Structural component of a bicycle, bicycle frame, bicycle comprising a structural component, and handlebar as structural component

Abstract

The invention relates to a structural component of a bicycle, comprising a core (2, 89) with at least one cavity (25, 25a, 46, 46a, 72, 95, 95a, 112, 112a, 129, 129a, 144, 144a, 158, 158a) and an encasing lateral surface (2a, 89a), and comprising a shell element (5, 90, 109, 126, 141, 155, 168) with the stipulation that both the core (2, 89) and the shell element (5, 90, 109, 126, 141, 155, 168) each have a structurally supporting function, and that the supporting function is reinforced by means of an integrally joined connection between the encasing lateral surface (2a, 89a) of the supporting core (2, 89) and an inner surface (5a, 90a, 126a, 141a, 155a, 168a) of the supporting shell element (5, 90, 109, 126, 141, 155, 168); and it relates to a bicycle frame comprising a plurality of frame components, of which at least one is formed as a structural component; and it relates to a bicycle comprising at least one component which is formed as a structural component, and it relates to a handlebar which is formed as a structural component.

Description

[0001] Structural component of a bicycle, bicycle frame,

[0002] Bicycle comprising a structural component and handlebars as a structural component

[0003] The invention relates to a structural component of a bicycle, wherein a structural component within the meaning of the invention is understood to mean, in particular, safety-relevant bicycle structural components. In the narrower sense, these are bicycle structural components such as the bicycle frame, fork or steering knuckle, stem, handlebars, seat post, crank arms and pedals which are safety-relevant for the operation of the bicycle. However, other components such as frame components which can be joined together to form a bicycle frame are also understood to be a bicycle structural component. In a broader sense, components such as rims or wheels are also meant. In addition, accessory components can be provided as a structural component according to the invention, for example a saddle, brake and gear levers, mudguards or dirt deflectors, bicycle support (stand), luggage rack, luggage container, child seat, etc.

[0004] The proposed structural component of a bicycle represents a bicycle structural component or may be referred to as a structural component intended for a bicycle, hereinafter simply referred to as a structural component.

[0005] The structural component comprises a core with at least one inner cavity and an enveloping shell surface and comprises a shell element.

[0006] Furthermore, the invention relates to a bicycle frame comprising at least one of the mentioned frame components, which is designed as a structural component according to the invention.

[0007] Furthermore, the invention relates to a bicycle comprising at least one component which is designed as a structural component according to the invention.

[0008] Furthermore, the invention relates to a handlebar which is designed as a structural component according to the invention.

[0009] In the relevant technical field, the publication DE 195 81 569 TI is known, which proposes several embodiments of bicycle frames. One example proposes a bicycle frame having a core made of injection-molded plastic. External ribs are arranged on the injection-molded core, pointing outwards. A sheath is provided around the external ribs, which preferably should not be required for structural purposes because this task is fulfilled by the core with the external ribs. The sheath is, for example, a shrink-wrap made of plastic, which is applied around the core and heated so that it fits tightly against the core. The structural strength in this example is provided by the core with its external ribs.

[0010] Another example from the same publication reverses the principle of the previous example and instead proposes an inner bladder to create the walls of the bicycle frame using a mold. The inner bladder acts as a core in the mold and may be filled with a liquid or other material to withstand the pressure during injection of thermoplastic material that will form the bicycle frame. Alternatively, the bladder may be constructed with a ribbed structure to withstand the existing pressure, although lower pressures may be used. The walls of the bicycle frame are created between the outer mold and the inner bladder; the space between the bladder and the outer mold corresponds to the thickness of the walls of the finished bicycle frame.

[0011] With regard to structural strength, the state of the art with the internal bladder is unsatisfactory. This also applies to the bicycle frame embodiment with its core featuring external ribs.

[0012] The invention now proposes a structural component for a bicycle, comprising a core with at least one cavity and an enveloping shell surface, as well as comprising a shell element, with the proviso that both the core and the shell element each have a structurally supporting function, and that the supporting function is reinforced by means of a material-fit connection between the enveloping shell surface of the supporting core and an inner surface of the supporting shell element. The cavity of the core is preferably a geometrically defined cavity.

[0013] The material-to-metal connection can be provided by fusing the material of the shell element with the material of the core. The fusion takes place between the outer surface of the core and the starting material of the shell element. The materials involved are in a state in which they are molten at least in some regions. For the material-to-metal connection, a filler material can also be added which can fuse with the materials involved. Identical starting materials can advantageously be used for the core elements and / or for the shell element. Any filler material for the material-to-metal connection can be made from the same starting material as the core elements and / or the shell element.Alternatively, a material-locking connection can be produced by means of an adhesive filler material which is arranged between the enveloping surface of the core and the inner surface of the supporting shell element.

