Main frame, front fork and bicycle frame comprising main frame and front fork

Abstract

The invention relates to a main frame (1) for a bicycle, having a saddle and having a front wheel and a rear wheel arranged in a track, which main frame is made of thermoplastic plastic in a closed molding tool, the main frame being shaped as a one-piece hollow body (2) having a frame wall (3) surrounding the cavity thereof, the frame wall (3) of the hollow body (2) has an unity which is produced by means of rotary moulding in a rotary moulding mould which can be heated from the outside; the invention also relates to a front fork and a bicycle frame comprising the main frame and the front fork.

Description

Technical Field

[0001] The invention relates to a bicycle frame for a bicycle having a saddle and having a front wheel and a rear wheel arranged in a wheel track, and also to the main components of the bicycle frame, namely the main frame and the front wheel fork.

[0002] In one aspect, the present invention relates to a main frame made of thermoplastic in a closed molding die. The present invention also relates to a front wheel fork made of thermoplastic in a closed molding die.

[0003] Furthermore, the invention relates to a main frame for a bicycle having a saddle and a front wheel and a rear wheel arranged in a wheel track, the main frame being made of thermoplastic and comprising a main beam and a single-sided rear wheel carrier in an integral manner, the rear wheel carrier being in the form of a hollow body, provided that the rear wheel carrier forms an encapsulated housing for a drive device and is provided with a rear wheel receiving portion.

[0004] The invention further relates to a front wheel fork for a bicycle having a saddle and provided with a front wheel and a rear wheel arranged in a wheel track, the front wheel fork being configured as a single piece made of thermoplastic or comprising a fork leg arranged on one side with an upper end and a lower end or comprising two such fork legs arranged symmetrically, wherein a receiving opening is respectively provided at the lower end of one fork leg or at the lower ends of both fork legs, wherein the receiving opening is provided for holding a front axle. Background Art

[0005] Compared to steel and aluminum, thermoplastics have lower strength as a material for bicycle frames. The modulus of elasticity is lower than that of steel and aluminum. The dimensional stability of plastics is also lower. This must be taken into account when designing a main frame and a front wheel fork made of plastic, as is known from DE 38 04 342 C2.

[0006] This prior art has already proposed a bicycle frame made of thermoplastic material, which comprises a main frame and a front wheel fork, which are manufactured by a die-casting process (so-called thermoplastic die-casting). The known die-cast main frame comprises a rear wheel frame with reinforcing ribs, and the front wheel fork is reinforced with longitudinal ribs. With this reinforcement configuration, the aim is to compensate for the lower strength of the plastic in this prior art.

[0007] The configuration of the main frame with reinforcement and the front wheel fork with longitudinal ribs appears complicated, and the achievable strength performance is not satisfactory. Summary of the invention

[0008] The invention is therefore based on the object of expanding a bicycle frame in such a way that the main frame and / or the front wheel fork are respectively given a spatially-physically simplified design which provides the required strength and durability of the bicycle frame and the main components mentioned.

[0009] According to the invention, this object is achieved by a main frame according to claim 1, which is in the form of a one-piece hollow body with a frame wall surrounding a cavity, wherein the frame wall of the hollow body has an integral nature which is produced by means of rotational molding in a rotational molding mold that can be heated from the outside.

[0010] For rotational molding, a thermoplastic material in powder form is filled into a rotational molding die, which is closed all around for the molding process. The rotational molding die has an inner wall, which forms the negative shape of the configuration to be formed. The rotational molding die is practically configured as a permanent casting mold, which is usually made of metal, preferably aluminum. For the molding process, the rotational molding die can be rotated around at least one axis and heated from the outside at the same time. The plastic powder is melted therein and can be distributed on the inner wall as a melt in a viscous state. Finally, the melt solidifies on the inner wall of the rotational molding die and can then be removed as a manufactured hollow body after opening the rotational molding die.

[0011] The main frame of a bicycle for single-track bicycles requires a dimensionally accurate configuration. The inventors have found that it is advantageous for the main frame of a bicycle that the plastic material which has expanded in the mold during solidification can expand freely inwardly into the hollow rotational molding mold. In this way, a low-stress molded main frame can be provided, which has the required shape accuracy for a bicycle for single-track bicycles and has less warping than a die-cast main frame, which in any case does not expand in the die-cast mold and build up stresses that lead to warping. In addition, the rotationally molded main frame is seamless due to its one-piece design, which is beneficial for strength.

[0012] The hollow body advantageously has regions of the frame wall with different wall thicknesses. In this way, the main frame can be arranged without internal reinforcement in such a way that, during travel, particularly stressed locations of the frame wall of the main frame can be reinforced with more material in order to counteract cracks and fractures at these locations.

[0013] In practice, regions of different wall thicknesses of the frame wall are produced by a regionally different heat input from the outside into the rotational molding die. At the more strongly heated regions, the powder melts faster and a greater wall thickness can be formed in the entire process to provide the required strength. Surprisingly, it has been shown that low stresses can be achieved even for main frames with different frame wall thicknesses, which low stresses can provide the required dimensional accuracy.

[0014] The rotational molding tool also allows the integration of separate structural elements during the molding process, which are adhesively and / or form-lockingly connected to the hollow body during the molding process. These can be metallic components, such as rods, screws, rings or tubes, which can supplement and reinforce the main frame.

[0015] Advantageously, the thermoplastic material of the frame wall is selected from one of the following plastics: polypropylene (PP), preferably polyethylene (PE), particularly preferably rigid polyethylene (English: High-Density-Polyethylen (HDPE)). Economic cycles already exist for the above-mentioned types, which can be recycled and made available in a reusable form. For this purpose, they are collected, for example, at sea and in agriculture. They occur in fishing nets, trawl nets, aquaculture nets or as net packaging for tying straw bales, and also as scaffolding protective nets for protecting road users. In the case of the proposed bicycle frame and its main components, it is very advantageous to recycle these varieties directly from everyday products and return them to the cycle without first polluting the environment.

[0016] If the thermoplastic does not contain fibers, it is very advantageous for reuse. In the context of the present invention, it is also possible to include a thermoplastic having fibers that are low enough to allow the thermoplastic to be processed to the point where it is suitable for rotational molding.

[0017] In addition, when the main frame includes a housing for encapsulating the drive device as defined in claim 6, the main frame also achieves the basic purpose when the main beam is configured to be hollow as a whole with the opposite frame wall and is implemented as a single piece with the rear wheel carrier. Compared with the main frame known from DE 38 04 342 C2, the proposed main beam omits reinforcement and is instead constructed as a hollow body with mutually opposite frame walls. This configuration can be achieved using different manufacturing processes. These include processes using a prototype of a molding mold or, for example, 3D printing processes that can also process thermoplastics. The configuration in which the main beam is a hollow body as a whole and is integrated with the hollow rear wheel carrier is considered an invention.

[0018] The rear wheel receiving portion is advantageously designed in the form of two coaxial bearing openings, wherein the coaxial bearing openings are arranged in mutually opposite frame walls of the rear wheel carrier. The bearing opening of the rear wheel carrier is located on the left side of the main frame in the direction of travel, where the rear wheel is arranged when the bicycle is ready to drive. This side of the rear wheel carrier should be referred to as the wheel side, while the opposite side of the rear wheel carrier should be referred to as the drive side. The bearing opening is practically provided for receiving a bearing seat of the rear wheel axle. The bearing opening arranged on the wheel side and / or the drive side is practically configured as a hollow cylinder and has a stop surface for the bearing element in the axial direction. The diameter of the hollow cylindrical bearing opening is preferably in the range of 40 mm to 130 mm. The diameter of the hollow cylindrical bearing opening on the wheel side is practically larger than the diameter on the drive side of the rear wheel carrier.

[0019] A main frame with an encapsulated housing for the drive means is also considered to be particularly advantageous if the frame wall of the hollow body is produced in one piece by means of rotational molding in a rotational molding tool that can be heated from the outside, as described above.

[0020] Furthermore, the hollow body can also have regions of different wall thicknesses of the frame wall. This can be achieved by rotational molding or, for example, by means of 3D printing.

[0021] As mentioned above, thermoplastics can also be selected for this purpose, such as polypropylene (PP), preferably polyethylene (PE), particularly preferably hard polyethylene (HDPE); for these types, there are already economic cycles that can recycle these plastics and make them available in a reusable processed form, which can be suitable for rotational molding or 3D printing. It is also advantageous for this purpose that the thermoplastic is fiber-free, as mentioned above, wherein for the purposes of the present invention, this is also understood to be a low-fiber plastic that can be processed to be suitable for rotational molding or 3D printing.

[0022] If rotational molding is provided, regions of different wall thicknesses of the frame wall can again be produced by supplying different amounts of heat from outside to the rotational molding tool in subregions, as described above.

[0023] Opposite wall regions of the main beam are advantageously provided with coaxial bearing openings for receiving the pedal drive.

