Bicycle component and method for manufacturing such a component

Abstract

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.

Claims

1. A semi-finished product for manufacturing an elongated body of a bicycle component having structural fibers incorporated in a matrix of polymeric material for mechanically coupling to at least one element of a bicycle and to transmit force, wherein the semi-finished product comprises: at least one first layer comprising continuous unidirectional structural fibers that are unidirectionally incorporated in a matrix of polymeric material, at least one second layer comprising small pieces of structural fibers incorporated in a matrix of polymeric material and randomly dispersed with respect to each other inside the at least one second layer, and a third layer of continuous unidirectional structural fibers arranged according to a direction complementary to a direction of said unidirectional fibers of said at least one first layer, wherein said at least one first layer and said at least one second layer overlap one another, and said at least one first layer and said at least one second layer are rolled around each other along a rolling axis.

2. The semi-finished product of claim 1, wherein said directions of said unidirectional fibers of said at least one first layer and third layer are +45 and 45 respectively.

3. The semi-finished product of claim 1, wherein said at least one first layer, said at least one second layer and third layer are arranged one next to the other wherein said at least one second layer is not between the other two.

4. The semi-finished product of claim 1, wherein said at least one first layer, said at least one second layer and said third layer of structural fibers are rolled along the rolling axis so that in rolled configuration said at least one first layer or said at least one second layer is on the outside.

5. The semi-finished product of claim 1, wherein the semi-finished product comprises any number of overlapping layers having structural fibers selected from the group consisting of: unidirectional fibers, fibers arranged at two or more incident angles forming a fabric configuration, fibers arranged complementary to the unidirectional fibers and fibers arranged +45 and 45 complementary to the unidirectional fibers.

6. An element body for use in manufacturing a bicycle component, the element body comprising: a predetermined configuration formed of multiple, overlapping layers of polymeric material including: at least one first layer comprising continuous unidirectional structural fibers that are unidirectionally incorporated in a matrix of polymeric material, at least one second layer comprising small pieces of structural fibers randomly dispersed with respect to each other and incorporated in a matrix of polymeric material, and a third layer of continuous unidirectional structural fibers arranged according to a direction complementary to a direction of said unidirectional fibers of said at least one first layer, wherein said at least one first layer and said at least one second layer are rolled around each other along a rolling axis.

7. An element body for use in manufacturing a bicycle component, the element body comprising: a predetermined configuration formed of: (i) multiple, overlapping layers of polymeric material including: at least one first layer comprising continuous unidirectional structural fibers that are unidirectionally incorporated in a matrix of polymeric material, at least one second layer comprising small pieces of structural fibers randomly dispersed with respect to each other and incorporated in a matrix of polymeric material, and a third layer of continuous unidirectional structural fibers arranged according to a direction complementary to a direction of said unidirectional fibers of said at least one first layer; and (ii) continuous winding of continuous layers of unidirectional fibers along suitable paths that define the element body's shape, wherein said at least one first layer and said at least one second layer are rolled around each other along a rolling axis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further characteristics and advantages of the invention shall become clearer from the description of some preferred embodiments, given with reference to the attached drawings, where:

(2) FIG. 1 represents a schematic isometric view of the component of the invention.

(3) FIG. 2 represents a section view from above of the component of FIG. 1.

(4) FIG. 3 represents an alternate embodiment of the component of FIG. 1.

(5) FIG. 4 represents an elevated section view of the component of FIG. 3.

(6) FIGS. 4A, 4B and 4C represent elevated section views of alternate embodiments of the component of FIG. 3.

(7) FIG. 5 represents another alternate embodiment of the component of FIG. 1.

(8) FIGS. 6 to 11 represent different isometric views of the semi-finished product of the invention.

(9) FIG. 12 represents an exploded isometric view of the mold used for manufacturing the component of the invention.

(10) FIG. 13 represents an isometric view of a detail of FIG. 12.

(11) FIG. 14 represents an exploded isometric view of a mold used for manufacturing an alternate embodiment of the component of the invention.

(12) FIG. 15 represents an isometric view of an alternate embodiment relative to the progression of the continuous layers of structural fibers in a branched pedal crank.

(13) FIG. 16 represents a plan view of FIG. 15.

(14) FIG. 17 represents another alternate embodiment relative to the progression of the continuous layers of structural fibers in a branched pedal crank.

