The present invention relates to a bicycle frame (100) and a method of production thereof. In one embodiment the bicycle frame (100) comprises a first hollow tube part (10) comprising a first thermoplastic fiber reinforced composite comprising a thermoplastic matrix and an embedded structure of fibers (11, 12); and a second hollow tube part (20) comprising at least a first fiber reinforced shell part (21) and a second fiber reinforced shell part (22) each comprising a second thermoplastic fiber composite. According to the method a fused interconnect is formed having an overlap (30) between the first hollow tube part (10) and the second hollow tube part (20), wherein the embedded structure of fibers (11, 12) of the first hollow tube part (10) at the overlap (30) crosses an overlap (30) between the hollow tube parts (10, 20).

The present invention relates to a bicycle frame (100) and a method of production thereof. In one embodiment the bicycle frame (100) comprises a first hollow tube part (10) comprising a first thermoplastic fiber reinforced composite comprising a thermoplastic matrix and an embedded structure of fibers (11, 12); and a second hollow tube part (20) comprising at least a first fiber reinforced shell part (21) and a second fiber reinforced shell part (22) each comprising a second thermoplastic fiber composite. According to the method a fused interconnect is formed having an overlap (30) between the first hollow tube part (10) and the second hollow tube part (20), wherein the embedded structure of fibers (11, 12) of the first hollow tube part (10) at the overlap (30) crosses an overlap (30) between the hollow tube parts (10, 20).

An electric mobility apparatus that can include at least one electric carbon fiber component. The electric carbon fiber component incorporating a structural battery, the structural battery including energy storage devices, each of the energy storage devices having an anode core of a continuous carbon fiber, an electrolyte arranged on the at least one continuous carbon fiber core, and a cathode layer arranged to the continuous carbon fiber core on the electrolyte. An interface is electrically connected to the structural battery, the interface for inputting power for charging the structural battery and for outputting power.

An electric mobility apparatus that can include at least one electric carbon fiber component. The electric carbon fiber component incorporating a structural battery, the structural battery including energy storage devices, each of the energy storage devices having an anode core of a continuous carbon fiber, an electrolyte arranged on the at least one continuous carbon fiber core, and a cathode layer arranged to the continuous carbon fiber core on the electrolyte. An interface is electrically connected to the structural battery, the interface for inputting power for charging the structural battery and for outputting power.

A seat rail installed on a vehicle body of a motorcycle. The seat rail includes an upper lateral member located on a lateral side in a width direction of the vehicle body and made of a fiber reinforced resin, the upper lateral member including a lower flange that protrudes in the width direction of the vehicle body from a lower edge of the upper lateral member. Furthermore, the seat rail includes a lower lateral member located downward from the upper lateral member and made of metal, and a lower surface of the lower flange of the upper lateral member is joined to an upper surface of the lower lateral member by adhesive.

A seat rail installed on a vehicle body of a motorcycle. The seat rail includes an upper lateral member located on a lateral side in a width direction of the vehicle body and made of a fiber reinforced resin, the upper lateral member including a lower flange that protrudes in the width direction of the vehicle body from a lower edge of the upper lateral member. Furthermore, the seat rail includes a lower lateral member located downward from the upper lateral member and made of metal, and a lower surface of the lower flange of the upper lateral member is joined to an upper surface of the lower lateral member by adhesive.

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 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.

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.

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.