[0024] One of the bearing openings for the pedal drive is used in practically integrated fashion as a service opening for the rear wheel carrier, which is designed as an encapsulated housing for the drive means.

[0025] Another benefit may be that the main beam is constructed as a trapezoidal structure, which includes an upper tube element, a lower tube element, a saddle tube element and a steering tube element. Since the main beam is generally hollow, all the mentioned tube elements of the trapezoidal structure form a hollow area of ​​the main beam.

[0026] A further improvement provides that the trapezoidal structure has a reinforcing bridge element arranged between the upper tube element and the lower tube element.

[0027] The saddle tube member may have an upper saddle tube extension that protrudes beyond the upper tube member.

[0028] The rear wheel carrier has a triangular structure. This structure includes the saddle tube element mentioned above and the upper bracket element and the lower bracket element. Therefore, the saddle tube element is an integral component of both the main beam and the rear wheel carrier, which approximately forms the interface between the main beam and the rear wheel carrier.

[0029] In this embodiment of the main frame, the left side of the main frame in the direction of travel is also called the wheel side, while the right side is called the drive side, which also relates to the rear wheel carrier. In the ready-to-drive state of the finished bicycle, the rear wheel is arranged on the rear wheel carrier in a one-sided manner on the wheel side.

[0030] If the lower support element of the rear wheel carrier is designed as a housing for a drive device, it adjoins the saddle tube element at the front end of the lower support element. This region is provided for receiving the pedal drive mentioned above. There is space there for a pedal bearing or for a pedal bearing transmission or for a pedal bearing drive, which can be equipped with an electric motor.

[0031] In addition, a reinforcing bridge element can be provided which extends from the top tube element to the saddle tube extension. The bridge element strengthens the main frame. The saddle tube extension is supported. In addition, the bridge element can serve as a design element and also fulfill the function as a handle element, so that the bicycle can be lifted and easily carried when necessary.

[0032] The main frame practically has an envelope volume in the range of 18 liters to 22 liters, preferably in the range of 19 liters to 21 liters and particularly preferably in the range of 20 liters to 20.5 liters.

[0033] For the purposes of the invention, the envelope volume of the main frame is understood to be the volume of the outer surface of the main frame, provided that all existing openings are interpreted as closed surface areas and are included in the outer surface. This means that in particular the opening of the rear wheel receptacle, the opening in the area of ​​the pedal drive receptacle and the openings in the area of ​​the steering tube element and the saddle tube element belong to the outer surface that defines the envelope volume.

[0034] Furthermore, it is advantageous, either alone or in combination with the mentioned envelope volume, if the main frame has a weight in the range of 3.5 kg to 5.5 kg, preferably in the range of 4.0 kg to 5.0 kg and particularly preferably in the range of 4.5 kg to 4.9 kg.

[0035] Based on its envelope volume, the main frame practically has a specific weight in the range of 0.16 kg / liter to 0.32 kg / liter.

[0036] The plastics proposed for the main frame, such as polyethylene (PE or HDPE), have relatively low strength, hardness and stiffness. For other technical products, such polyethylene is usually reinforced by reinforcing fillers such as fibers. For reasons of recyclability, the present invention abandons fiber-reinforced materials and chooses pure plastics of the type. In order to increase the strength of the bicycle frame, the solution is to configure the main frame as a large hollow body. Compared with known steel or aluminum bicycle frames, its volume is significantly larger and is also larger than the volume of bicycle frames / main frames made of fiber-reinforced plastics. If the strength is to be increased further, the inner volume of the hollow body can be at least partially provided with foam material.

[0037] The foam material is practically produced by foaming in the inner volume of a hollow body.

[0038] The main frame is practically designed to have no cracks or breaks after an impact test with a drop mass of 22.5 kg from a drop height of 180 mm in accordance with DIN-ISO 4210-6:2015, Chapter 4.1 for city and trekking bicycles and in accordance with DIN-ISO 4210-2:2015, Chapter 4.8.2.

[0039] The main frame is practically configured to be capable of being used with a pedal force F of 1000 N according to DIN-ISO 4210-6:2015, Chapter 4.3, for city and hiking bicycles. 1 After dynamic testing and after the required number of test cycles of 100,000 according to DIN-ISO 4210-2:2015, Chapter 4.8.4, the main frame showed no cracks or breaks.

[0040] Furthermore, the main frame is advantageously configured to withstand a horizontal force F of 450 N in the direction of travel with a replacement fork mounted according to DIN-ISO 4210-6:2015, Chapter 4.4, for city and hiking bicycles. 2 and a horizontal force F of 450N in the opposite direction of travel 3 After dynamic testing and after the required number of test cycles of 100,000 according to DIN-ISO 4210-2:2015, Chapter 4.8.5, the main frame showed no cracks or breaks.

[0041] Furthermore, the main frame can be set to a vertical force F of 1000 N for city and trekking bicycles according to DIN-ISO 4210-6:2015, Chapter 4.5.4 After dynamic testing and after the required number of test cycles of 50,000 according to DIN-ISO 4210-2:2015, Chapter 4.8.6, the main frame showed no cracks or breaks.

[0042] It is particularly helpful if the main frame is provided with a data storage element, preferably an RFID storage element, preferably to store material information and / or data related to the production of the main frame, in particular about the plastic material used. When the bicycle is returned to the economic cycle at the end of its useful life, the stored information can help to process and reuse the plastic as a pure raw material.

[0043] Each main frame can be configured to move the rear wheel by means of a drive device, which is configured as a traction device with a traction section and an unloaded section, such as a bicycle chain or a toothed belt. In the case where such a drive device requires a certain tension in the traction section and / or the unloaded section, the main frame is provided with a device for providing the tension. This device can be a tensioning element or simply a preventive element on the main frame for fixing the tensioning element.

[0044] Furthermore, a front wheel fork is provided for achieving this object, which is designed as a fork hollow body with fork walls, wherein the fork walls of the fork hollow body have a single-piece structure which is produced by means of rotational molding in a rotational molding tool which can be heated from the outside.

[0045] The front wheel fork is practically designed in such a way that the hollow fork body has regions of different wall thicknesses of the fork wall.

[0046] A further advantage is that, on the front wheel fork, regions of different wall thicknesses of the fork wall are produced by a regionally different input of heat from the outside into the rotational molding tool.

[0047] The advantages resulting from the different wall thicknesses of the fork walls and by targeted heat input correspond in principle to the advantages described above for a rotationally molded main frame if it has different wall thicknesses of the frame walls; reference here also applies to the advantages of the front wheel fork.

[0048] Furthermore, a front wheel fork with either a fork leg arranged on one side or with two such fork legs arranged symmetrically achieves the task by constructing a fork bridge region at the upper end of the fork leg, on which a fork arm pointing upward is arranged on one side, or by placing two fork arms pointing upward and arranged symmetrically on the fork bridge region.

[0049] In the middle of the fork bridge, a fork stud is practically provided, which can be connected and replaced with the fork bridge area in a torsionally rigid manner as a metal tube. Alternatively, the fork stud can be inserted into a rotational molding die so as to be connected with the fork hollow body as an integral component of the front wheel fork.

[0050] It is helpful if the fork arm has an upper end, wherein the upper end of the fork arm is connected to the handlebar element.

[0051] The handlebar element is practically designed in one piece as part of the hollow fork body.

[0052] Furthermore, the handlebar element can be split in the middle and have a left and a right handlebar half, which are connected to the respective left or right fork arm, respectively. The division of the handlebar element simplifies the assembly of the front wheel fork. For this purpose, the fork arms are advantageously configured so that they can be elastically spread apart from each other. The handlebar halves can thus be moved far enough away from each other to be able to insert the front wheel fork, or its fork-shaped stud, into the steering bearing of the bicycle frame. The fork arms then rebound and are fixed.

[0053] A connection system is advantageously provided for the fastening. The handlebar halves are advantageously configured as part of the connection system. For this purpose, the handlebar halves can each be provided with a cone pointing upward and downward. The two cones belonging to one handlebar half are advantageously constructed integrally with the handlebar half. When the cones of the two handlebar halves abut against one another, they advantageously form a double-cone element. The double-cone element is thus divided in a vertical plane and comprises a double-cone side surface assigned to each handlebar half. The double-cone side surface is advantageously an integral component of the fork hollow body.

[0054] It is also advantageous to provide a cup-shaped lower clamping element. This clamping element is conveniently arranged on the fork-shaped stud and has a conical inner surface. For this purpose, when the handlebar halves are joined together in the middle and form the described double cone element, the inner surface is conveniently arranged to rest against the downwardly pointing cones of the two handlebar halves.

[0055] In the same way, a cap-shaped upper clamping element can be provided. This upper clamping element can advantageously close the free end of the fork-shaped stud. In simple terms, this upper clamping element is also provided with a conical inner surface. When the handlebar halves are joined in the middle, this inner surface is practically arranged to abut against the upwardly pointing cones of the two handlebar halves.

[0056] The upper clamping element can also be provided with a through opening for an adjusting screw, which can project into the fork-shaped stud and can be screwed into the nut element, as is customary in front steering bearing sets.