(15) FIG. 18 represents an isometric view of a further alternate embodiment relative to the progression of the continuous layers of structural fibers in a branched pedal crank.

DETAILED DESCRIPTION OF THE INVENTION

(16) With reference to FIG. 1, the layers of continuous structural fibers 13 and 14 are made with unidirectional fibers orientated substantially parallel to the middle plane through the component, in this case a pedal crank 1. Middle plane is a substantially flat surface that intersects the pedal crank 1 longitudinally and divides it substantially in half along its height H. Given the typical shape of the pedal crank 1, such a surface is slightly curved when one moves from one end 11 to the other 12 of the pedal crank 1.

(17) Typically, said continuous structural fibers are chosen from the group consisting of carbon fibers, glass fibers, boron fibers, aramidic fibers, ceramic fibers, carbon fiber being preferred.

(18) As it can be clearly seen in FIG. 2, the layers of continuous structural fibers 13 and 14 surround the end zones 9 and 10 of seats 5 and 6, in a single closed loop 15 of unidirectional fibers that extend longitudinally along the body 2 of the pedal crank 1. This configuration could be different, like for example a series of unidirectional structural fibers surrounding the two seats 5 and 6 according to a typical figure-eight configuration.

(19) In FIG. 2, the layers of continuous structural fibers 13 and 14 are provided only in a part of the thicknesses S1 and S2 of the end zones 9 and 10 and can, at most, also be reduced to a single layer. Such layers 13 and 14 are provided only for a part of the height H of the pedal crank component 1 and are confined in height by means of an annular retainer element 16, coaxial to the insert 7.

(20) The arrangement of a limited number of layers 13 and 14 of fibers in the pedal crank 1 implies that the inserts 7, 8 are substantially covered with the composite material 18 with which the body 2 of the pedal crank 1 is formed, as can be seen more clearly in FIG. 2.

(21) A different solution is shown in FIGS. 3 and 4, wherein the layers of continuous structural fibers 33 and 34 substantially fill the thicknesses of both S1 and S2 of the end zones 29 and 30 of the pedal crank 20. In this solution the composite material 38, with which the body 2 of the pedal crank 1 is formed, is confined inside loop 35 defined by the layers of continuous fibers 33 and 34.

(22) The alternate embodiments shown in FIG. 4A differ from the solution shown in FIG. 4 for the fact that the body 2 has a core C filled with a material having a lower specific weight than the composite material 38.

(23) In the embodiments shown in FIG. 4B and FIG. 4C the core C is removed after molding, so that the weight of the pedal crank is reduced.

(24) FIG. 5 shows an alternate embodiment of the arrangement of the layers of continuous structural fibers 53 and 54 wherein the layers completely and separately surround the two seats 45 and 46 and the corresponding metal inserts 47 and 48.

(25) As can be seen with reference to FIGS. 1-2, the component 1 has, at its end parts 3 and 4, respective seats 5 and 6 for mechanical coupling with a bottom bracket and with a pedal of the bicycle. The seats 5 and 6 incorporate cylindrical metal inserts 7 and 8 in which holes, not shown, are formed to connect the inserts 7 and 8 the bottom bracket and to the pedal, respectively.

(26) In an alternate embodiment, the seats 5 and 6 comprise a hole of a suitable shape adapted to allow the direct connection of the pedal crank to the bottom bracket and to the pedal or else the subsequent insertion of metal inserts.

(27) In the two end zones 9 and 10 of the pedal crank 1, between the seats 5 and 6 and ends 11 and 12 of the body 2 of the pedal crank 1, there are layers of continuous structural fibers 13 and 14 that surround the end zones 9 and 10 of the seats 5 and 6, as previously described. Such layers of continuous structural fibers 13 and 14 ensure that in such end zones 9 and 10 there is structural and mechanical continuity.

(28) In different embodiments, the layers of continuous structural fibers can take different shapes and sizes. For example, such layers can extend, at the end zone, for the entire height H of the pedal crank 1. Moreover, such layers can be made of interwoven structural fibers according to at least two incident directions to make a fabric. In a preferred embodiment, such a fabric comprises a majority of fibers orientated according to a direction parallel to the middle plane of the pedal crank 1. Finally, it is possible that in further embodiments there are a plurality of layers of continuous structural fibers, according to any combination of the continuous layers described above.

