Method making a composite bicycle frame using composite lugs

In a method for forming an all-composite bicycle frame that includes bonding a plurality of cured hollow reinforced resin composite tubes to a plurality of cured, reinforced resin composite lugs, said lugs having non-developable surfaces, the method of forming each of the precured lugs comprising;

• overlaying layers of composite material to form a generally flat stack of composite material, said individual layers of composite material comprising a multiplicity of unidirectional, small diameter fibers of high modulus and high tensile strength fiber in an uncured resin matrix, wherein the fibers in any layer in the stack are aligned at substantially forty-five or substantially ninety degrees in relation to the fibers in adjacent layers;
• cutting the stack to form a first preform and a second preform, said preforms being sized such that each preform will provide one-half of said lug;
• providing a mold having a first half and a second half which together define a cavity corresponding with a desired lug shape;
• arranging first and second preforms around a conforming, inflatable bladder such that edges of the preforms overlap and placing the preforms and bladder into mold cavity, said bladder having a shape corresponding to shape of the preforms and to the mold cavity;
• inflating the bladder to either a constant pressure of at east substantially 125 psig or to a repeated cycle of pressurization to at least substantially 50 psig to press the preforms against the first and second mold halves and then curing the resin matrix with the bladder inflated by heating the mold halves to form a shaped, substantially void-free lug;
• deflating the bladder to atmospheric pressure and removing the lug and bladder from the mold cavity as a unit;
• removing the bladder to provide the cured lug.

A method of manufacturing an all composite bicycle frame, which supports a rider and withstands pedalling loads, said frame having separate hollow, thin walled lugs and tubes, said lugs having different shapes and non-developable surfaces;

• wherein said method comprises:
• providing a corresponding mold for each lug shape, each corresponding mold having a first half and a second half which together define a cavity corresponding with a separate lug shape;
• for each separate lug, overlaying layers of composite material to form a generally flat stack of composite material, said individual layers of composite material comprising a multiplicity of unidirectional, small diameter fibers of high modulus and high tensile strength fiber in an uncured resin matrix, wherein the fibers in any layer in the stack are aligned in crossing relation to the fibers in adjacent layers;
• for each separate lug, cutting a stack to form a first preform and a second preform, said preforms being shaped to fit a specific corresponding mold cavity and being sized such that each preform will provide one-half of said separate lug;
• for each separate lug, arranging first and second preforms around a conforming, inflatable bladder such that edges of the preforms overlap and placing the preforms and bladder in a corresponding mold cavity, said bladder having a shape corresponding to shape of the preforms and the corresponding mold cavity;
• inflating the bladder to press the preforms against the first and second mold halves and then curing the resin matrix to form a shaped, substantially void-free lug;
• removing the lug from the mold cavity and the bladder from the lug;
• bonding the separate lugs with cured, fiber reinforced resin tubes to form said bicycle frame.