Trek Bicycle Corporation

Weston M Wilcox

Michael L Zeigle

Ronald Harry Nelson

Dimitrije Milovich

Matthew A Rhoades

Robert F Read

Stephen J Baumann

Andre Terzaghi

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 lug components. The precured lug components are separately shaped from preforms comprising a plurality of resin impregnated fibrous layers formed into a stack in which the fibers of adjacent layers cross one another, with such preforms of each such lug component being in the nature of a set of similarly shaped overlapping halves of the frame lug component to be formed therefrom, with such overlapping halves being brought together in a hollow nature and placed around an inflatable bladder to form an assemblage that is applied between a set of female mold halves of molding tools that are closed for forming the lug component itself, and the resulting assemblage is subjected to a curing heat, with such bladder of each two hundred (200) set of preforms being arranged to first be pressurized to a pressure greater than or equal to two hundred (200) pounds per square inch, for urging the respective preforms against the mold shaping surfaces opposing same, thereby providing a high laminate compaction pressure during cure that produces a uniform, thin walled, strong, tubular, lug component. The said lug components are also each formed with one or more male members or plugs for closely fitting into adjacent open ends of the aforementioned all-composite tubes. Such composite tubes are formed by wrapping a preform, that is similar to the lug component preform, around a mandrel and cured, with the wrap being subject to a compaction pressure therearound during cure, thereby providing a thin walled high strength tube, for forming of the bicycle frame as above indicated.

Composite bicycle frame and methods for its construction

A bicycle rear suspension system providing rearward relative motion of the rear axle includes a chain stay, seat stay, chain stay link, seat stay link and shock absorber, with those components being assembled to a main front frame. The frame includes a head tube for supporting a front steering fork, a seat tube for supporting a seat, and a bottom bracket for supporting a pedal crank and chain drive mechanism, the seat tube and bottom bracket being supported so that there is a vertical space between them. The components of the rear suspension system are assembled to the frame within the space between the seat tube and bottom bracket. The chain stay link is pivotally attached to the frame so that, upon upward movement of the chain stay, the chain stay link pivots to cause the chain stay and thus the rear axle supported thereon to move slightly rearwardly relative to the frame.

Bicycle rear suspension system providing relative rearward motion of rear axle

A variable reduction cross-linkage for a rear suspension bicycle includes a four-bar linkage comprised of a portion of the frame between a first pivot point and a second pivot point, a portion of the rear swing arm, a long link and a short link. The swing arm is pivotable relative to the frame about the first pivot point. The long link is pivotable relative to the frame about the second pivot point. A shock absorber is pivotally attached to the frame and long link. The four-bar linkage operates so that upward pivotal movement of the swing arm results in a forward movement of the long link to thereby compress the shock absorber.

Variable reduction cross-linkage for rear suspension bicycle

A front derailleur for shifting gears on a chain driven bicycle, the chain having a drive run and a return run from a plurality of chainwheels, uses a chain supporting idler cog to vertically control the chainline of the chain drive run and to also move transversely to shift the chain from one of the chainwheels to another.

Front derailleur with chainline controlling idler cog

Road bicycle frame with unified rear triangle

A suspension for a bicycle having a unified rear triangle pivotably connected to a Y shaped frame. The unified rear triangle provides a fixed chain length, isolating rear wheel movement from pedaling motion. A shock absorbing means is connected to the Y shaped frame at the intersection of the arms of the frame and to the rear triangle. A pivot is preferably connected near the bottom bracket of the bicycle in order to reduce movement of the bottom bracket.

Suspension for a bicycle having a Y shaped frame

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.

Growing community of inventors

Sun Prairie, WI, United States of America

Weston M Wilcox