The present invention relates to a method of assembling a rim, in particular a bicycle rim of composite material. The invention further relates to a rim obtainable by such a method.

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.

An integrally formed bearing free pedal includes a central axle and a pedal body. The pedal body has a rotation axis, and is provided with an axle bore formed along the rotation axis. The central axle has an installation portion and an opposite combination portion. The central axle and the pedal body are integrally molded. The combination portion is disposed in the axle bore. A rotation gap is formed between the periphery of the central axle and the axle bore, so as to allow the central axle to rotate with respect to the pedal body along the rotation axis. Thus, the pedal has no bearings and other related components, so as to be structurally simple, and the manufacturing cost is reduced.

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.

The invention relates to a bicycle frame made by injection molding pellets of a long glass fibre reinforced polypropylene composition having a core containing glass fibres and an impregnating agent and a sheath of polypropylene surrounding said core, wherein the pellets have an average length of at least 1 mm, the amount of the glass fibers is 10 to 70 wt % with respect to the composition and the polypropylene has a flexural modulus determined according to ASTM D790A of at least 1000 N/mm.sup.2.

A composite bicycle rim, and a process for manufacturing the rim, having a plurality of perforated spoke-attachment seats having spaced apart first and second areas of cut structural fibers. The second area has both end portions of cut structural fibers having a longitudinal dimension greater than the first area's cut structural fibers and continuous structural fibers. At least some of the end portions of the second area's cut structural fibers are mutually juxtaposed or interposed with respect to the second area's continuous structural fibers.

The invention relates to a bicycle frame made by injection molding pellets of a long glass fibre reinforced polypropylene composition having a core containing glass fibres and an impregnating agent and a sheath of polypropylene surrounding said core, wherein the pellets have an average length of at least 1 mm, the amount of the glass fibers is 10 to 70 wt % with respect to the composition and the polypropylene has a flexural modulus determined according to ASTM D790A of at least 1000 N/mm.sup.2.

A crank arm for a bicycle may include a body extending along a body axis and having a first body end and a second body end axially spaced apart from the first body end. The insert may also include an insert provided toward the first body end. The insert may include a base portion having a radially outer surface. At least one extension may extend outwardly from the radially outer surface and may be encased within a corresponding recess in the body whereby relative planar movement between the body and the at least one extension in a first plane. The retaining portion may have a retaining portion width measured in the first direction and the retaining width may be greater than the throat width thereby inhibiting relative radial movement between the at least one extension and the recess and preventing radial extraction of the extension from the corresponding recess.

The invention relates to a method of manufacturing a plastic frame for a two-wheeler having at least one hollow space in the interior by means of plastic injection molding having a series of method steps, wherein a fluid is injected to displace the plastic core from the component cavity after the injection of a preferably thermoplastic plastic melt into a closed injection molding tool.

Method for the producing of an extruded frame element with battery pack profile for use in a bicycle frame comprising a plurality of frame elements, where the frame elements are interconnected and constitute a structure with such great rigidity that the bicycle frame under ordinary loading does not change its geometrical shape, wherein the at least one frame element is extruded with variable material thicknesses in a given cross sectional profile, and a recess is made in the at least one extruded frame element, as well as a bicycle frame comprising such a frame element, wherein a stable bicycle frame with sufficient strength is achieved, and wherein the bicycle frame becomes as discreet as possible.