(29) The pedal crank 1, and specifically its elongated body 2, is formed from a semi-finished product, indicated as 60 in FIG. 6, consisting of three layers. Each of the layers is formed as a sheet of material. As used hereinafter in the description and claims, the term sheet refers to a defined thickness of material forming either an individual layer, or one of a plurality of independent or joined layers of a structure. One layer 61 is formed of small lengths of structural fiber 61a incorporated in a matrix of polymeric material and randomly arranged within the layer 61 and two layers 62 and 63 are formed of continuous structural fibers 62a and 63a which are incorporated in a matrix of polymeric material and orientated according to directions which are preferably angled relative to each other. The layers 61, 62 and 63 overlap one another and give the semi-finished product 60 characteristics of structural strength through the unidirectional fibers 62a and 63a and good characteristics of fluidity through the sheeted structure 61a, this last characteristic being exploited in the molding step of the pedal crank 1.

(30) With regards to the continuous structural fiber, the small lengths of structural fibers are chosen from the group consisting of carbon fiber, glass fibers, boron fibers, aramidic fibers, and ceramic fibers, carbon fiber being preferred.

(31) The polymeric material may be a thermosetting plastic material or a thermoplastic material.

(32) The arrangement and number of layers, as well as the directions of the structural fibers, can be chosen according to the particular properties of desired structural strength of the component. For example, in FIG. 7 layer 61 is arranged between layers 62 and 63.

(33) The embodiment of FIG. 8 differs from that of FIG. 6 in that the unidirectional fibers 72a and 73a are incorporated in the matrix of polymeric material of respective layers 72 and 73 in complementary directions and are respectively orientated at +90 and 0.

(34) In FIG. 9 the semi-finished product comprises a layer of small lengths of structural fibers 61a incorporated in a matrix of polymeric material overlapping a single layer 63 formed of continuous structural fibers 63a orientated on a bias within layer 63.

(35) In FIG. 10 the semi-finished product comprises a layer of small lengths of structural fibers 61a and a layer 81 in which the continuous structural fibers 81a are arranged according to two incident directions and form a fabric configuration.

(36) Finally, in FIG. 11 a semi-finished product formed of five layers is shown. Two layers 91 and 93 are formed of small lengths of structural fibers incorporated in a matrix of polymeric material intercalated in three layers 92, 94 and 95 formed of continuous structural fibers of adjacent layers in which the fibers are orientated at an angle relative to each other.

(37) The semi-finished product 60 used for manufacturing the body 2 of the pedal crank 1, according to any of the above illustrated embodiments and all other possible configurations, are preferably rolled around a rolling axis before the molding step, as described below. This allows the characteristics of unidirectional strength of the structural fibers to be spatially distributed.

(38) Referring now to FIG. 12, the method for manufacturing the pedal crank 20 shown in FIG. 3 is described. However, it should be understood that the same method can be used for the other embodiments shown or described, for example those of FIGS. 1 and 5.

(39) The method provides for the use of a mold 100 which comprises three parts, two half-shells 101 and 102 and a plunger 103. The upper half-shell 102, as seen more clearly in the bottom view of FIG. 13, has a through-opening 104 which allows the passage and the sliding of a press element 105 of the plunger 103.

(40) A first step of the method provides for the formation of an intermediate product 110 comprising the inserts 7 and 8 on which the layers of continuous unidirectional structural fibers are wound in a closed loop configuration 35. Such an intermediate product 110 can be realized, for example, by winding a long fiber around the inserts 7, 8 in a number of layers sufficient to obtain a desired thickness and height. In particular, the arrangement of the fibers around the insert 7 is defined through retainer loop 16 which confines them in an upper portion of the insert 7. Experience has demonstrated that it is precisely such an area that is subjected to the greatest torsional stress during pedaling, thus requiring a greater structural strength.

(41) The intermediate product 110 thus obtained is placed inside the lower half-shell 101 above which the upper half-shell 102 is closed so that its shapings 102a and 102b (FIG. 13) are in contact with the heads of the metal inserts 7 and 8.

(42) When the half-shells 101 and 102 of mold 100 are closed, the semi-finished product 60 previously wound around the rolling axis A is inserted in through opening 104. The winding of the semi-finished product 60 is arranged so that its outer surface consists of layer 63 formed of unidirectional fibers 63a. The semi-finished product 60 is pre-heated to ease the subsequent molding.

