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.

A fiber composite laminate having one or more fiber layers, comprising a first laminate region and a second laminate region. In the first laminate region, the fiber layers of the fiber composite laminate are impregnated with a thermoplastic elastomer material. In the second laminate region, fiber layers of a first lamina of the fiber composite laminate are impregnated with the thermoplastic elastomer matrix, and fiber layers of at least one second lamina of the fiber composite laminate that is positioned on top of the first lamina are impregnated with a thermosetting polymer matrix.

A composite rim for a bicycle wheel that has a wall of structural fibers incorporated in a thermosetting polymeric material and a plurality of spoke attachment seats. The composite material includes at least one layer of woven bi-directional fibers where some fibers are in a nominal direction substantially parallel to the circumferential direction of the rim and some fibers are substantially orthogonal to the circumferential direction of the rim.

A reusable mandrel for forming flexible molding bladders. The mandrel comprises a base adapted to form a bladder opening and a secondary mandrel piece coupled to the base to form a complex mandrel shape. The secondary mandrel piece is adapted to be removable from the base when within a bladder formed on the mandrel to allow the base and the secondary mandrel piece to be removed from the bladder through the bladder opening without damaging the bladder. The reusable mandrel is configurable in a non-removable and a removable configuration.

Forming features in the surface of a bicycle component involves depositing a substance onto a substrate in a geometric pattern to form a transfer medium. Forming features may also involve positioning the transfer medium relative to an unformed bicycle component, and forming a negative of the geometric pattern in the bicycle component through the application of heat and/or pressure to the transfer medium and the unformed bicycle component. The transfer medium may be configured for use in the molding of carbon fiber reinforced plastic (CFRP) bicycle components and may include a substrate formed of a flexible material, and a geometric pattern formed of a hard material, the hard material different than the flexible material.

A method for making a bicycle crank arm includes (a) providing an inner frame unit, (b) winding a first bundle of unidirectional continuous fibers on the inner frame unit to form an intersecting pattern, (c) impregnating the intersecting pattern with a curable resin material to obtain an impregnated structure, and (d) molding the impregnated structure in a mold.

A method of bonding materials may comprise defining a bond interface between two materials in a cure zone on a surface of an object and heating the bond interface with sound waves. Heating the bond interface may include applying ultrasonic sound waves to the bond interface.

A method for producing a fiber composite laminate, including the steps of applying pressure and/or heat to a first preform, which has one or more dry fiber layers and a thermoplastic elastomer, such that the thermoplastic portion of the thermoplastic elastomer completely impregnates the dry fiber layers of the first preform in at least one first region and only partially impregnates the dry fiber layers in at least one second region and, in a thermosetting polymer matrix, impregnating and curing the fiber layers of the second region of the first preform that are still dry and have not been impregnated with the thermoplastic portion of the thermoplastic elastomer.

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.

A bicycle component is provided comprising an elongated body consisting of structural fibers incorporated in a matrix of polymeric material and having, in an end part thereof, a seat for the mechanical coupling of the component with an element of the bicycle. Also provided in the zone between the seat and the end of the body is a continuous layer of structural fibers which surround the seat and which ensure mechanical continuity in the aforementioned zone. The central part of the component comprises at least one first layer formed of continuous structural fibers incorporated in a matrix of polymeric material and at least one second layer formed of small pieces of structural fibers incorporated in a matrix of polymeric material and arranged randomly inside the layer, such layers overlapping each other.