[0014] The proposed structural component can, as in the prior art, be designed as a bicycle frame, for example, whereby the structural component according to the invention has improved strength. On the one hand, the shell element not only improves the aerodynamics and appearance, but also contributes to its own structural strength as a load-bearing shell element. Its structural strength is increased by the likewise inherent structural strength of the load-bearing core. Furthermore, by means of the material-fit connection which connects the load-bearing core to the load-bearing shell element, the strength of the structural component as a whole is further improved. On the other hand, when the structural component is designed as a bicycle frame, the shell element preferably makes a significant contribution to the strength and rigidity of the bicycle frame.Particularly preferably, the shell element is designed such that its contribution to the strength and stiffness of the bicycle frame is at least as great as the contribution of the core.

[0015] According to the invention, the enveloping surface of the supporting core is a substantially smooth surface. It can be designed as a freely shaped surface, e.g. similar to a curved vehicle body, or for example form a simple cylindrical surface. The surface can also be composed of sections, for example sections of cylindrical, prismatic or conical basic shapes. A surface with external ribs is not regarded as a substantially smooth surface within the meaning of the invention. The shape of the enveloping surface is also expediently based on the outer contour of the shell element. Advantageously, a uniform thickness for the wall thickness of the shell element is formed between the outer contour of the shell element and the surface of the core. The wall thickness of the shell element can vary slightly in some regions in order to be able to provide regions with greater strength and rigidity.It is advantageous to provide a smooth, stepless transition between smaller and larger wall thicknesses in order to prevent a notch effect.

[0016] Advantageously, either the core and / or the shell element is produced using a starting material which is flowable in a plastic state within the mould cavity of a shaping tool. In a preferred embodiment, the shell element can be produced, for example, using a shaping injection moulding tool. For this purpose, the core is advantageously placed within the injection moulding tool. The mould cavity of the injection moulding tool forms the negative of the outer contour of the shell element. The core remaining therein forms the inner contour of the shell element. At the same time, the material-to-material connection is produced by means of the injection moulding process in which the injected starting material of the shell element melts the material of the outer surface of the core and the materials of the shell element and core are thus bonded together.The core is made sufficiently stable so that a sufficiently strong wall is provided beneath its molten shell surface, which can withstand the injection pressure during injection molding of the shell element starting material.

[0017] The injection molding tool is advantageously equipped with at least one stationary tool part and at least one movable tool part. When closed, the tool parts meet at a parting line. The injection molding tool can be opened and closed at the parting line and repeatedly filled with starting material in order to remove a finished workpiece after each molding process.

[0018] The structural strength and rigidity of the load-bearing shell element is enhanced when its starting material can be injected into the mold cavity at high injection pressure. For this purpose, the core is preferably specially designed to withstand even high injection pressure due to the flowable starting material for the shell element without collapsing.

[0019] For this purpose, the outer surface of the core is preferably designed with a wall thickness that can withstand the high injection pressure so well that no hole is created through which starting material could penetrate into the cavity of the core.

[0020] The load-bearing shell element makes a significant contribution to the structural strength of the structural component. Its contribution to strength can be influenced by the selection and quality of the raw material as well as by the shell thickness of the shell element. In addition, there is the contribution of the core, which has its own structural strength. The overall structural strength of the structural component is further enhanced by the integral connection, which firmly joins the load-bearing core to the load-bearing shell element.

[0021] The quality of the structural component, its strength and rigidity, depends on the shell element in combination with the core and the interconnection. The quality of the core and the material connection lie hidden beneath or within the shell element. They can be examined non-destructively using imaging methods for materials testing, for example, computed tomography.

[0022] The starting material for the core and / or the shell element is preferably a thermoplastic. The plastic can be a single-variety plastic or a compound comprising a base plastic mixed with at least one other plastic. Furthermore, the single-variety plastic or the compound can be provided with at least one filler, for example a filler made of reinforcing fibers and / or other reinforcing particles.

[0023] The core can be formed in one piece or it can be composed of several core elements. Because the core has at least one cavity, a one-piece construction can be manufactured using 3D printing, for example, using a suitable starting material. For other starting materials, an investment casting process is suitable for producing a one-piece core. For this purpose, a lost mold can easily be made from wax. This mold has the identical shape to the core and melts when the starting material is poured.

