wheel drop out, the second leg member comprising a resin matrix and reinforcing fiber; and wherein the mounting protrusions are installed into the steer tube receptacle.
- 48. A fork as recited in claim 47, wherein each of the leg members includes:
(1) a first thickness of resin matrix and reinforcing fiber, (2) a second thickness of resin matrix and reinforcing material, and (3) a third thickness of structural foam disposed between the first thickness and the second thickness.
- 49. A fork for a wheeled vehicle, comprising:
(a) a steer tube; (b) a crown having a top and a bottom, the crown having a receptacle in its top into which the steer tube is installed; and (c) a unitary fork leg member having
(1) a center mounting section configured for mounting to the crown, (2) a right fork leg beginning at a right leg drop out end configured for joining with a wheel drop out and ending with the mounting section, and (3) a left fork leg beginning at a left leg drop out end configured for joining with a wheel drop out and ending with the mounting section; wherein the unitary fork leg member is a continuous piece from the right leg drop out end to the center mounting section to the left leg drop out end.
- 50. A fork as recited in claim 49, wherein in cross section the unitary fork leg member comprises:
(1) a first thickness of resin matrix and reinforcing fiber, (2) a second thickness of resin matrix and reinforcing material, and (3) a third thickness of structural foam disposed between the first thickness and the second thickness.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a continuation-in-part of U.S. patent application Ser. No. 08/794,044, filed Feb. 3, 1997, now U.S. Pat. No. 6,267,399, which is a continuation-in-part of U.S. patent application Ser. No. 08/294,421, filed Aug. 22, 1994, now U.S. Pat. No. 5,609,349; the disclosures of which are incorporated by reference herein.
Continuation in Parts (2)
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Number |
Date |
Country |
Parent |
08794044 |
Feb 1997 |
US |
Child |
09919774 |
Jul 2001 |
US |
Parent |
08294421 |
Aug 1994 |
US |
Child |
08794044 |
Feb 1997 |
US |