[0057] With the aid of the adjusting screw, the handlebar halves can be precisely fixed on the one hand and simultaneously connected with the fork-shaped column head. In addition, the axial play of the steering bearing can be adjusted with the aid of the adjusting screw.

[0058] The proposed connection system is thus designed such that it allows the connection of two handlebar halves and their fastening to the fork stud with a single adjusting screw. It is also advantageous if the fork legs are designed to hold the front axle with the receiving opening forming a fork end that is open downwards and into which the front axle can be inserted laterally.

[0059] A closing element is advantageously provided, with which the fork end open at the bottom can be closed.

[0060] The closing element can be a structural element separated from the fork hollow body. Therefore, a different plastic material and a different manufacturing process can be used for the closing element than fork hollow body.

[0061] Preferably, at least one connecting device is provided for fastening the closing element to the fork leg so that the front axle can be fixed. The fixing can be carried out in a form-locking and / or force-locking manner. Simply put, the fork end and the closing element have the shape of a semi-cylindrical shell, with a clamping groove retained in between. The closing element can then be fastened to the fork end using a screw as a connecting device. For this purpose, the area of ​​the fork end at the fork hollow body is practically provided with at least one threaded insert, preferably two threaded inserts. Matching this, the closing element is provided with at least one through-opening for the screw, or two through-openings. In this way, a receiving opening is formed, with which a clamping effect can be produced in order to fix the shaft element.

[0062] It is particularly practical if the front wheel fork has an envelope volume in the range of 3.5 liters to 6.5 liters, preferably in the range of 4.5 liters to 5.5 liters and particularly preferably in the range of 4.7 liters to 5.3 liters.

[0063] For the purposes of the invention, the envelope volume of the front wheel fork is understood to be the volume of the outer surface of the front wheel fork, provided that all existing openings (as in the definition of the envelope volume of the main frame) are interpreted as closed surface areas and included in the outer surface of the front wheel fork.

[0064] Furthermore, it is advantageous, either alone or in combination with the aforementioned envelope volume, if the front wheel fork has a weight in the range of 1.9 kg to 3.7 kg, preferably 2.4 kg to 3.2 kg and particularly preferably 2.7 kg to 2.9 kg.

[0065] Advantageously, the front wheel fork has a specific weight of 0.29 kg / litre to 1 kg / litre based on its envelope volume.

[0066] A further advantage for the front wheel fork is that the fork hollow body is produced in one piece by means of rotational molding in a rotational molding mold which can be heated from the outside.

[0067] The fork hollow body can have regions of different wall thicknesses of the fork wall.

[0068] Regions of different wall thicknesses of the fork wall can be produced by a subregionally different heat input from the outside into the rotational molding tool.

[0069] The advantages of different wall thicknesses of the fork walls and of targeted heat input for the front wheel fork also correspond in principle to the advantages described above for the main frame if it has different wall thicknesses of the frame walls by rotational molding.

[0070] It is particularly advantageous if the front axle is assigned to the front wheel fork as a structural component.

[0071] The front axle can include two pot-shaped or two hollow cylindrical axle elements, each of which has a bearing seat for a running wheel bearing and a mating area for connection with the fork end of a fork leg. The bearing seat and the mating area are arranged in the circumferential direction. The mating area has a cylindrical or polygonal cross section, provided that the unit consisting of the fork end and the closing element has a hollow cylindrical or hollow polygonal cross section matching therewith. The front axle is arranged in a torsion-proof manner relative to the rest of the front wheel fork. In the assembled state, the front axle forms a structural reinforcement of the front wheel fork.

[0072] The two axle elements of the front axle can be simply connected to each other flush to provide the axle connection. In this case, each axle element has a connecting end. The axle connection can be established by means of the connecting end.

[0073] The connecting ends of the two shaft elements are practically designed in such a way that the shaft connection can be produced by means of a screw.

[0074] The screw thread can have a separate screw and a separate nut, or the nut thread can be integrated in one of the shaft elements and can interact with the screw.

[0075] The spiral is preferably provided by a connection end which is configured in the form of an external thread on the cylindrical outer surface of one of the shaft elements, wherein the connection end of the other shaft element is configured in the form of a matching internal thread. This embodiment allows the shaft element to be implemented as a hollow cylinder. This can save weight. The hollow embodiment also presents an attractive design element.

[0076] Like the main frame, the front wheel fork may be provided with a data storage element, preferably an RFID storage element, in order to preferably store material information and / or data relating to the processing of the plastic material for the front wheel fork.

[0077] The plastics proposed for the front wheel fork correspond to the plastics used for the main frame. For example, in the case of polyethylene (PE or HDPE), these have relatively low strength, hardness and stiffness, since reinforcing fillers such as fibers are omitted for reasons of recyclability and a simple type of plastic is used instead. In order to provide strength to the bicycle frame, the solution is to also configure the front wheel fork as a large-volume fork hollow body. Compared to the volume of known steel or aluminum front wheel forks, its volume is significantly greater and is also greater than the volume of front wheel forks made of fiber-reinforced plastic, such as carbon front wheel forks.

[0078] The invention also comprises a bicycle frame for a bicycle having a saddle and having a front wheel and a rear wheel located in a wheel track, the bicycle frame comprising a main frame according to any one of claims 1 to 25 and comprising a front wheel fork according to any one of claims 26 to 46.

[0079] The front wheel fork advantageously has two fork legs.Thereby a bicycle frame is provided which combines a single-sided rear wheel frame for the rear wheel and a two-sided bearing element for the front wheel.

[0080] The bicycle frame according to claim 41 or 42, characterized in that the main frame and the front wheel fork form a unit in the assembled state, wherein when the unit is subjected to an impact test, the total drop mass of 90 kg (which consists of sub-masses, namely the 50 kg mass M on the saddle tube element) is 90 kg (which consists of sub-masses, namely the 50 kg mass M on the saddle tube element) at a drop height of 200 mm according to DIN-ISO 4210-6:2015, Chapter 4.2 for city and trekking bicycles and according to DIN-ISO 4210-2:2015, Chapter 4.8.3. 1 , Test the 10kg mass M on the control head 2 and a 30kg mass M on the test pedal bearing 3 ) after impact testing, there were no cracks or breaks.

[0081] The bicycle frame proposed here, or the main frame and / or the front wheel fork, is designed to be used in an economic cycle. For this purpose, the material used to produce the main frame and / or the front wheel fork should be a thermoplastic that can be easily recycled. If the plastic is a homogeneous plastic, it can be easily recycled. The homogeneous nature of the plastic facilitates processing prior to reuse and simplifies the circular economy. In this way, old bicycle frames can be used as raw material, for example, to produce new bicycle frames.

[0082] The proposed main frame and / or front wheel fork advantageously use recyclable thermoplastics. The proposed solution consists in already using recycled plastics for initial production.

[0083] Finally, a bicycle component from the group consisting of a main frame, a front wheel fork and a running wheel is proposed. The bicycle component comprises a one-piece hollow body having a component wall surrounding its cavity, wherein the component wall of the hollow body is produced from a thermoplastic in a closed molding tool and has a one-piece structure, which is produced by means of rotational molding in a molding tool that can be heated from the outside and is provided for rotational molding, provided that a foam material is arranged in the cavity and that the foam material at least partially extends as a foam material layer on the inner side of the component wall or preferably completely fills the cavity.

[0084] The foaming process is advantageously implemented in the cavity. Preferably, the foaming process is implemented while the rotational molding of the component wall is still being carried out using the molten thermoplastic for the rotational molding of the component wall. The starting material of the foam material is filled into the produced cavity by at least one suitable filler arranged on the molding die so as to foam therein. In short, the starting material is filled into the same opening of the molding die as the thermoplastic used for the component wall before. A feed tube that can be inserted into the molding die can be used. The feed tube can be inserted deep to penetrate the layer of molten thermoplastic that has been formed inside the molding die. When the rotational motion of the molding die stops, the filling of the foam starting material can be easily implemented. The rotational motion of the molding die is not only a circular motion, but also advantageously, it is a complex three-dimensional motion in space. In order to fill the foam starting material, a component of the complex motion can be stopped, for example, so that the feed tube is inserted into the filling device of the molding die here, and the foam starting material can be filled into the remaining cavity.

[0085] In principle, the foaming process can be a physical process or the foaming process is based on a chemical reaction. The starting material of the foam material is practically filled in the form of particles through the filling device of the molding mold until the cavity is generated. For chemical foaming, it is simple to provide a foaming agent for the particles of the starting material. The foaming agent is preferably designed so that it can volatilize due to the heat input. When the starting material also melts due to the heat input, the volatilized foaming agent causes the molten starting material to foam. BRIEF DESCRIPTION OF THE DRAWINGS

[0086] The invention is illustrated in the following by way of example in the drawings and described in detail with reference to a number of diagrams. It is shown that:

[0087] Figure 1 A perspective view of a main frame according to the present invention,

[0088] Figure 2 according to Figure 1 A view of the right side of the main frame,

[0089] Figure 3 according to Figure 1 A view of the rear of the main frame,

[0090] Figure 4 according to Figure 1 A top view of the main frame.