[0024] For a core composed of multiple core elements, the above manufacturing methods are also applicable, as are other manufacturing methods. Individual core elements can, for example, be manufactured using a starting material that can be processed in a flowable, plastic state within the mold cavity of a shaping tool, for example by injection molding. This is preferably carried out using an injection molding tool that has at least one stationary and one movable tool part, which can be opened and closed at a parting line in order to be able to repeat injection molding processes cyclically.

[0025] The core according to the invention may have a complex shape. Its shape may be provided with undercuts relative to the shell element, which make the use of a reusable tool-side core impossible.

[0026] Each core element advantageously has an outer surface and edges. The outer surfaces of several core elements form the outer surface of the core when assembled. The edges of the core elements adjoin one another when assembled.

[0027] At least one parting line is formed at the edges of the outer surfaces of assembled core elements, with a sealing means preferably being provided for the parting line. Particularly when the shell element is manufactured in a molding tool and the core is placed in the mold cavity, the effective sealing helps prevent flowable, plastic starting material of the shell element from penetrating the parting lines of the core or into its cavity.

[0028] A material-bonding additive, e.g., an adhesive, can be provided as a sealing means, or mechanically interacting sealing edges can advantageously be formed as a sealing means at the edges of the core elements. Such sealing edges are preferably designed in a complementary manner, for example, as folded edges or edges with tongue-and-groove elements.

[0029] Advantageously, the core, or at least one of the core elements, is provided with at least one inner stiffening element.

[0030] This measure strengthens the core. The reinforced core facilitates the production of the shell element around it, particularly if the shell element is to be produced by injection molding. For this purpose, the core is inserted into an injection mold to form the shell element and, as a structurally supporting core, remains a central component of the structural component, yet hidden within the shell element.

[0031] The inner stiffening element is simply designed in the form of a strut or rib.

[0032] A strut or rib can advantageously be designed so that the core element can be manufactured in a mold cavity of a molding tool, for example by injection molding. Core elements can expediently be manufactured cyclically in an injection molding tool.

[0033] The positive effect on the stability of the structural component can be increased if struts or ribs of core elements, which are combined to form a core, support each other.

[0034] For a shell element that is produced by injection molding, it is advantageous to provide a core that is so stable that it can withstand a high injection pressure of the starting material of the shell element when this is injected into the mold cavity to give the shell element the desired shape. A high injection pressure promotes the flow properties of the starting material in its plastic state, i.e. in the molten, flowable state. The injection pressure advantageously influences the viscosity of the starting material in such a way that the viscosity increases. The high viscosity means that thin-walled areas of a mold cavity can be filled more easily. This allows struts or ribs to be optimized. They can be designed to be as thin-walled as possible in order to use the least possible material but still support the core when a high injection pressure acts on its outer surface from the outside.In this way, material volume can be saved and the structural component can be designed to be as stable as possible while still being lightweight.

[0035] It is also useful if the core has at least one protruding positioning element on its outer surface and if the positioning element is designed to fix the core in a mold cavity of a molding tool, within the mold cavity, for the production of the supporting shell element.

[0036] The core or core element is advantageously provided with a sufficient number of protruding positioning elements. These are distributed over the outer surface and hold the core in its desired shape and position, for example, when the shell element is injection-molded. Its molten, flowable starting material can exert uneven forces on the core in certain areas within the mold cavity, which could deform under the action of this force and lose its desired position within the mold cavity. The protruding positioning elements advantageously counteract any change in the shape of the core or any departure from its desired position within the mold cavity.

[0037] The positioning element effectively forms a spacer that establishes contact with the inside of the mold cavity, thus easily enabling the desired, precise positioning relative to the forming tool. The positioning elements also have a favorable effect on the shape of the core. Due to the fixation, it retains its shape despite high compressive forces acting on the core from the outside.

[0038] The positioning elements on the outer surface of the core or core elements also contribute a positive-locking component for the connection to the shell element. As the positioning element protrudes into the finished shell element, an undercut is created. The undercut contributes a positive-locking component to the connection, which supports the material-locking connection between the load-bearing core and the load-bearing shell element.

[0039] Alternatively, positioning elements on the outer surface of the core can be dispensed with if, instead, at least one tool-side positioning element is arranged in the molding injection mold. Advantageously, the tool-side positioning element is arranged in its mold cavity and expediently integrated into the inside of the mold cavity. When the injection mold is closed, the tool-side positioning element protrudes from the inside of the mold cavity and touches the outer surface of the core to hold it in shape and in its intended position within the mold cavity.

