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US 6,267,399 B1Granted
Net shape filament winding manufacturing process, articles made therefrom and composite bicycle fork and other components
AssigneeAdvanced Composites, Inc.
InventorsDaniel K. Buckmiller, David Wayne Erickson, Douglas G. Olsen, Randall J. Philpot
Life of this patent
Estimating the term…
Abstract
A high production net shape filament winding manufacturing process and resulting products are disclosed. The manufacture of bicycle frame and their components from filament wound components which have been cut from a section of filament wound stock is disclosed. Also disclosed is a bicycle frame and its manufacturing process and a composite bicycle fork and components thereof.
Claims40
A frame for a two-wheeled vehicle comprising:
- a three-sided, continuous front structural element with a left side and a right side, the front structural element comprising:
- a top beam having a first end and a second end,
- a seat beam having a first end and a second end, and
- a down beam having a first end and a second end,
- said top beam first end connected to said seat beam first end, said top beam second end connected to said down beam second end, said down beam first end connected to said seat beam second end, and said front structural element constructed from composite material;
- a rear structural element with a right side and a left side said rear structural element comprising:
- a seat stay having a first end and a second end,
- a chain stay having a first end and a second end,
- a first mounting protrusion integral with and extending from said seat stay first end, and
- a second mounting protrusion integral with and extending from said chain stay first end, said rear structural element mounted to said front structural element by said first and second mounting protrusions;
- a bottom bracket tube in the vicinity of the juncture of said chain stay and said seat beam;
- and
- a bottom bracket cap, said bottom bracket cap having a body portion and mounting protrusions for attaching said bottom bracket cap to said frame, said bottom bracket cap body portion extending around said bottom bracket tube;
- wherein said bottom bracket has six mounting protrusions extending from said body portion, two of said bottom bracket cap mounting protrusions mounted to the right side of said front structural element, two of said bottom bracket cap mounting protrusions mounted to the left side of said front structural element, one of said bottom bracket cap mounting protrusions mounted to the right side of said chain stay, and one of said bottom bracket cap mounting protrusions mounted to the left side of said chain stay.
11 more elements
A frame for a two-wheeled vehicle comprising:
- a three-sided, continuous front structural element with a left side and a right side, the front structural element comprising:
- a top beam having a first end and a second end,
- a seat beam having a first end and a second end, and
- a down beam having a first end and a second end,
- said top beam first end connected to said seat beam first end, said top beam second end connected to said down beam second end, said down beam first end connected to said seat beam second end, and said front structural element constructed from composite material;
- a rear structural element with a right side and a left side, said rear structural element comprising:
- a seat stay having a first end and a second end,
- a chain stay having a first end and a second end,
- a first mounting protrusion integral with and extending from said seat stay first end, and
- a second mounting protrusion integral with and extending from said chain stay first end,
- said rear structural element mounted to said front structural element by said first and second mounting protrusions;
- a left seat beam channel on the left side of said seat beam, an elongate reinforcing member installed in said left seat beam channel,
- a left top beam channel on the left side of said top beam, an elongate reinforcing member installed in said left top beam channel,
- a left down beam channel on the left side of said down beam, an elongate reinforcing member installed in said left down beam channel,
- a left seat stay channel on the left side of said seat stay, an elongate reinforcing member installed in said left seat stay channel,
- a left chain stay channel on the left side of said chain stay, an elongate reinforcing member installed in said left chain stay channel,
- a right seat beam channel on the right side of said seat beam, an elongate reinforcing member installed in said right seat beam channel,
- a right top beam channel on the right side of said top beam, an elongate reinforcing member installed in said right top beam channel,
- a right down beam channel on the right side of said down beam, an elongate reinforcing member installed in said right down beam channel,
- a right seat stay channel on the right side of said seat stay, an elongate reinforcing member installed in said right seat stay channel, and
- a right chain stay channel on the right side of said chain stay, an elongate reinforcing member installed in said right chain stay channel.