[0091] Figure 5 according to Figure 2 Detailed view of the rear wheel receiving part along the section line VV,

[0092] Figure 6 according to Figure 2 Detailed view of the rear wheel receiving part with respect to the standard axle, center section line VV,

[0093] Figure 7 according to Figure 2 Detailed view of the pedal drive receiving part of VII-VII,

[0094] Figure 8 according to Figure 2 Detailed view of an alternative pedal drive receiving portion of VII-VII,

[0095] Fig. 9 A perspective view of a front wheel fork according to the invention,

[0096] Fig.10 according to Figure 8 A view of the right side of the front wheel fork.

[0097] Fig.11 according to Fig. 9 A cross-sectional view of the front wheel fork.

[0098] Fig.12 Front view of the front wheel fork with the assembled front axle,

[0099] Fig.13 Fig.12 The front axle,

[0100] Fig.14 A partial sectional view of the front axle in the state of being mounted on the fork end of the front wheel fork,

[0101] Fig.15 Alternative embodiment of a partial sectional view of a fork end of a front wheel fork for a standard axle,

[0102] Fig.16 Detailed view of the connection system for the handlebar halves according to XVI-XVI in 12,

[0103] Fig.17 A perspective view of a bicycle frame according to the present invention, comprising a main frame and a front wheel fork,

[0104] Fig.18 Perspective view of an alternative front wheel fork based on Fig. 9 A front wheel fork configured as a bicycle component having a rotationally molded hollow body and a foam material filling,

[0105] Fig.19 A right side view of another alternative front wheel fork, based on Fig.10 A front wheel fork is configured as a bicycle component having a rotationally molded hollow body with a layer made of a foam material. DETAILED DESCRIPTION

[0106] Figure 1 An embodiment of a main frame 1 according to the invention is shown for a bicycle which is ridden in an upright position with a saddle and with a front wheel and a rear wheel. The wheels are arranged on the same wheel track. The main frame 1 shown is manufactured as a hollow body 2 with a frame wall 3 surrounding a cavity. The hollow body 2 is designed as a single piece, or its frame wall 3 is designed as a single piece. The single-piece main frame 1 is manufactured by means of rotational molding in a rotational molding mold that can be heated from the outside from a fiber-free thermoplastic material, here a pure type of recycled rigid polyethylene (HDPE). The frame wall 3 is provided with a data storage element 3c, in which preferably material information and / or data related to the production of the main frame, in particular information about the plastic material used, is stored.

[0107] In order to provide the required strength of a bicycle frame, the main frame 1 is configured as a massive hollow body 2. The outer volume thereof is significantly greater than the outer volume of known main frames made of steel, aluminum or carbon.

[0108] The main frame 1 comprises a main beam 4 and a single-sided rear wheel frame 5 on which the rear wheel can be supported only on one side.

[0109] The structure of the main beam 4 has a region T where the frame wall 3 has a larger wall thickness. 1 、T 2 and T 3 In addition, according to Figure 1 Trapezoidal. An upper tube element 6, a lower tube element 7, a saddle tube element 8 and a steering tube element 9 are provided. All of the mentioned tube elements of the trapezoidal structure are voluminous and hollow and form the region of the hollow main beam 4. The lower tube element 7 and the saddle tube element 8 meet at a lower node 10 and form there a pedal drive receptacle 11 in the form of a closed pedal drive housing 12.

[0110] The steering tube element 9 is arranged at the front in the direction of travel. It is provided for receiving a control bearing that cooperates with the fork-shaped stud. The steering tube element 9 is configured as a hollow cylinder. It is designed to receive a steering bearing. For example, a steering bearing is understood to be a so-called front steering bearing group, which comprises a lower bearing and an upper bearing and a tensioning device with an adjustment element for the fork-shaped stud, wherein the lower bearing can be arranged at the bottom in the steering tube element 9 and the upper bearing can be arranged at the top in the steering tube element 9. The bearing clearance between the upper bearing and the lower bearing in the front steering bearing group can be adjusted by means of the tensioning device. Generally speaking, the terms "lower" and "upper" in this description always relate to the main components of the bicycle frame, more precisely when the bicycle equipped with the bicycle frame is in an upright position, such as, for example, in a forward driving operation.

[0111] The rear wheel frame 5 has a triangular structure 13. This includes the already mentioned saddle tube element 8 as well as an upper support element 14 and a lower support element 15. The saddle tube element 8 approximately forms the interface between the main beam 4 and the rear wheel frame 5. The left side of the rear wheel frame 5 in the direction of travel is called the wheel side W, and the right side of the rear wheel frame 5 is called the drive side D. In the ready-to-ride state of a bicycle with this main frame, the rear wheel is arranged on the wheel side W.

[0112] The lower support element 15 of the rear wheel carrier 5 is configured as a housing 16 for a drive device. At the front end 15a of the lower support element 15, it is connected to the lower tube element 7 and the saddle tube element 8 at the lower node 10. The area of ​​the lower node 10 is configured as the pedal drive housing 12 mentioned above. In the pedal drive housing 12, there is space for the pedal bearing and, alternatively, there is also sufficient space for a pedal bearing transmission. Alternatively, a pedal bearing drive that can be equipped with an electric motor can also be arranged.

[0113] The upper support element 14 of the rear wheel carrier 5 is connected to the saddle tube element 8 and the upper tube element 6 of the main beam 4 at the upper node 17. In the rear region 5a of the rear wheel carrier 5, the upper support element 14 and the lower support element 15 are connected at the rear node 18 and form a rear wheel receiving portion 19 there. The rear wheel receiving portion 19 is configured in the form of a bearing opening. The bearing opening 20 is arranged on the wheel side W, and the bearing opening 21 is arranged on the drive side D. The bearing openings 20 / 21 can be provided for receiving an axle support for a drive shaft (not shown) that rotates relative to the rear wheel carrier 5 and to which the rear wheel can be fastened. Alternatively, the bearing openings 20 and 21 can be provided for receiving a rear axle (not shown) that is fixedly arranged relative to the rear wheel carrier 5, so that the rear wheel supported on the rear axle rotates. The rear axle can be a standard rear axle.

[0114] Furthermore, the trapezoidal structure of the main beam 4 is provided with a reinforcing hollow bridge element 22 arranged between the upper tube element 6 and the lower tube element 7. Figure 1 The bridge member 22 is arranged substantially parallel to and close to the steering tube member 9. A polygonal open area 23 is provided between the bridge member 22 and the steering tube member 9. The bridge member 22 configured in this manner strengthens the main beam 4 of the main frame 1.

[0115] In addition, the saddle tube element 8 is provided with an upper saddle tube extension 24, which projects upward from the upper tube element 6. A reinforcing hollow bridge element 25 is provided on the saddle tube extension 24, which extends to the upper tube element 6. The saddle tube extension 24 is supported in this way. In addition, the bridge element 25 serves as a handle element 26, so that the bicycle can be lifted and easily carried when necessary.

[0116] also, Figure 1 It is shown that in the region of the pedal drive housing 12 on the drive side D a large service opening 27 is provided which provides access for maintenance and assembly purposes to the housing 16 for the drive means which can be received in an encapsulated manner in the lower support element 15 of the rear wheel carrier 5 .

[0117] Figure 2 , shows a right side view of the main frame 1, that is to say the drive side D. The pedal drive housing 12 can be seen, the large service opening 27 of which is closed here by a service cover 28. The service cover 28 is provided with a bearing opening 29 for receiving a bearing element, for example a bearing element for a pedal crankshaft.

[0118] On the left side of the main beam 4, the pedal drive housing 12 may not have a maintenance cover; only one bearing opening 30 for the pedal crankshaft is provided here, as in Figure 7 In order to provide stable bearing openings 29 and 30, the area T of the frame wall 3 1 The region T of the frame wall 3 forming the steering tube element 9 2 It is also reinforced.

[0119] Figure 3 The rear part of the main frame 1 is shown. It can be seen that the rear wheel receiving portion 19 on the rear wheel carrier 5 on the drive side D (right side) protrudes the furthest laterally. This serves to provide a sufficient distance between the bearing opening 21 on the drive side D and the bearing opening 20 on the wheel side W in order to be able to absorb the forces / torques introduced into the rear wheel carrier 5 by the rear wheel arranged on one side. In order to be able to provide stable bearing openings 20 and 21, the area T of the frame wall 3 is 3 Reinforced structure.