[0040] Furthermore, it is also possible to produce a structural component according to the invention without positioning elements that protrude on the outer surface of the core and also without tool-side positioning elements that protrude on the inside of the mold cavity in the direction of the core, if the core has a suitable holding section away from its outer surface and the injection molding tool has a suitable means for fixing the position of the core within the closed mold cavity.

[0041] In one embodiment, the supporting shell element can form the shape of a bicycle frame, comprising a front section contour with a head tube section, a substructure contour with a bottom bracket section, a superstructure contour with a seat tube section and a rear section contour with a rear axle section for a rear wheel axle.

[0042] In this design, the shell element of the structural component is preferably a single piece when viewed from the outside. However, it contains the core as a second load-bearing component inside, which is advantageously composed of several core elements. As a bicycle frame, this structural component is designed to meet the requirements standardized for bicycles in DIN EN ISO

[0043] 4210 : 2015 .

[0044] Furthermore, a bicycle frame is proposed, comprising a plurality of frame components, which are partly designed as node elements and partly as frame elements, wherein the node elements and frame elements are connected to one another, with the proviso that at least one of the node elements and / or one of the frame elements is designed as a structural component according to the invention.

[0045] The frame component as a structural component is advantageously designed such that, within the finished bicycle frame, it meets the safety requirements standardized for bicycles in DIN EN ISO 4210:2015. This applies in particular to all frame components of the bicycle frame that are designed as structural components according to the invention. Other frame components that are not structural components within the meaning of the invention may also meet this requirement. Furthermore, these requirements are met by the bicycle frame as a whole.

[0046] If the bicycle frame can be assembled from multiple frame components, this offers a high degree of variability, allowing it to be adapted, for example, to a person's individual physical characteristics. For example, the bicycle frame can be adjusted to the person's individual body measurements, such as their arm length, leg length, and back length. Furthermore, the person's desired posture on the bicycle can be taken into account, such as seat height, sitting posture, back angle, etc., to provide the right bicycle frame.

[0047] Alternatively, frame components in the form of structural components according to the invention can be provided as a modular system, for example modules in graduated sizes.

[0048] A material-to-material connection is advantageously provided to connect the node element(s) to the frame element(s).

[0049] The material-to-material bond is simply provided by means of a filler material. The filler material can, for example, be a one-component or two-component adhesive. Alternatively, the filler material can be a castable material that can be processed in a forming tool, for example, a flowable material that can also be injection-molded like an injection-molded starting material for the shell element.

[0050] Preferably, at least one node element is provided with a fusion region, wherein at least one frame element is provided with a connecting region that interacts with the fusion region of the node element. It is advantageous if the fusion region and the connecting region, when assembled, define the relative position of the node element and the frame element to one another.

[0051] The bonding filler material, or adhesive, is simply arranged between the fusion area of ​​the node element and the connection area of ​​the frame element. The fusion area and the connection area then represent bonding surfaces, between which a narrow gap for the adhesive is preferably formed.

[0052] Finally, a bicycle is proposed, comprising at least one component from the following group (bicycle frame, fork, stem, handlebars, seat post, crank arms), wherein at least one of the said components is designed as a structural component according to the invention.

[0053] Furthermore, a handlebar for a bicycle is proposed, which is designed as a structural component according to the invention.

[0054] The proposed handlebar offers excellent safety. It can withstand heavy use during ferry operation. High loads generally occur during acceleration and braking. Acceleration causes alternating loads, for example if the handlebar grips are pulled alternately on the left and right. During braking, a more even load can act on both handlebar grips. Handlebar failure can lead to injuries. Handlebars are therefore one of the safety-relevant components on a bicycle. For safety reasons, a used handlebar should be replaced with a new one after a certain period of use. This should apply even if there is no obvious damage to the used handlebar.The safety of the proposed handlebar is based on a load-bearing core and a load-bearing shell element, each providing its own structural strength and rigidity, and on the fact that their strength and rigidity are further enhanced by means of the intended material-fit connection between the core and the shell element.

[0055] Advantageously, a core is provided which is composed of at least two core elements, and the core elements are injection-molded from a thermoplastic material.

[0056] A further benefit is achieved by arranging a holding section at each free end of the core elements, and by preparing the holding section to fix the core element in an injection mold. The precise positional fixation of the core element or the assembled core facilitates the production of a precise shell element whose defined shell wall contributes the desired strength and rigidity.

[0057] Preferably, the holding sections of the core elements are designed to be complementary, each core element having a means for correctly positioning it in contact with the complementary core element.

