Solid, Multi-Plastic Handlebar

Abstract

A solid, multi-plastic handlebar is provided. The handlebar includes an inner substrate component made of a load-bearing, structural plastic material. In one embodiment, the substrate component includes a first set of circumferentially-spaced, longitudinally-extending locking members. The handlebar also includes an outer component overlying the substrate component and made of a plastic material less rigid than the plastic material of the substrate component. The outer component is configured to be gripped by a human hand. The outer component includes a second set of circumferentially-spaced, longitudinally-extending locking members which interlock with the first set of locking members to mechanically lock the substrate component and the outer component together.

Claims

1. A solid, multi-plastic handlebar comprising: an inner substrate component made of a load-bearing, structural plastic material; the substrate component including a first set of circumferentially-spaced, longitudinally-extending locking members; and an outer component overlying the substrate component and made of a plastic material less rigid than the plastic material of the substrate component, wherein the outer component is configured to be gripped by a human hand and wherein the outer component includes a second set of circumferentially-spaced, longitudinally-extending locking members which interlock with the first set of locking members to mechanically lock the substrate component and the outer component together.

2. The handlebar as claimed in claim 1, wherein both of the components are injection molded in a two-shot, injection molding process.

3. The handlebar as claimed in claim 2, wherein the plastic material of both components is thermoplastic.

4. The handlebar as claimed in claim 3, wherein the thermoplastics of the components are compatible so that the components adhere to each other.

5. The handlebar as claimed in claim 1, wherein the first set of locking members include a pair of head portions which extend radially outwardly in opposite directions from a base portion of the substrate component, the base portion extending radially outwardly in opposite directions substantially perpendicular to the head portions.

6. The handlebar as claimed in claim 1, wherein the outer component has a decorative, soft-touch finish.

7. A solid, multi-plastic handlebar for exercise equipment, the handlebar comprising: an inner substrate component made of a load-bearing, structural plastic material; the substrate component including a first set of circumferentially-spaced, longitudinally-extending locking members; and an outer component overlying and in contact with the substrate component and made of a plastic material less rigid than the plastic material of the substrate component, wherein the outer component is configured to be gripped by a human hand and wherein the outer component includes a second set of circumferentially-spaced, longitudinally-extending locking members which inter-engage with the first set of locking members to mechanically lock the substrate component and the outer component together.

8. The handlebar as claimed in claim 7, wherein both of the components are injection molded in a two-shot, injection molding process.

9. The handlebar as claimed in claim 8, wherein the plastic material of both components is thermoplastic.

10. The handlebar as claimed in claim 9, wherein the thermoplastics of the components are compatible so that the components adhere to each other.

11. The handlebar as claimed in claim 7, wherein the first set of locking members include a pair of head portions which extend radially outwardly in opposite directions from a base portion of the substrate component, the base portion extending radially outwardly in opposite directions substantially perpendicular to the head portions.

12. The handlebar as claimed in claim 7, wherein the outer component has a decorative, soft-touch finish.

13. A solid, multi-plastic handlebar for aerobic exercise equipment, the handlebar comprising: an inner substrate component made of a load-bearing, structural plastic material; and an outer component overlying and in contact with the substrate component and made of a plastic material less rigid than the plastic material of the substrate component, wherein the outer component is configured to be gripped by a human hand and wherein the inner and outer components have inter-engaging lobed profiles to mechanically lock the substrate component and the outer component together.

14. The handlebar as claimed in claim 13, wherein both of the components are injection molded in a two-shot, injection molding process.

15. The handlebar as claimed in claim 14, wherein the plastic material of both components is thermoplastic.

16. The handlebar as claimed in claim 15, wherein the thermoplastics of the components are compatible so that the components adhere to each other.

17. The handlebar as claimed in claim 13, wherein the inner substrate component has first set of locking members including a pair of head portions which extend radially outwardly in opposite directions from a base portion of the substrate component, the base portion extending radially outwardly in opposite directions substantially perpendicular to the head portions.

18. The handlebar as claimed in claim 13, wherein the outer component has a decorative, soft-touch finish.

19. The handlebar as claimed in claim 13, wherein the aerobic exercise equipment comprises an exercise bicycle.

20. The handlebar as claimed in claim 19, wherein the exercise bicycle comprises a stationary exercise bicycle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] FIG. 1 is an environmental, rear perspective view of a stationary exercise bike with a rider shown by phantom lines;

[0033] FIG. 2 is an exploded perspective view of a prior art handlebar assembly;

[0034] FIG. 3 is a top perspective view of the handlebar assembly of FIG. 2;

[0035] FIG. 4 is a side elevational view of the handlebar assembly of FIG. 2; and

[0036] FIG. 5 is a sectional view of a solid, multi-plastic handlebar taken along lines 5-5 of FIG. 1 and constructed in accordance with at least one embodiment of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0037] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0038] In two shot injection molding, a product is formed by injecting two different materials into the same mold. These materials are not injected simultaneously, but rather in succession. It is, however, done in one manufacturing step in which the product is not ejected from the mold between the two shots.

[0039] Two shot injection molding offers freedom to the designer, as it negates the use of multiple steps in manufacturing. It provides many advantages such as lower manufacturing cost, better aesthetics, and ergonomics, superior mechanical bonds and lower production times. The process of two shot injection molding can manufacture ergonomically designed products to perfection. Structural plastic can easily be covered or added on using materials that are more suited for human interface. Soft, rubbery material is better equipped for the human hand as it provides a grip and a softer touch.

[0040] Referring now to the drawing FIGS. 1 and 5, there is illustrated an exercise bicycle, generally indicated at 11, including a solid, multi-plastic handlebar, generally indicated at 10. The handlebar 10 includes an inner substrate component, generally indicated at 12, made of a load-bearing, structural plastic material. The substrate component 12 including a first set of circumferentially-spaced, longitudinally-extending locking members 14.

[0041] The handlebar 10 also includes an outer component, generally indicated at 16, overlying and in contact with the substrate component 12 and made of a plastic material less rigid than the plastic material of the substrate component 12. The outer component 16 is configured to be gripped by a human hand as shown in FIG. 1. The outer component 16 includes a second set of circumferentially-spaced, longitudinally-extending locking members 18 which interlock or inter-engage with the first set of locking members 14 to mechanically lock the substrate component 12 and the outer component 16 together. In other words, the inner and outer components 12 and 16 have inter-engaging lobed profiles to mechanically lock the components 12 and 16 together.

[0042] Both of the components 12 and 16 are preferably injection molded in a two-shot, injection molding process. The plastic material of both components 12 and 16 is thermoplastic. The thermoplastics of the components 12 and 16 are compatible so that the components adhere to each other.

[0043] The first set of locking members 14 include a pair of head portions 20 which extend radially outwardly in opposite directions from a base portion 22 of the substrate component 12. The base portion 22 extends radially outwardly in opposite directions substantially perpendicular to the head portions 20.

[0044] The outer component 16 preferably has a decorative, soft-touch finish.

[0045] The handlebar 10 may be used for exercise equipment such as aerobic exercise equipment like the stationary exercise bike 11 of FIG. 1.

[0046] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.