18 more elements
A frame for a two-wheeled vehicle comprising:
- a three-sided, continuous front structural element with a left side and a right side, the front structural element comprising:
- a top beam having a first end and a second end,
- a seat beam having a first end and a second end, and
- a down beam having a first end and a second end,
- said top beam first end connected to said seat beam first end, said top beam second end connected to said down beam second end, said down beam first end connected to said seat beam second end, and said front structural element constructed from composite material;
- a rear structural element with a right side and a left side, said rear structural element comprising:
- a seat stay having a first end and a second end,
- a chain stay having a first end and a second end,
- a first mounting protrusion integral with and extending from said seat stay first end, and
- a second mounting protrusion integral with and extending from said chain stay first end, said rear structural element mounted to said front structural element by said first and second mounting protrusions;
- a channel in one of said structural elements, said channel comprising:
- a main channel having a first depth, and
- a secondary channel having a second depth, said secondary channel deeper than said main channel, and
- a reinforcing side element installed in said channel, said reinforcing side element comprising:
- a main reinforcing member body of a first thickness, and
- a protrusion having a second thickness, wherein said second thickness exceeds said first thickness;
- wherein said reinforcing side element is installed in said channel so that said main reinforcing member body lies within and substantially covers said main channel;
- and
- wherein said protrusion lies within and substantially covers said secondary channel.
16 more elements
A frame for a two-wheeled vehicle comprising:
- a three-sided, continuous front structural element with a left side and a right side, the front structural element comprising:
- a top beam having a first end and a second end,
- a seat beam having a first end and a second end, and
- a down beam having a first end and a second end,
- said top beam first end connected to said seat beam first end, said top beam second end connected to said down beam second end, said down beam first end connected to said seat beam second end, and said front structural element constructed from composite material;
- a rear structural element with a right side and a left sides said rear structural element comprising:
- a seat stay having a first end and a second end,
- a chain stay having a first end and a second end,
- a first mounting protrusion integral with and extending from said seat stay first end, and
- a second mounting protrusion integral with and extending from said chain stay first end, said rear structural element mounted to said front structural element by said first and second mounting protrusions;
- wherein one of said structural elements comprises:
- a first thickness of resin matrix and reinforcing fiber, said first thickness having a first side and a second side,
- a second thickness of structural foam, said second thickness of structural foam having a first side and a second side, said first side of said second thickness in contact with said second side of said first thickness, and
- a third thickness of resin matrix and reinforcing fiber, said third thickness having a first side and a second side, said first side of said third thickness in contact with said second side of said second thickness.
11 more elements
A frame for a two-wheeled vehicle comprising:
- a three-sided, continuous front structural element with a left side and a right side the front structural element comprising:
- a top beam having a first end and a second end,
- a seat beam having a first end and a second end, and
- a down beam having a first end and a second end,
- said top beam first end connected to said seat beam first end, said top beam second end connected to said down beam second end, said down beam first end connected to said seat beam second end, and said front structural element constructed from composite material;
- a rear structural element with a right side and a left side, said rear structural element comprising:
- a seat stay having a first end and a second end,
- a chain stay having a first end and a second end,
- a first mounting protrusion integral with and extending from said seat stay first end, and
- a second mounting protrusion integral with and extending from said chain stay first end, said rear structural element mounted to said front structural element by said first and second mounting protrusions;
- wherein one of said structural elements comprises:
- a first thickness of resin matrix and reinforcing fiber,
- a second thickness of structural foam, and
- a third thickness of resin matrix and reinforcing fiber;
- wherein said second thickness is located between said first thickness and said third thickness.
12 more elements
A frame for a two-wheeled vehicle comprising:
- a three-sided, continuous front structural element with a left side and a right side, the front structural element comprising:
- a top beam having a first end and a second end,
- a seat beam having a first end and a second end, and
- a down beam having a first end and a second end,
- said top beam first end connected to said seat beam first end, said top beam second end connected to said down beam second end, said down beam first end connected to said seat beam second end, and said front structural element constructed from composite material;
- a rear structural element comprising:
- a seat stay having a first end and a second end, and
- a chain stay having a first end and a second end;
- said chain stay first end connected to said seat beam second end, said chain stay second end connected to said seat stay second end, and said seat stay first end connected to said seat beam first end;
- a channel in a side of said structural elements, and
- a reinforcing side element installed in said channel;
- said channel in one of said structural elements further comprising:
- a main channel having a first depth, and
- a secondary channel having a second depth, said secondary channel deeper than said main channel, and
- said reinforcing side element further comprising:
- a main reinforcing member body of a first thickness, and
- a protrusion having a second thickness, wherein said second thickness exceeds said first thickness;
- wherein said reinforcing side element is installed in said channel so that said main reinforcing member body lies within and substantially covers said main channel;
- and
- wherein said protrusion lies within and substantially covers said secondary channel.