(43) After its insertion in the mold 100, the wound semi-finished product 60 is then located in the zone defined between the inserts 7 and 8 and the inner part of the loop 35. When the plunger 103 is lowered, the presser tool 105 slides inside the opening 104 of the upper half-shell 102 urging the semi-finished product 60 inside the mold 100. During such a molding step, the semi-finished product 60 flows into and uniformly fills the recess defined by the two half-shells 101 and 102. The closed loop configuration 35 of the unidirectional fibers allows them to keep their continuous configuration even during molding, since the pressure forces applied by the composite material which constitutes the semi-finished product 60 are uniformly distributed along the loop 35. After insertion of the presser tool 105, the mold 100 is heated, according to known techniques, and the materials inside of mold 100 polymerizes in the desired pedal crank structure. Finally, the mold 100 is opened and the pedal crank is removed.

(44) It is clear that for the described method any of the semi-finished products described above with reference to FIGS. 6-11 can be used, possibly even in a non-wound configuration. If one wishes to manufacture the pedal crank according to the shape shown in FIG. 5, it is then advisable for the intermediate product, in this case comprising the inserts on which the unidirectional fibers are individually wound, to undergo a prepolymerization treatment, so that the subsequent molding does not modify the shape of the wound fibers.

(45) Alternatively, the component may further comprise a core C as depicted in FIGS. 4A, 4B and 4C. In the manufacture of the component of FIG. 4A, a mold 100 is provided, having first and second portions 101, 102 and plunger 103 as shown in FIG. 12. An intermediate product 110 is first formed comprising first and second inserts 7, 8, about which layers of continuous unidirectional structural fibers are wound in a closed loop configuration 35. A core C is then arranged in the area within the closed loop of unidirectional structural fibers.

(46) Once the intermediate product 110 is in position in the first mold portion 101, the second portion 102 is closed above the first portion so that shapings 102a and 102b contact the upper portions of the inserts 7, 8. When the first 101 and second 102 mold portions are closed about the intermediate product 110, a composite material 38 is inserted into an opening 104 of the second portion 102 of the mold 100. The composite material 38 comprises small lengths of randomly arranged structural fibers incorporated in a matrix of polymeric material. Next, the plunger 103 is lowered, to force presser 105 into the opening 104 of the second mold portion 102. The presser 105 forces the composite material 38 into the mold 100. During this step the composite material 38 flows into the mold 100 and uniformly fills the recess defined by the first and second mold portions 101, 102 thereby enclosing the core C. With the presser 105 inserted, the mold is heated to a temperature sufficient to polymerize the composite material 38, thereby producing the desired pedal crank structure. The mold is then opened and the pedal crank is removed. The core C is made of a material having a lower specific weight than the composite material 38. The weight of the pedal crank with the core enclosed is less than the weight of the pedal crank completely made of composite material.

(47) In the manufacture of the component of FIG. 4B, a mold 100 is provided, having first and second portions 101, 102 and plunger 103 as shown in FIG. 12. An intermediate product 110 is first formed comprising first and second inserts 7, 8, about which layers of continuous unidirectional structural fibers are wound in a closed loop configuration 35. A core C made of a removable material is then arranged in the area within the closed loop of unidirectional structural fibers. The core helps to maintain the position of the closed loop of unidirectional structural fibers 35 and inserts 7, 8.

(48) Once the intermediate product 110 is in position in the first mold portion 101, the second portion 102 is closed above the first portion so that shapings 102a and 102b (FIG. 13) contact the upper portions of the inserts 7, 8. When the first 101 and second 102 mold portions are closed about the intermediate product 110, a composite material is inserted into an opening 104 of the second portion 102 of the mold 100. The composite material 38 comprises small lengths of randomly arranged structural fibers incorporated in a matrix of polymeric material. Next, the plunger 103 is lowered, to force presser 105 into the opening 104 of the second mold portion 102. The presser 105 forces the composite material 38 into the mold 100. During this step the composite material 38 flows into the mold 100 and uniformly fills the recess defined by the first and second mold portions 101, 102 thereby enclosing the core C. With the presser 105 inserted, the mold is heated to a temperature sufficient to polymerize the composite material 38, thereby producing the desired pedal crank structure. The mold is then opened and the pedal crank is removed.

