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Abstract

The bicycle frame of the invention is formed by selecting and adhesively joining previously formed and precured composite tubes to previously formed and precured composite lugs. The precured lugs are shaped from preforms comprising a plurality of resin impregnated fiber reinforced layers formed into a stacks having the fibers of adjacent layers cross one another, with preforms of each lug component being a set of shaped overlapping segments of the lug to be formed. The overlapping segments are then brought together and placed around an inflatable bladder to form an assemblage that is placed in a female mold, preferably of two halves, that are closed for forming the lug. The resulting assemblage is cured, with the bladder pressurized for urging the respective preforms to the mold shaping surfaces, providing a high laminate compaction during cure for a uniform, thin walled, strong, tubular, lug. The lugs are preferably formed with one or more plugs for closely fitting into adjacent open ends of the tubes. The composite tubes may be formed by a method similar to the lug forming method described, or by wrapping a preform up of a number of reinforced fiber layers, around a mandrel, and subjecting the preforms to an inward compaction pressure during cure. These methods provide a thin walled high strength tube.

Other References

• Bicycling magazine, Mar., 1989, "New Products" col., pp. 46 and 50, Trek 5000
• Bicycling magazine, Mar., 1989, "Bike Tech" col., pp. 204 and 206, Inside The Kestrel MX-Z
• Advanced Composites, Jan./Feb., 1987, pp. 40-42, 44 and 46, Bicycling With Advanced Composite