17 more elements
A frame for a two-wheeled vehicle comprising:
- a three-sided, continuous front structural element with a left side and a right side, the front structural element comprising:
- a top beam having a first end and a second end,
- a seat beam having a first end and a second end, and
- a down beam having a first end and a second end, said top beam first end connected to said seat beam first end, said top beam second end connected to said down beam second ends said down beam first end connected to said seat beam second end, and said front structural element constructed from composite material;
- a rear structural element comprising:
- a seat stay having a first end and a second end, and
- a chain stay having a first end and a second end;
- said chain stay first end connected to said seat beam second end, said chain stay second end connected to said seat stay second end, and said seat stay first end connected to said seat beam first end;
- wherein one of said structural elements comprises:
- a first thickness of resin matrix and reinforcing fiber, said first thickness having a first side and a second side,
- a second thickness of structural foam, said second thickness of structural foam having a first side and a second side, said first side of said second thickness in contact with said second side of said first thickness, and
- a third thickness of resin matrix and reinforcing fiber, said third thickness having a first side and a second side, said first side of said third thickness in contact with said second side of said second thickness.
9 more elements
A frame for a two-wheeled vehicle comprising:
- a three-sided, continuous front structural element with a left side and a right side, the front structural element comprising:
- a top beam having a first end and a second end,
- a seat beam having a first end and a second end, and
- a down beam having a first end and a second end,
- said top beam first end connected to said seat beam first end, said top beam second end connected to said down beam second end, said down beam first end connected to said seat beam second end, and said front structural element constructed from composite material;
- a rear structural element comprising:
- a seat stay having a first end and a second end, and
- a chain stay having a first end and a second end;
- said chain stay first end connected to said seat beam second end, said chain stay second end connected to said seat stay second end, and said seat stay first end connected to said seat beam first end;
- a steer tube, said steer tube comprising:
- an elongate tubular main steer tube section having a first end, a second end, an exterior surface, and an interior passageway, said main steer tube comprising resin matrix and reinforcing fiber,
- an upper insert having an upper portion and a lower portion, said lower portion installed into said main steer tube interior passageway so that said upper portion protrudes from said main steer tube facilitating installation of a component thereon;
- and
- a reinforcing sleeve section, said sleeve section installed into said main steer tube internal passageway to reinforce said main steer tube.
11 more elements
A frame for a wheeled vehicle comprising:
- a front structural element having
- a top beam having a first end and a second end,
- a down beam having a first end and a second end, said down beam second end being joined to said top beam first end,
- a seat beam having a first end and a second end, said seat beam first end being joined to said top beam first end, and said seat beam second end being joined to said down beam second end;
- an upper rear structural element having
- a left seat stay beam having a first end and a second end,
- a right seat stay beam having a first end and a second end,
- a mounting portion mounted to said front structural element, said mounting portion being formed by a joining of said left seat stay first end and said right seat stay first end,
- a lower rear structural element having
- a left seat chain beam having a first end and a second end,
- a right seat chain beam having a first end and a second end,
- a mounting portion mounted to the frame, said mounting portion being formed by a joining of said left chain stay first end and said right chain stay first end;
- wherein one of said structural elements comprises:
- a first thickness of resin matrix and reinforcing fiber, said first thickness having a first side and a second side,
- a second thickness of structural foam said second thickness of structural foam having a first side and a second side said first side of said second thickness in contact with said second side of said first thickness,
- a third thickness of resin matrix and reinforcing fiber said third thickness having a first side and a second side, said first side of said third thickness in contact with said second side of said second thickness;
- a channel in said second thickness of structural foam, and
- a reinforcing side element installed in said channel
- wherein said upper rear structural element is positioned closer to said top beam than said lower structural element is;
- wherein said upper rear structural element left seat stay second end is joined to said lower rear structural element left chain stay second end;
- and
- wherein said upper rear structural element right seat stay second end is joined to said lower rear structural element chain stay second end.
19 more elements
Dependencies are inferred from the claim text.