(49) Small openings D1, D2 are formed to remove the core material from the crank structure. The openings D1, D2 may be formed by drilling or other known methods. Two or more openings are preferred to allow for better air exchange between the core and the ambient space which aids in removing the core material. The core material may be sand, a powdered material or a metallic alloy having a low melting point. A core of sand or powdered material can be removed from the crank by falling through the openings D1, D2 under the force of gravity. If a metallic alloy is used as the core, it may be removed simply by heating the crank above the alloy's melting point and allowing the melted core to flow through the openings D1, D2. Removal of the core material may also be expedited by blowing high-pressured air or fluid through one of the openings. Once the core material has been removed, the openings are then sealed to prevent contaminants from entering the pedal crank. The weight of the pedal crank is further reduced with respect to weight of the pedal crank above described by removal of the core material.

(50) A similar method as above for manufacturing the pedal crank of FIG. 4B can be used for manufacturing the pedal crank of FIG. 4C. In this case, rather than a metal insert, a support is used for the winding of the unidirectional fibers. The support remains incorporated in the pedal crank whereby a seat can be formed, by machining, for the insertion of a metal insert. In this embodiment, the removal of the core material takes place through openings D3 and D4 before the insertion of the metal insert.

(51) FIG. 14 shows a variation of the mold shown in FIG. 12 which is used for manufacturing a branched pedal crank, commonly known as right pedal crank. Such a method differs from the previous one in that the semi-finished product, when inserted in the mold 200, covers the top of the metal insert intended for coupling with the bottom bracket. In this case, the metal insert can be accessed by machining away excess material left over from the molding process. Rather than the metal insert, a support can be used for the winding of the unidirectional fibers. The support remains incorporated in the pedal crank, through machining, for direct coupling with a bottom bracket or the insertion of a metal insert. It is also clear that the mold 200 can be modified so as to obtain a right pedal crank in which the insert intended for coupling with the bottom bracket is also immediately accessible.

(52) FIGS. 15 and 16 show the arrangement of the layers of continuous structural fibers 413a, 413b, 413c, 413d for manufacturing another branched pedal crank, commonly referred to as a right pedal crank.

(53) In such a case it is desired to ensure high structural and mechanical continuity of end parts 403a, 403b, 403c, 403d of the spokes of intermediate product 400, four in this embodiment, where respective seats 405a, 405b, 405c, 405d which allow connection of front chain rings of the bicycle are formed. The seats 405a, 405b, 405c, 405d can incorporate respective metal inserts in which suitable holes for connection to the chain rings are formed. Alternatively, they can comprise a hole of such a suitable shape and size as to allow the direct connection of the chain rings to the branches of the pedal crank. For the sake of simplicity of explanation, no insert is shown in the figures.

(54) As shown in FIGS. 15 and 16, the layers of continuous structural fibers 413a, 413b, 413c, 413d partially surround the seats 405a, 405b, 405c, 405d of the end parts 403a, 403b, 403c, 403d of the spokes which form an arc of circumference of about 180. These layers are each arranged in such a way as to form respective loops 415a, 415b, 415c, 415d which close on a central zone 414 where the pedal crank has a suitable seat 406 for connecting to the bottom bracket.

(55) The structural fibers thus arranged define an intermediate product 400 which is star-shaped. As shown in FIG. 15, intermediate product 400 is advantageously made through continuous winding, along suitable paths, of continuous layers of unidirectional fibers. The intermediate product 400 can be made either in the mold, i.e., inside the mold shown in FIG. 14, or it can be made separately using a mask which mirrors the shape of the spokes. The manufacturing of the intermediate product 400 separately allows for prior preheating of the fibers which allows them to be a pre-shaped before the positioning in loco into the mold.

(56) The intermediate product 400 is arranged within the mold 200 on a plane overlapping the one in which the closed loop of structural fibers 15 (represented in FIG. 2) is arranged, said fibers being arranged along the elongated body 2 of the pedal crank. The configuration thus obtained allows a right pedal crank to be manufactured having the zones intended for coupling with a pedal as well as with a bottom bracket and the ends of the spokes with high structural and mechanical continuity.

(57) In an alternate embodiment, shown in FIG. 17, each seat 405a, 405b, 405c, 405d can be completely surrounded by structural fibers 413a, 413b, 413c, 413d by using a closed loop configuration similar to the type shown in FIG. 5.

(58) The same result can be obtained by the manufacturing of a pre-formed product 500, as shown in FIG. 18, where the continuous layers of structural fibers associated with the spokes and with the main body are on the same plane and substantially constitute a single element comet-shape. As is the previous embodiment, the intermediate product 500 can either be formed within the mold or can be formed separately using a mask which mirrors the shape of the pedal crank.