[0120] Figure 4 is based on Figure 11 , which shows the position of the center line M of the main beam 4. This center line M coincides with the wheel track in which the working wheel of the bicycle is arranged. In the area of ​​the rear wheel frame 5, its asymmetrical one-sided position is shown, namely on the right side of the wheel track in the direction of travel. The frame wall 3 of the main frame 1 has two frame walls 3a and 3b that are opposite to each other. In the top view of the drive side D, it can also be seen that the rear wheel receptacle 19 on the rear wheel frame on the drive side D protrudes the farthest laterally. It is also shown that the pedal drive housing 12 is flush with the lower bracket element 15 of the rear wheel frame 5. In addition, the top view provides a view looking into the upper opening 31 of the steering tube element 9 and the upper opening 32 of the saddle tube element 8.

[0121] Figure 5 Shown according to Figure 2 Cross section of the rear wheel receiving part 19 of the rear wheel carrier 5 along the center section line VV (more precisely in the indicated viewing direction). Two bearing openings are arranged thereafter, the bearing opening 20 being on the wheel side W. The second bearing opening 21 is arranged coaxially with the bearing opening 20, more precisely on the opposite drive side D of the rear wheel carrier 5. The bearing opening 20 / 21 is provided for receiving an axle support for a rear wheel axle (not shown). The bearing opening is configured as a hollow cylinder in order to receive the axle support. The bearing opening 20 has an inner stop surface 33 in the axial direction, which serves as an axial stop surface for the bearing element. The cylindrical inner surface 33a serves as a support for the bearing element. The diameter of the bearing opening 20 and the mass of the inner surface 33a must be designed to match the desired bearing element, that is to say within the required tolerances. The inner surface 33a can be a plastic surface. Using a rotational molding process, a precisely fitting bearing opening with a surface made of plastic can be produced. Alternatively, a metal ring can be integrated during the rotational molding process, which is prefabricated in an exact-fitting manner. Alternatively, an exact-fitting integrated aluminum ring 34 is indicated by dash-dotted lines in the region of the inner face 33a. The aluminum ring 34 is connected to the plastic of the rear wheel carrier by bonding and / or form-locking.

[0122] The bearing opening 21 arranged on the wheel side W has an inner stop surface 35 and a cylindrical inner surface 35a. The dash-dotted line in the area of ​​the inner surface 35a represents an alternative to an integrated, precisely fitted aluminum ring 36. The aluminum ring 36 is also connected to the plastic of the rear wheel carrier 5 by bonding and / or form-locking.

[0123] The bearing opening 20 has a larger diameter than the bearing opening 20 arranged on the drive side D. This is advantageous if the drive means arranged in the encapsulated housing 16 are arranged closer to the wheel side W and greater forces tend to be expected there.

[0124] The diameter of the hollow cylindrical bearing openings 20 and 21 is preferably in the range of 40 mm to 130 mm. In the present exemplary embodiment, the wheel-side bearing opening 20 has a diameter of 120 mm, while the bearing opening 21 arranged on the drive side D has a diameter of 90 mm.

[0125] Figure 6 It also shows that according to Figure 2 , wherein the rear wheel carrier 19 is shown together with the rear wheel 100 indicated by dashed lines. In this embodiment, a fixed solid rear axle 101 is provided. The rear wheel carrier 5 on one side corresponds to the rear wheel carrier 5 on the other side. Figure 5 The rear wheel carrier 5 is a single-sided rear wheel carrier, i.e. it has bearing openings 20 and 21. A cylindrical disk element 102 is arranged in the bearing opening 21, which is provided with a through opening 102a for the rear axle 101. The rear wheel 100 has a hub sleeve 103, which forms a seat 103a for a rolling bearing 104 on the outside, more precisely for the inner ring of the rolling bearing 104. The associated outer ring of the rolling bearing 104 is mounted in the rear wheel carrier 5, more precisely in the bearing opening 20 of the rear wheel carrier 5. The hub sleeve 103 also has a hollow cylindrical interior 105, which provides space for a rolling bearing 106 and a freewheel element 107. The rolling bearing 106 is configured so that it must be prestressed in the axial direction. The prestressing is provided by means of the rear axle 101 which, for this purpose, has threaded ends 101 a and 101 b in order to prestress them by means of axle nuts 108 and 109 .

[0126] A pinion 112 as part of the bicycle drive is supported on the rear axle 101 by means of two rolling bearings 110 and 111. In the assembled state, the pinion 112 interacts with a bicycle chain (not shown) as a drive element, wherein the drive element is arranged in the rear wheel carrier 5. The rear wheel carrier 5 serves as a housing 16 for encapsulating the drive element and the pinion 112.

[0127] The mentioned freewheel element 106 is connected between the pinion 112 and the hub sleeve 103 so that a rotational movement can only be transmitted in one rotational direction of the rear wheel and a torque can be transmitted.

[0128] for Figure 6 In an embodiment of the invention, the rear wheel may for example be provided with a conventional hub gear with a fixed axle. The axle may be a solid axle or alternatively a hollow axle.

[0129] Figure 7 Shown in Figure 2VII-VII through the cross section of the pedal drive receptacle 11 of the main frame 1. The pedal drive receptacle 11 comprises a maintenance opening 27 on the drive side D, which is provided for receiving a maintenance cover 28. The maintenance cover 28 has a bearing opening 29, preferably for a sliding bearing element 120, which is used to support a pedal crankshaft (not shown). In this exemplary embodiment, the sliding bearing element 120 has a diameter of 30 mm. On the opposite side, the pedal drive receptacle 11 has a bearing opening 30, in which a bearing element (not shown) for the pedal crankshaft can also be received, preferably also a sliding bearing element. In the exemplary embodiment, the maintenance opening 27 for the maintenance cover 28 is provided with a diameter of 120 mm.

[0130] Figure 8 It also shows that according to Figure 2 VII-VII, which can be seen in FIG. 1 , shows a cross section through the pedal drive receiving part 11 of the main frame 1 . It relates to an alternative configuration of the pedal drive receiving part 11 , which differs in the modified bearing openings 121 and 122 . Both bearing openings 121 and 122 have a large cross section. In the embodiment, their diameter is 120 mm. The large bearing opening is used, for example, to receive rolling bearings whose inner ring and / or outer ring are made of plastic. For example, this embodiment makes it possible to receive a pedal drive, which includes a pedal bearing transmission or a pedal bearing drive with an electric motor.

[0131] according to Figures 1 to 4 The main frame shown has an envelope volume of 20.25 litres with a tolerance of ±0.25 litres. Its weight is 4.75 kg with a tolerance of ±0.2 kg.

[0132] Fig. 9 4 is a perspective view of a front wheel fork 40 according to the present invention. The front wheel fork is designed for a bicycle that is ridden in an upright position using a saddle. The bicycle is provided with a front wheel and a rear wheel that are arranged in a wheel track.

[0133] The front wheel fork 40 has a stable fork bridge region 41. Two fork legs 42 and 43 are arranged symmetrically and pointing downwards in the fork bridge region. In addition, a fork arm 44 or 45 is arranged at the top of each fork leg, which extends to an integrated handlebar element 46 and is connected to it. A fork stud 47 is arranged in the middle of the fork bridge, which is shown in dashed lines. In the present embodiment, the fork stud 47 is a metal tube connected to the fork bridge region 41 in a torsionally fixed manner.

[0134] It can be clearly seen that the handlebar element 46 is split in the middle. It has a left handlebar half 48 and a right handlebar half 49, which are each connected to a corresponding fork arm. This division serves to simplify the assembly of the front wheel fork 40. The fork arms 44 and 45 are designed so that they can be elastically spread out, so that the handlebar halves 48 and 49 can be moved far enough away from each other to thereby be able to insert the fork stud 47 of the front wheel fork into the steering bearing of the bicycle frame. The fork arms then rebound and are finally fixed by means of a connection system, which is Fig.11 in and best in Fig.17 Shown in.

[0135] The proposed front wheel fork 40 is manufactured from a thermoplastic in a closed rotational molding tool. It forms a fork hollow body 50 with a fork wall 51. The fork hollow body 50 is integral and its fork wall 51 is seamless. In the present embodiment, as described above, only the fork stud 47 is subsequently inserted and connected to the fork bridge area 41 of the fork hollow body 50. This integral structure is produced by means of rotational molding in a rotational molding tool that can be heated from the outside, more precisely from a fiber-free thermoplastic, here a pure type of recycled rigid polyethylene (HDPE). The subsequently inserted fork stud 47 can also be placed in the rotational molding tool as an alternative, so as to be connected to the thermoplastic of the fork hollow body 50 during the rotational molding process. In this way, the metal tube of the fork stud is also provided as an integrated component of the front wheel fork.

[0136] The fork leg 44 is provided with a fork end 52 and the fork leg 45 is provided with a fork end 53 to receive a front axle. It is a special front axle with a large diameter, as can be seen in the fork ends 52 and 53. The fork ends are configured to be open downwards and a separate closing element is provided for each fork end 52 / 53, as will be described below.

[0137] The fork leg 42 is also provided with a fastening element 54 which can be used, for example, for mounting a brake device, in particular a brake caliper for a disc brake.

