A seat rail structure installed on a vehicle body of a motorcycle. In such a seat rail structure, each of two lateral members and a first coupling member configured to allow a seat to be placed thereon has a laminated structure made of a fiber reinforced resin, each lateral member includes a vertical wall and an upper flange, the first coupling member includes two upper surface contact portions in contact with the upper flanges of the two lateral members, respectively, and two side surface contact portion extending downward from outer edges of the two upper surface contact portions, respectively, each upper surface contact portion is fastened to the upper flange being in contact with the upper surface contact portion, and each side surface contact portion is fastened to the vertical wall being in contact with the side surface contact portion.

A mold manufacturing method for monocoque bicycle components comprises the steps of i) providing a first female mold comprising a pair of first half molds delimiting first surfaces to circumscribe a first mold cavity to form first component portions; ii) providing a second female mold comprising a pair of second half molds delimiting second surfaces to circumscribe a second mold cavity to form second component portions; and iii) interposing at least part of third female molds between the first and second female molds, so that third surfaces delimited by the third female molds join with continuity the first and the second surfaces, the third surfaces being configured to form third component portions in a single piece with the first and second component portions. Step iii) comprises a sub-step of manufacturing at least part of the third surfaces of the third female molds by rapid prototyping.

A main body frame (100) for an electric motorcycle comprises a front fork support member (101) with a front fork through hole for loading a pivot stem of a front fork (200), the front fork through hole has a pivotal axis arranged in a central plane (P) of the main body frame; the main body frame further comprises a right and a left frame part (102, 105) arranged on opposite sides of the central plane of the main body frame, each having an elongated shape and being formed of an upper part (102a, 102b) and a lower part (102c, 102d), respectively at different sides of an elongation direction changing portion (102e), a first buffer member (120) attached, at opposite sides thereof, to the right and the left frame part, and crossing the central plane. wherein starting from the respective elongation direction changing portions thereof. the upper parts of the left and the right frame part extend inwardly towards the central plane so as to embrace the front fork support member, and are attached to opposite sides of the front fork support member, and a largest width (a7) of the main body frame in a width direction (Z) perpendicular to the central plane is 10 cm or more and 30 cm or less.

The present invention relates to a monocoque frame (100) for a motorcycle, comprising: a structural loop (102) formed of composite material, comprising a plurality of mounts for mounting components of the motorcycle; and at least one structural panel (104, 106) formed of composite material, removably mounted to an open side of the structural loop (102). The or each structural panel (104, 106) comprises at least one elongate formation (110a, 110b) for providing structural rigidity. The invention further relates to a motorcycle, such as an electric motorcycle, incorporating the monocoque frame.

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.

This leaning vehicle that turns in a leaning posture and has a leaning frame structure made of a material containing fiber-reinforced resin can achieve weight reduction and help reduce changes in ride quality. The vehicle includes a rear structure that leans to the left during a left turn and leans to the right during a right turn with respect to the left-right direction of the vehicle, and is made of a material containing carbon-fiber-reinforced resin, and a leaning frame structure damage notification unit that, when the rear structure receives an impact caused by a fall of the vehicle in the left direction or the right direction, and the impact damages a non-visible part of the rear structure, makes a notification of the damage.

This leaning vehicle that turns in a leaning posture and has a leaning frame structure made of a material containing fiber-reinforced resin can achieve weight reduction and help reduce changes in ride quality. The vehicle includes a rear structure that leans to the left during a left turn and leans to the right during a right turn with respect to the left-right direction of the vehicle, and is made of a material containing carbon-fiber-reinforced resin, and a leaning frame structure damage notification unit that, when the rear structure receives an impact caused by a fall of the vehicle in the left direction or the right direction, and the impact damages a non-visible part of the rear structure, makes a notification of the damage.

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.

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.