Klein Bicycle Corporation

Richard W Randall

Darrell W Voss

Gary G Klein

A method of making a bicycle front fork of molded composite laminates of fiber in a resin matrix, the front fork including a steerer portion, a tubular crown portion, a pair of tubular blade portions. Each has upper ends joined by said crown to the steerer, respectively, and lower ends adapted to receive dropouts. According to the invention, the front fork is molded in two substantially mirror image halves having mutually congruent joining surfaces in said steerer portion.

Bicycle front forks and methods of making same

The invention disclosed herein is a very durable, lightweight, front fork assembly for use on competition bicycles. The invention provides improved fatigue and impact resistance compared to prior art designs. The invention makes maximum use of advanced, high strength composite materials and high strength, lightweight metal alloys, improving its stiffness-to-weight and strength-to-weight ratios. The superior structural performance of the invention is provided by a unique section geometry and ply configuration that efficiently utilizes the material to maximize bending and torsional stiffness while minimizing weight. The improved strength also comes from the superior control of the molding process, made possible with a removable pressure bladder that remains connected to the pressure source, and is regulated, during the molding process. The invention is produced using an efficient, 'cigar' roll-up procedure where the fiber lay-up is first made in a flat pattern and later rolled up into the final 'cigar' roll-up configuration.

A high efficiency lightweight bicycle handlebar using strong, stiff fibers and a structural resin is disclosed. Relatively low modulus fibers are used in the axial direction and relatively high modulus fibers in the transverse or hoop direction. The hoop fibers are placed on the inside and outside diameters.

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Chehalis, WA, United States of America

Richard W Randall