[0138] The fork hollow body 50 has regions of different wall thickness of the fork wall 51. The thicker regions of the fork wall 51 are produced by the higher heat input into this region from the outside into the rotational molding die. In this embodiment, the lower regions 42a and 43a of the fork legs 42 and 43 are provided with thicker fork walls.

[0139] The fork wall 51 is provided with a data storage element 51 a , in which preferably material information and / or data related to the production of the front wheel fork 40 , in particular information about the plastic material used, is stored.

[0140] according to Fig.10The front wheel fork 40 including the closing elements 55 and 57 has an envelope volume of 5 liters with a tolerance of ±0.15 liters. Their weight is in the range of 2.4 kg to 3.2 kg with a tolerance of ±0.1 kg.

[0141] Fig.10 A side view of a front wheel fork 40 is shown. A closing element 55 is mounted on the fork end 53 of a fork leg 43. The closing element 55 complements the fork end 53 and together with it forms a receiving opening 56 for holding a special front axle. Connecting means 55a and 57a in the form of screws (not shown) are provided to fasten the closing elements 55 and 57 to the fork leg 42 or 43. For assembly, the front axle can be inserted laterally or from below and fixed with the closing element 55.

[0142] In the present embodiment, the closing element 55 causes a clamping connection which fixes the front axle to the fork end in a torsionally fixed manner. Instead of a clamping connection with a friction lock, a form-locking configuration can also be provided to achieve a torsionally fixed fixation of the front axle in the receiving opening of the fork leg.

[0143] In the present embodiment, in order to provide fixation, a screw is provided as a connecting means. Therefore, the fork end is provided with an internal thread, and matching this, the closing element has a through opening for the screw.

[0144] Fig.11 Shown according to Fig. 9 The cross section of the section line XI-XI in FIG. 1 is shown in FIG. 1 , wherein the fork-shaped stud 47 is at Fig.11 The fork-shaped stud 47 is held at the bottom in the fork bridge area 41 and at the top by means of the already mentioned connection system, according to Fig.16 The connection system is described in detail. Fig.11 4 shows a closure element 57 belonging to the fork end 52 of the fork leg 42 , which thus forms a receiving opening 58 for the front axle.

[0145] like Fig.12 As shown, the front wheel fork 40 is equipped with a special front axle 59. The front axle 59 is a structurally important component for the proposed front wheel fork 40. For the front wheel fork 40 with the fork hollow body 50 made of a simple type of plastic, it is advantageous to provide the front axle 59 as a reinforced structural element. As a result, the strength of the front wheel fork 40 can be significantly increased.

[0146] The front axle 40 includes two pot-shaped or Fig.13Two hollow cylindrical shaft elements 60 and 61 are shown. The two shaft elements of the front axle are arranged flush and connected to each other. For this purpose, connecting ends 60a or 61a are provided, wherein the connecting end 60a of the shaft element 60 is provided with an external thread 62, and the connecting end 61a of the shaft element 61 is provided with a matching internal thread 63, which are screwed to each other.

[0147] The shaft element 60 has a bearing seat 64 for the impeller bearing. In addition, the shaft element 60 is provided with a cylindrical mating region 65 for connection with the fork end 52 of the fork leg 42. The mating region 65 comprises lateral tabs 65a and 65b, such as Fig.14 . The distance between the tabs 65a and 65b corresponds to the thickness of the fork leg 42. The fork leg 42 is fixed between the tabs 65a and 65b. In the same way, the axle element 61 is provided with a bearing seat 66 for the running wheel bearing and has a mating area 67 for the purpose of connecting to the fork end 53 of the fork leg 43. The mating area 67 is also provided with tabs 67a and 67b. These tabs fix the fork leg 43 in the axial direction of the front axle 59 in the same way.

[0148] The bearing seats 64 / 66 and the engagement areas 65 / 67 are arranged on the circumference of the axle element 60 / 61. In the present embodiment, the engagement areas 65 / 67 have a cylindrical cross section and are clamped in the receiving openings 56 or 58 of the fork legs. In this way, the front axle 59 is arranged in a torsionally fixed manner relative to the front wheel fork 40 and serves as an element of the reinforcement structure of the front wheel fork 40.

[0149] Fig.15 An alternative configuration of the fork ends of a front wheel fork for a standard axle is shown. The fork legs 42 and 43 correspond to Fig.14 42 and 43. The adapter element 56a or 58a is arranged in the receiving opening 56 or 58, respectively. The adapter elements 56a and 58a are identical components. They each have a central opening 56b or 58b, respectively, which is provided for receiving a standard axle. The central openings 56b / 58b are respectively longitudinal holes. This makes it possible to adjust the orientation of the front wheel centrally between the fork legs 42 and 43.

[0150] Fig.16 It is shown in Fig.12 Detailed view along the center section line XVI-XVI. The handlebar half 48 of the split handlebar element 46 and the fork arm 44 carrying the handlebar half 48 can be seen. In order to be able to assemble the front wheel fork 40 in the steering bearing element of the main frame, the fork arm 44 / 45 with the handlebar half 48 / 49 located thereon is unfolded and springs back in the assembled state. The handlebar halves are then fixed to each other and to the fork stud 47 by means of the connecting system 68.

[0151] The proposed connection system 68 is designed so that it connects the two handlebar halves 48 and 49 with a single screw and also realizes the fastening thereof to the fork stud 47. It comprises a double-cone element 69 which is divided in a vertical plane and forms two double-cone side surfaces 70 and 71. The double-cone side 70 is assigned to the handlebar half 48 and the double-cone side surface 71 is assigned to the handlebar half 49. In the present embodiment, the double-cone side surfaces 70 and 71 are integral components of the fork hollow body 50.

[0152] The double cone side 70 comprises an upwardly directed cone part 70a and a downwardly directed cone part 70b, and the double cone side 71 comprises an upwardly directed cone part 71a and a downwardly directed cone part 71b.

[0153] Furthermore, a pot-shaped lower clamping element 72 is provided, which is arranged on the fork-shaped stud 47. The inner surface 73 of the clamping element 72 is conical and abuts against the downwardly directed cones 70b and 71b of the two handlebar halves 48 / 49 in order to fix them.

[0154] Likewise, a cap-shaped upper clamping element 74 is provided, which closes the free end of the fork-shaped stud 47. The upper clamping element has a conical inner surface 75. The inner surface 75 abuts against the upwardly directed cones 70a and 71a in order to fix them or the separate handlebar halves 48 / 48.

[0155] The upper clamping element 73 is provided with a through opening 76 for an adjusting screw 77. The adjusting screw 77 projects into the fork-shaped stud 47 and is screwed into a nut element 78, which can be fixed with a friction fit in the hollow cylindrical fork-shaped stud 47. In the exemplary embodiment, this is a claw nut 79, which can be fixed by means of elastic claws 80.

[0156] By means of the adjusting screw 77, the handlebar halves 48 and 49 are precisely fixed and at the same time connected to the fork stud 47. In addition, the axial play of the steering bearing can be adjusted by means of the adjusting screw 77.

[0157] Fig.17 A bicycle frame 81 including a main frame 1 and a front wheel fork 40 is shown.

[0158] Fig.18 A perspective view of an alternative bicycle component is shown. Taking the front wheel fork as an example, it is explained how to construct and manufacture the alternative bicycle component. The embodiment of the alternative bicycle component is based on Fig. 9 The front fork in. Fig.18The bicycle component is configured as a one-piece hollow body (here the fork hollow body 50) with a component wall surrounding its cavity, here the fork arm 51. The fork wall 51 is manufactured from a thermoplastic material in a closed molding die. The one-pieceness of the fork wall 51 is manufactured by means of rotational molding in a molding die that can be heated from the outside and is provided for rotational molding. Fig.18 The alternative is Fig. 9 The embodiment of EMBODIMENT 2 differs from that of EMBODIMENT 2 in that a foam material 125 is additionally arranged in the fork hollow body 50 , which fills the cavity in this embodiment.

[0159] The foaming process is carried out in the cavity while the rotational molding of the fork wall 51 is still being carried out using the molten thermoplastic for the fork wall 51. The starting material of the foam material is filled into the molding mold as particles via suitable filling means. The particles used can be foamed by chemical reaction, for which purpose they contain a foaming agent. In this embodiment, the foaming agent is designed to volatilize due to the heat input. Due to the heat input, the starting material is also melted, and the starting material is foamed due to the volatilized foaming agent.

[0160] Fig.19 Another embodiment of an alternative bicycle component is shown. By way of example, for this alternative, how to construct and manufacture an alternative bicycle component is explained based on a front wheel fork. This embodiment is based on Fig.10 Illustration of the front fork. Fig.19 The bicycle component is again constructed as a one-piece hollow body, here a fork hollow body 50 with a component wall, namely a fork wall 51. The fork wall 51 surrounds the cavity. The fork wall is produced from a thermoplastic material in a closed molding tool. The one-pieceness of the fork wall 51 is again produced by means of rotational molding in a molding tool, which can be heated from the outside for rotational molding.

