Hollow composite bicycle component and method of manufacturing the hollow composite bicycle component
AssigneeSram, LLC
InventorsCHIA CHANG CHANG, CHEN HSIUNG CHEN, HUAN CHING HSU, CHING HAN LIU, CHU CHEN WANG
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Abstract
A bicycle component includes a composite laminate. The composite laminate includes a hollow container made of a first polymer-based material, a layer of a second polymer-based material disposed on the hollow container, and a layer of a composite material disposed on the layer of the second polymer-based material. The bicycle component also includes a water soluble core material disposed within hollow container. The water soluble core material is dissolvable and removable from the composite laminate after lamination of the composite laminate
Claims20
An intermediate product for a bicycle, the intermediate product comprising:
- a composite laminate comprising:
- a hollow container made of a first polymer-based material;
- a layer of a second polymer-based material disposed on the hollow container;
- and
- a layer of a composite material disposed on the layer of the second polymer-based material;
- and
- a water soluble core material disposed within the hollow container,
- wherein the water soluble core material is dissolvable and removable from the composite laminate after lamination of the composite laminate.
A hollow bicycle component comprising:
- a composite laminate comprising:
- a hollow container made of a first polymer-based material;
- a layer of a second polymer-based material disposed on the hollow container;
- and
- a layer of a composite material disposed on the layer of the second polymer-based material, the composite material including a matrix of a third polymer-based material and fibers of a reinforcing material.
A method for manufacturing a hollow bicycle component, the method comprising:
- forming a hollow container, the hollow container being made of a first polymer-based material;
- preparing a core material mixture, the core material mixture including a salt, expandable microspheres, or a combination thereof;
- filling the hollow container with the core material mixture;
- forming a layup pattern, forming the layup pattern comprising positioning at least a layer of a second polymer-based material and a layer of a composite material on the hollow container;
- forming a composite laminate including the hollow container, the layer of the second polymer-based material, and the layer of the composite material;
- and
- dissolving, removing, or dissolving and removing the core material mixture.
Dependencies are inferred from the claim text.