A method for forming a resin-based composite structure is provided. The method includes: providing a prepreg layup, wherein the prepreg layup includes an epoxy resin-carbon fiber composite material; covering a thermal-fusion material on a surface of the prepreg layup; and performing a molding and curing process to fuse the thermal-fusion material with the prepreg layup. Wherein the molding and curing process includes: heating at a first temperature to melt, soften and fully fuse the thermal-fusion material with the prepreg layup; and heating at a second temperature to solidify the thermal-fusion material for forming the resin-based composite structure. Wherein the first temperature is lower than the second temperature.

A method of making a bicycle frame includes placing an impact resistant film into one or more portions of a bicycle frame mold. The method also includes placing a plurality of layers of carbon fiber into the bicycle frame mold. The method further includes applying heat to the bicycle frame mold to form a bicycle frame that has an exterior surface, wherein at least a portion of the exterior surface is covered by the impact resistant film.

A hybrid composite comprising a thermoplastic or thermoset matrix in which brittle and ductile fibers are present, wherein the fibers are configured such that the ductile fibers of the hybrid composite dissipate energy at a impact or overload by plastic deformation of the ductile fibers and show residual properties after impact or overload.

A cushion connecting rod of a saddled vehicle is configured in such a manner that an initial failure condition can be visually recognized in combination with fiber composite material and metal without using a special adhesive. A cushion connecting rod as a long member applied with a load when a swing arm is swung against a springing force of a rear cushion is configured in such a manner that a part of a surface of a metallic member is covered with an endless fiber-reinforced plastic. The fiber-reinforced plastic adheres to the surface of the metallic member with a film adhesive. Supporting portions applied with the load are provided at both ends in a longitudinal direction of the metallic member. A recessed portion and a plurality of lightening holes are formed between the supporting portions at both the ends, the recessed portion being configured in such a manner that a thickness dimension of the metallic member is set to be smaller than a thickness dimension of the supporting portions. The fiber-reinforced plastic covers surfaces of the supporting portions and the recessed portion.

The invention relates to an injection molding method of manufacturing a two-wheeler frame in which a melt of a thermoplastic is injected into a cavity of an injection molding tool before a portion of the plastic melt is displaced from the cavity again by a subsequent fluid injection to form the inner hollow space of the tubular frame, with the fluid flowing upward in the course of the displacement process.

Composite structures and methods of forming composite structures are provided. The composite structures can include one or more composite structure components. Each composite structure component is formed from a composite panel that includes one or more sheets of material. The sheets of material include a thermoplastic material and a plurality of reinforcing fibers. A composite panel can be formed in three dimensions to form a composite structure component. Multiple composite structure components can be fused to one another to form a composite structure. In addition, each composite structure component and the composite structure formed therefrom can include an aperture. An interior volume can be formed between adjacent composite structure components. Methods for forming a composite structure can include a step of simultaneously molding and fusing composite structure components.

A method for the manufacture of a fiber-composite article for a bicycle frame or other bicycle component uses an outer mold configured to define an outer surface of the fiber-composite article and an inner mold configured to define an inner surface of the fiber-composite article. The method comprises: securing in the inner mold a supportive armature for a space-filling mandrel, the mandrel being configured to occupy a space within the inner surface of the fiber-composite article during lay up and curing of the fiber-composite article; forming the mandrel by injection molding a solidifiable fluid into the inner mold, around the armature, the solidifiable fluid being configured to form a solidified, molded material; applying a fiber composition to the mandrel; securing the mandrel with the fiber composition in the outer mold; heating the fiber composition in the outer mold to form the fiber-composite article and concurrently heating the solidified, molded material. In this manner, the fiber composition is compressed into the outer mold due to expansion of the solidified, molded material.

Composite structures and methods of forming composite structures are provided. A composite structure as disclosed herein incorporates one or more composite structure components, such as composite panels and composite inserts. A composite panel is formed from one or more sheets of fiber reinforced thermoplastic material. Composite inserts can include one or more composite blocks or braided sleeves. A composite block can be formed as a stacked or molded structure from trimmings or waste produced during the formation of the composite structures. A braided sleeve can include a seamless, woven sleeve formed of reinforcing fibers and thermoplastic threads. In a completed composite structure, composite inserts are at least partially disposed within a volume defined by surfaces of composite panels. The various composite structures and inserts can be given a final shape and can be fused to one another in a molding and fusing step.

A method of manufacturing a composite rim includes following steps of: disposing a composite material on an outer surface of an air bag to form a semi-formed rim, wherein the air bag is a completely closed annular tube without any through opening on the outer surface and contains a thermal expansion material thereinside; disposing the semi-formed rim in a mold; and heating the thermal expansion material so that the thermal expansion material expands and inflates the air bag and the semi-formed rim is then solidified.

The disclosure relates to a method of manufacturing a component composed of a thermoplastic having at least one hollow space in the interior for a two-wheeler by means of plastic injection molding, said method comprising the following steps: closing the configured injection molding tool; injecting a plasticized thermoplastic melt into the closed injection molding tool; injecting at least one fluid into the closed injection molding tool to displace the plastic core from the interior of the component; and opening the injection molding tool and demolding the component. wherein the component is a handlebar.