Manufacturing method of thermoplastic composite bicycle frame

A manufacturing method of a thermoplastic composite bicycle frame comprising:

• a shell forming step:
• turning thermoplastic composite laminates into multiple separate shells by compression molding, wherein
• the multiple shells are capable of being assembled together;
• each one of the multiple shells has a cavity surrounded by the shell, at least one straight segment and at least one curved segment connected with the at least one straight segment;
• the straight segments of the multiple shells are aligned with one another and configured to be assembled to one another as frame tubes of a bicycle frame component which are substantially straight;
• the curved segments of the multiple shells are aligned with one another and configured to be assembled to one another as a connecting part of the frame tubes;
• each straight segment has a straight connecting edge;
• and
• each curved segment has a curved connecting edge;
• a shell assembling step:
• assembling the multiple shells to make the straight connecting edges of the multiple shells overlapped with one another and to make the curved connecting edges of the multiple shells butt jointed with one another rather than being overlapped;
• and
• a hot pressing step:
• through compression molding, turning the overlapped straight connecting edges and the butt jointed curved connecting edges of the multiple shells into multiple fusion areas by heating and compressing so as to connect the multiple shells as the bicycle frame component;
• wherein in the shell forming step, forming a transitional segment between adjacent said straight connecting edge and said curved connecting edge on each one of the multiple shells;
• and
• in the shell assembling step, assembling the multiple shells to make said transitional segment of each one of the multiple shells partially abutted with and partially mislaid as non-overlapping and non-abutting with said transitional segment of another said shell, thereby dividing the transitional segment into an abutted part and a mislaid part, and the abutted part and the mislaid part of each said transitional segment are arranged along an extending direction of the corresponding straight segments.