[0161] Fig.19 The alternative is Fig.10 Embodiments and Fig.18 The difference of the embodiment of is that a foam material 126 is additionally arranged in the fork hollow body 50, which in this embodiment coats the component wall of the bicycle component (i.e. the fork wall 51) on its inner side facing the cavity. Although the cavity of the fork hollow body 50 is reduced in this way, it does not disappear.

[0162] Reference numerals list

[0163] 1 Main frame

[0164] 2 Hollow body

[0165] 3 Frame wall

[0166] 3a Frame wall

[0167] 3b frame wall

[0168] 3c data storage components

[0169] 4 Main beam

[0170] 5 Rear wheel frame

[0171] 5a Rear area

[0172] 6 Upper tube element

[0173] 7 Down tube element

[0174] 8 Saddle tube element

[0175] 9 Steering tube element

[0176] 10 Next Node

[0177] 11 pedal driver receiving part

[0178] 12 pedal drive housing

[0179] 13Triangle structure

[0180] 14 Upper bracket element

[0181] 15 Lower bracket element

[0182] 15a Front end

[0183] 16 Housing (driving device)

[0184] 17 nodes

[0185] 18th node

[0186] 19 Rear wheel receiving part

[0187] 20 bearing opening

[0188] 21 bearing opening

[0189] 22 bridge elements

[0190] 23 Opening area

[0191] 24 Seat Tube Extension

[0192] 25 Intermediate components

[0193] 26 handle elements

[0194] 27 maintenance openings

[0195] 28 Maintenance cover

[0196] 29 bearing opening

[0197] 30 bearing opening

[0198] 31 upper opening (steering tube element)

[0199] 32 upper opening (saddle tube element)

[0200] 33 inner stop surface (bearing opening 20)

[0201] 34 inner stop surface (bearing opening 21)

[0202] 40 front wheel fork

[0203] 41 Fork Bridge Area

[0204] 42 Left fork leg

[0205] 42a Enhanced area (fork wall)

[0206] 43 right cross leg

[0207] 43a Enhanced area (fork wall)

[0208] 44 Left wishbone

[0209] 45 right fork arm

[0210] 46 handlebar components

[0211] 47 Forked Column

[0212] 48 Left handlebar half

[0213] 49 right handlebar half

[0214] 50 fork hollow body

[0215] 51 Fork Wall

[0216] 51a Data storage element

[0217] 52 Fork end

[0218] 53 Fork end

[0219] 54 Fastening elements

[0220] 55 Closure element

[0221] 55a Connector

[0222] 56 receiving part opening

[0223] 56a Adapter element

[0224] 56b Center opening

[0225] 57 Closure element

[0226] 57a Connector

[0227] 58 receiving part opening

[0228] 58a Adapter element

[0229] 58b Center opening

[0230] 59 front axle

[0231] 60 axis components

[0232] 60a connection end

[0233] 61 shaft components

[0234] 61a Connection end

[0235] 62 external thread

[0236] 63 internal thread

[0237] 64 bearing seat

[0238] 65 Coordination Area

[0239] 65a splice

[0240] 65b splice

[0241] 66 bearing seat

[0242] 67 Coordination Area

[0243] 67a Splice

[0244] 67b splice

[0245] 68 connection system

[0246] 69 double chamber element

[0247] 70 double chamber side

[0248] 70a Upper cone

[0249] 70b Lower cone

[0250] 71a Upper cone

[0251] 71b Lower cone

[0252] 72 Lower clamping element

[0253] 73 inner surface (lower clamping element)

[0254] 74 Upper clamping element

[0255] 75 inner surface (upper clamping element)

[0256] 76 through opening

[0257] 77 Adjustment screw

[0258] 78 nut element

[0259] 79 claw nut

[0260] 80 claws

[0261] 81 Bicycle Frame

[0262] 100 Rear wheel

[0263] 101 Rear axle

[0264] 101a Threaded end

[0265] 101b Threaded end

[0266] 102 disk components

[0267] 102a Through opening

[0268] 103 Wheel hub sleeve

[0269] 103a Support

[0270] 104 Rolling bearings

[0271] 105 Hollow cylindrical interior space

[0272] 106 Rolling bearings

[0273] 107 Freewheel element

[0274] 108 Shaft nut

[0275] 109 Shaft nut

[0276] 110 Rolling bearings

[0277] 111 Rolling bearings

[0278] 112 Small gear

[0279] 120 Sliding bearing elements

[0280] 121 Bearing opening

[0281] 122 Bearing opening

[0282] 125 Foam filling

[0283] 126 Foam material layer

[0284] D Drive side

[0285] W wheel side

[0286] M Centerline

Claims

1. A main frame (1) for a bicycle having a saddle and having a front wheel and a rear wheel arranged in a wheel track, the main frame being manufactured from thermoplastic in a closed molding mold, characterized in that The main frame is formed as a one-piece hollow body (2), which has a frame wall (3) surrounding the cavity of the hollow body; and the frame wall (3) of the hollow body (2) has an integral nature, which is manufactured by means of rotational molding in a rotational molding mold that can be heated from the outside.

2. The main frame (1) according to claim 1, characterized in that: The hollow body (2) has regions of different wall thicknesses of the frame wall (3).

3. The main frame (1) according to claim 2, characterized in that: Regions of different wall thicknesses in the frame wall (3) are produced by a regionally different input of heat from the outside into the rotational molding tool.

4. The main frame (1) according to any one of claims 1 to 3, characterized in that: The thermoplastic plastic of the frame wall (3) is selected from one of the following plastics: polypropylene (PP), preferably polyethylene (PE), and particularly preferably high-density polyethylene (HDPE).

5. The main frame (1) according to any one of claims 1 to 4, characterized in that: The thermoplastic is fiber-free.

6. A main frame (1) for a bicycle having a saddle and a front wheel and a rear wheel arranged in a wheel track, the main frame being made of thermoplastic, wherein: The invention relates to an integrated vehicle comprising a main beam (4) and a single-sided rear wheel frame (5), wherein the rear wheel frame (5) is configured as a hollow body (2) under the following conditions, the rear wheel frame (5) forms a housing (16) for encapsulating a drive device, and the rear wheel frame (5) is provided with a rear wheel receiving portion (19), and is characterized in that the main beam (4) is integrally hollow with opposing frame walls (3a, 3b) and is implemented as an integrated unit with the rear wheel frame (5).

7. The main frame (1) according to claim 6, characterized in that: The rear wheel receiving portion (19) is constructed in the form of two coaxial bearing openings (20, 21); the coaxial bearing openings (20, 21) are arranged in mutually opposite frame walls (3a, 3b) of the rear wheel carrier (5).

8. The main frame (1) according to claim 7, characterized in that: The frame wall (3) of the hollow body (2) has an integral structure which is produced by means of rotational molding in a rotational molding tool which can be heated from the outside.

9. The main frame (1) according to claim 8, characterized in that: The hollow body (2) has regions of different wall thicknesses of the frame wall (3).

10. The main frame (1) according to claim 7, characterized in that: Regions of different wall thicknesses in the frame wall (3) are produced by a regionally different input of heat from the outside into the rotational molding tool.

11. The main frame (1) according to any one of claims 1 to 10, characterized in that: Opposite wall regions of the main beam are provided with coaxial bearing openings (29, 30) for receiving a pedal drive.

12. The main frame (1) according to claim 11, characterized in that: One of the bearing openings for the pedal drive is used in an integrated manner as a maintenance opening for the rear wheel carrier (5), which is designed as an encapsulated housing (16) for the drive means.

13. The main frame (1) according to any one of claims 6 to 12, characterized in that: The main beam (4) is constructed as a trapezoidal structure, which comprises an upper tube element (6), a lower tube element (7), a saddle tube element (8) and a steering tube element (9).

14. The main frame (1) according to claim 13, characterized in that: The trapezoidal structure has a reinforcing bridge element (22) arranged between the upper tube element (6) and the lower tube element (7).

15. The main frame (1) according to claim 13 or 14, characterized in that: The saddle tube element (8) has an upper saddle tube extension (24) protruding beyond the upper tube element (6).

16. The main frame (1) according to claim 15, characterized in that: A reinforcing bridge element (25) is provided extending from the upper tube element (6) to the saddle tube extension (24).

17. The main frame (1) according to any one of claims 1 to 16, characterized in that: The main frame (1) has an envelope volume in the range of 18 to 22 liters, preferably in the range of 19 to 21 liters and particularly preferably in the range of 20 to 20.5 liters, and a weight in the range of 3.5 to 5.5 kg, preferably in the range of 4.0 to 5.0 kg and particularly preferably in the range of 4.5 to 4.9 kg.

18. The main frame (1) according to claim 17, characterized in that: The main frame (1) has a specific gravity in the range of 0.16 kg / liter to 0.32 kg / liter with respect to its envelope volume.

19. The main frame (1) according to any one of claims 1 to 18, characterized in that: The inner volume of the hollow body (2) is at least partially provided with a foam material.

