Bicycle component and method for manufacturing such a component

A bicycle component comprising an elongated body for mechanically coupling to at least one element of a bicycle and for transmitting force, wherein said elongated body comprises spaced apart end parts, each defining a seat for mechanically coupling said component to said at least one element of a bicycle, and multiple loops of continuous structural fibers that are wrapped around said seats and stacked together to define an interior space having a length defined by a distance between said seats of said end parts and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers, said interior space filled entirely by a composite material formed by molding at least one first layer formed of continuous structural fibers incorporated in a matrix of polymeric material and at least one second layer formed of small lengths of structural fibers incorporated in a matrix of polymeric material and arranged randomly inside said at least one second layer, said at least one first layer and at least one second layer overlapping each other.

A bicycle component comprising an elongated body having a first end and a second end, and having, in each of said first and second ends, a seat for mechanically coupling the component with an element of a bicycle, wherein multiple loops of continuous structural fibers wrap around said seats of said first and second ends forming a closed loop and at least partially surrounding said seat to ensure mechanical continuity, said loops of continuous structural fibers being stacked together to define an interior space having a length defined by a distance between said seats of said first and second ends and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers, said interior space filled entirely by a composite material formed by molding at least one first layer formed of continuous structural fibers incorporated in a matrix of polymeric material and at least one second layer formed of small lengths of structural fibers incorporated in a matrix of polymeric material and arranged randomly inside the second layer, said at least one first layer and at least one second layer overlapping each other.

A bicycle crank arm comprising:

• an elongated body having spaced apart first and second ends that each include a seat for coupling said bicycle crank arm to an element of a bicycle, and multiple loops of continuous structural fibers that wrap around said seats of said first and second ends and are stacked together to define an interior space having a length defined by a distance between said seats of said first and second ends and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers, said interior space filled entirely by a composite material formed by molding at least two overlapping sheets of structural fibers incorporated in a matrix of polymeric material with at least one of said sheets having the fibers randomly arranged, said composite material being located between and in contact with said seats to ensure mechanical continuity between the seats.

A bicycle component comprising an elongated body having a first end and a second end, and having, in each of said first and second ends, a seat for mechanically coupling the component with an element of a bicycle, wherein multiple loops of continuous structural fibers wrap around said seats of said first and second ends at least partially surrounding said seat to ensure mechanical continuity, said loops of continuous structural fibers being stacked together to define an interior space having a length defined by a distance between said seats of said first and second ends and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers, said interior space filled entirely by a composite material formed by molding at least one first layer formed of continuous structural fibers incorporated in a matrix of polymeric material and at least one second layer formed of small lengths of structural fibers incorporated in a matrix of polymeric material and arranged randomly inside the layer, said at least one first layer and at least one second layer overlapping each other.

A bicycle crank arm comprising:

• an elongated body having a first end part and a spaced apart second end part, each one of the first and second end parts defines a seat for mechanical coupling;
• multiple loops of continuous structural fibers that wrap around said seats of said first and second end parts and at least partially surround said seats, said loops of continuous structural fibers being stacked together to define an interior space filled entirely by a composite material formed by molding a plurality of overlapping sheets of fiber reinforced material, at least one of the sheets being formed of small lengths of structural fibers, said interior space having a length defined by a distance between said seats of said first and second end parts and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers.

A bicycle crank arm comprising an elongated body having a first end part and a second end part, each defining a seat for mechanically coupling said bicycle crank arm to an element of a bicycle, at least one of said seats having a metal insert, wherein there are multiple loops of continuous structural fibers that wrap around said seats of said first and second end parts and at least partially surround said seat ensuring mechanical continuity in an end zone between said seat and an end of the body, said loops of continuous structural fibers being stacked together to define an interior space having a length defined by a distance between said seats of said first and second end parts and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers, said interior space filled entirely by a composite material formed by molding a plurality of overlapping sheets of fiber reinforced material, at least one of the sheets formed of small lengths of structural fibers.

A bicycle crank arm comprising an elongated body having a first end part and a second end part, said first and second end parts each comprising a seat for mechanically coupling said bicycle crank arm to an element of a bicycle, wherein there are multiple loops of continuous structural fibers that wrap around said seats of said first and second end parts and at least partially surround said seat ensuring mechanical continuity in an end zone between said seat and an end of the body, said loops of continuous structural fibers being stacked together to define an interior space having a length defined by a distance between said seats of said first and second end parts and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers, said interior space filled entirely by a composite material formed by molding a plurality of overlapping sheets of fiber reinforced material, at least one of the sheets having the fibers randomly arranged.

A bicycle crank arm comprising:

• an elongated body with spaced apart end parts, each defining a respective seat for mechanically coupling the bicycle crank arm to one of a bicycle pedal or crank shaft;
• the body including multiple loops of continuous structural fibers that wrap around the seats and are stacked together to define an interior space having a length defined by a distance between said seats and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers, said interior space filled entirely by a composite material formed by molding a plurality of overlapping sheets of fiber reinforced material, at least one of the sheets formed of continuous structural fibers and at least one of the sheets formed of small lengths of structural fibers.

A bicycle crank arm having a body including spaced apart end parts that each define a respective seat for mechanically coupling said bicycle crank arm to an element of a bicycle;

• multiple loops of continuous structural fibers that wrap around said seats and are stacked together to define an interior space having a length defined by a distance between said seats and a height defined by a distance between a topmost one and a bottommost one of said loops of continuous structural fibers, said interior space filled entirely by molding a thermoset fiber reinforced material.