20. The main frame (1) according to claim 19, characterized in that: The foam material is produced by foaming in the inner volume of the hollow body (2).

21. The main frame (1) according to any one of claims 1 to 20, characterized in that: The main frame is configured to have no cracks or breaks after an impact test with a drop mass of 22.5 kg from a drop height of 180 mm according to DIN-ISO 4210-6:2015, Chapter 4.1 for city and trekking bicycles and according to DIN-ISO 4210-2:2015, Chapter 4.8.

2.

22. The main frame (1) according to any one of claims 1 to 21, characterized in that: The main frame is designed so that it has no cracks or breaks after a dynamic test with a pedal force F1 of 1000 N for city and hiking bicycles according to DIN-ISO 4210-6:2015, Chapter 4.3 and after 100,000 required test cycles according to DIN-ISO 4210-2:2015, Chapter 4.8.

4.

23. The main frame (1) according to any one of claims 1 to 22, characterized in that: The main frame is designed so that it has no cracks or breaks after dynamic testing according to DIN-ISO 4210-6:2015, Chapter 4.4, for city and hiking bicycles using an installed replacement fork with a horizontal force F2 of 450 N in the direction of travel and a horizontal force F3 of 450 N against the direction of travel, and after 100,000 required test cycles according to the requirements of DIN-ISO4210-2:2015, Chapter 4.8.

5.

24. The main frame (1) according to any one of claims 1 to 23, characterized in that: The main frame is designed so that it has no cracks or breaks after a dynamic test with a vertical force F4 of 1000 N for city and hiking bicycles according to DIN-ISO 4210-6:2015, Chapter 4.5 and after 50,000 required test cycles according to DIN-ISO 4210-2:2015, Chapter 4.8.

6.

25. The main frame (1) according to any one of claims 1 to 24, characterized in that: The main frame is provided with a data storage element (3c), preferably an RFID storage element, in order to preferably store material information and / or data related to the processing of the plastic material used for the main frame (1).

26. A front wheel fork (40) for a bicycle having a saddle and provided with a front wheel and a rear wheel arranged in a single track, the front wheel fork being manufactured from thermoplastic in a closed molding tool, wherein: At least one fork leg (42, 43) is provided, characterized in that the front wheel fork is constructed as a fork hollow body (50) having a fork wall (51); and the fork wall (51) of the fork hollow body (50) has an integral structure, which is manufactured by means of rotational molding in a rotational molding mold that can be heated from the outside.

27. The front wheel fork (40) according to claim 26, characterized in that: The fork hollow body (50) has regions of different wall thicknesses of the fork wall (51).

28. The front wheel fork (40) according to claim 27, characterized in that: The regions of different wall thickness of the fork wall (51) are produced by a regionally different input of heat from the outside into the rotational molding tool.

29. A front wheel fork (40) for a bicycle, the bicycle having a saddle and provided with a front wheel and a rear wheel arranged in a single wheel track, the front wheel fork being formed in one piece from thermoplastic, the front wheel fork comprising either a fork leg (42, 43) arranged on one side or two such fork legs (42, 43) arranged symmetrically, the fork leg having an upper end and a lower end, wherein: A receiving opening (56, 58) is provided at the lower end of one fork leg or at the lower ends of both fork legs (42, 43), wherein the receiving opening (56, 58) is provided for holding a front axle (59), characterized in that a fork bridge area (41) is constructed at the upper end of the fork legs (42, 43), a fork arm (44, 45) pointing upward is arranged on one side of the fork bridge area, or two fork arms (44, 45) pointing upward and arranged symmetrically are arranged at the fork bridge area.

30. The front wheel fork (40) according to claim 29, characterized in that: The fork arms (44, 45) have an upper end; and the upper ends of the fork arms (44, 45) are connected to a handlebar element (46).

31. The front wheel fork (40) according to claim 30, characterized in that: The handlebar element (46) is designed in one piece as a part of the hollow fork body (50).

32. The front wheel fork (40) according to any one of claims 29 to 31, characterized in that: The receiving openings (56, 58) of the fork legs (42, 43) which are provided for holding a front axle (59) form downwardly open fork ends (52, 53), into which the front axle (59) can be inserted laterally.

33. The front wheel fork (40) according to claim 32, characterized in that: Closing elements (55, 57) are provided, by means of which the downwardly open fork ends (52, 53) can be closed.

34. The front wheel fork (40) according to claim 33, characterized in that: At least one connecting device (55a, 57a) is provided for fastening the closing element (55, 57) to the fork legs (42, 43), thereby enabling the front axle (59) to be fixed.

35. The front wheel fork (40) according to any one of claims 29 to 34, characterized in that The front wheel fork has an envelope volume in the range of 3.5 to 6.5 liters, preferably in the range of 4.5 to 5.5 liters and particularly preferably in the range of 4.7 to 5.3 liters, and a weight in the range of 1.9 to 3.7 kg, preferably 2.4 to 3.2 kg and particularly preferably 2.7 to 2.9 kg.

36. The front wheel fork (40) according to claim 35, characterized in that The front wheel fork has a specific weight of 0.29 kg / litre to 1 kg / litre in relation to its envelope volume.

37. The front wheel fork (40) according to any one of claims 29 to 36, characterized in that The fork hollow body (50) is produced in one piece by means of rotational molding in a rotational molding mold which can be heated from the outside.

38. The front wheel fork (40) according to claim 37, characterized in that The fork hollow body (50) has regions of different wall thicknesses of the fork wall (51).

39. The front wheel fork (40) according to claim 38, characterized in that The regions of different wall thickness of the fork wall (51) are produced by a regionally different input of heat from the outside into the rotational mould.

40. The front wheel fork (40) according to any one of claims 29 to 39, characterized in that The front axle (59) is assigned as a structural member.

41. The front wheel fork (40) according to claim 40, characterized in that The front axle (59) comprises two pot-shaped or two hollow cylindrical axle elements (60, 61), each axle element (60, 61) having a bearing seat (64) for a running wheel bearing and a matching area (65) for connecting to the fork ends (52, 53) of fork legs (42, 43); under the following conditions, the matching area (65) has a cylindrical or polygonal cross-section, and the unit composed of the fork ends (52, 53) and the closing element (55, 57) has a hollow cylindrical or hollow polygonal cross-section matching therewith.

42. The front wheel fork (40) according to claim 41, characterized in that Two shaft elements (60, 61) can be connected to each other flush to establish a shaft connection; each shaft element (60, 61) has a connecting end (60a, 61a); and the shaft connection can be established by means of the connecting end (60a, 61a).

43. The front wheel fork (40) according to claim 42, characterized in that The connecting ends (60a, 61a) of the two shaft elements (60, 61) are designed in such a way that the shaft connection can be produced by means of a screw.

44. The front wheel fork (40) according to claim 43, characterized in that The screw has a separate screw with a separate nut, or the nut thread is integrated in one of the shaft elements (60, 61).

45. The front wheel fork (40) according to claim 43 or 44, characterized in that: The helical portion is provided by a connection end (60a) in the form of an external thread (62) on the cylindrical outer surface of one of the shaft elements (60), wherein the connection end (61a) of the other shaft element (61) is configured in the form of a matching internal thread (63).

46. ​​The front wheel fork (40) according to any one of claims 29 to 45, characterized in that The front wheel fork is provided with a data storage element (51a), preferably an RFID storage element, in order to preferably store material information and / or data related to the processing of the plastic material used for the front wheel fork (40).

47. A bicycle frame (81) for a bicycle having a saddle and having a front wheel and a rear wheel located in a wheel track, the bicycle frame comprising a main frame (1) according to any one of claims 1 to 25 and a front wheel fork (40) according to any one of claims 26 to 46.

48. The bicycle frame according to claim 47, characterized in that The front wheel fork (40) has two fork legs (42, 43).

49. The bicycle frame according to claim 47 or 48, characterized in that The main frame (1) and the front wheel fork (40) form a unit in the assembled state; and when the unit is subjected to an impact test, after an impact test at a drop height of 200 mm with a total drop mass of 90 kg according to DIN-ISO 4210-6:2015, Chapter 4.2 for urban and trekking bicycles and according to DIN-ISO 4210-2:2015, Chapter 4.8.3, the unit has no cracks or breaks, the total drop mass consisting of sub-masses, namely a 50 kg mass M1 on the saddle tube element, a 10 kg mass M2 on the test control head and a 30 kg mass M3 on the test pedal bearing.

50. A bicycle component from the group consisting of a main frame, a front wheel fork and a running wheel, the bicycle component comprising a one-piece hollow body (50) having a component wall (51) surrounding its cavity, wherein: The component wall (51) of the hollow body (50) is manufactured from thermoplastic in a closed molding tool, wherein the component wall (51) has an integral structure, which is manufactured by means of rotational molding in a molding tool designed for rotational molding and can be heated from the outside, with the additional condition that foam material is arranged in the cavity and that the foam material at least partially extends as a foam material layer (126) on the inner side of the component wall (51) or completely fills the cavity as a foam material filler (125).

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