[0058] It has also proven advantageous for the holding sections of the core elements, when assembled as a core, to form a polygonal cross-section. The assembled holding sections have external holding surfaces that match the polygonal cross-section. The holding sections interact with suitable receiving areas of an injection mold. In particular, this type of fixation counteracts rotation of the core within the injection mold.

[0059] The holding surfaces can also be inclined toward the free end of the handlebar. This allows a holding section to be provided whose polygonal cross-section is somewhat larger proximally and which has a somewhat smaller polygonal cross-section with the same number of corners distally.

[0060] The polygonal cross-section of the core is preferably a hexagonal cross-section.

[0061] The invention is illustrated below by way of example in a drawing and described in detail with reference to several figures. They show:

[0062] Fig. 1 is a perspective view of a first core element for a handlebar designed as , Fig. 2 is a view of the first core element as indicated in Fig. 1 with the arrow II,

[0063] Fig. 3 is a perspective view of a structural component according to the invention of the second core element for the handlebar,

[0064] Fig. 4 is a view of the second core element, as marked in Fig. 3 with the arrow IV,

[0065] Fig. 5 is a perspective view of the structural component according to the invention in the form of the handlebar,

[0066] Fig. 6 a detail according to the section line VI - VI noted in Fig. 5,

[0067] Fig. 7a shows an embodiment of the edges of the second core element as sealing edges according to the section line VII - VII, as noted in Fig. 3,

[0068] Fig. 7b shows a first alternative embodiment of the edges of the second core element according to the section line VII - VII, as noted in Fig. 3,

[0069] Fig. 7c shows a second alternative embodiment of the edges of the second core element according to the section line VII - VII, as noted in Fig. 3,

[0070] Fig. 7d shows a third alternative embodiment of the edges of the second core element according to the section line VII - VII, as noted in Fig. 3,

[0071] Fig. 8 is a reduced schematic plan view of a bicycle frame provided as a structural component according to the invention,

[0072] Fig. 9 is a schematic sectional view of the bicycle frame according to section IX - IX, as noted in Fig. 8,

[0073] Fig. 10 shows an alternative bicycle frame which is assembled from frame components which are designed as structural components according to the invention.

[0074] A first example of a bicycle structural component according to the invention is explained below with reference to Figures 1 to 5. The first example relates to a handlebar 1 of a bicycle designed as a structural component. The essentially finished handlebar 1 is shown in Figure 5. It comprises a core 2 which is composed of two core elements 3 and 4 and is surrounded by a shell element 5. The core elements 3 and 4 are formed from thermoplastic in an injection mold and then assembled. The shell element 5 is also made from thermoplastic and is manufactured using a second injection mold into which the assembled core 2 has previously been inserted.

[0075] Fig. 1 shows only the first of the core elements 3. It is located in the finished handlebar 1 on its front side 6, which, when installed, is at the front in the direction of travel of the bicycle. The first core element 3 is provided with a central region 7 which has the largest cross-section. On the finished structural component, the central region 7 forms part of a clamping region 8 of the handlebar 1, which on the finished bicycle interacts with a handlebar clamp. The handlebar is clamped using a stem element which usually has a slotted stem eye for this purpose. The finished handlebar 1 is designed to fit such a stem eye. By means of a conventional slotted clamp, the stem eye can connect the clamping region 8 of the handlebar 1 to the stem element.The cross section of the central region 7 of the core element 3 is therefore advantageously designed so that the clamping area of ​​the finished handlebar structural component is compatible with the usual dimensions of a stem element / stem eye. Towards its ends, the core element 3 is designed with a smaller cross section than in the central region 7. The ends include two grip areas 9 and 10 of the finished handlebar structural component. The grip area 9 has a partial surface 9a on the outside and the grip area 10 has a partial surface 10a on the outside. A transition area 11 is provided between the grip area 9 and the central region 7 of the first core element 3 and a transition area 12 is provided between the grip area 10 and the central region 7. The transition area.

[0076] 11 forms a partial area 11a on the outside and the transition area

[0077] 12 a partial surface 12a . The transition areas 11 and 12 create a continuous change in the cross-section , i.e. starting from the large cross-section of the central area 7 the cross-section becomes smaller towards the grip areas 9 and 10 . The partial surfaces 7a, 7a, 10a, 11a and 12a together form an outer surface 3a of the first core element 3 . At one free end of the first core element 3 there is also a holding section 13 with holding surfaces 14 and at the other free end there is a holding section 15 with holding surfaces 16 . The holding sections 13 and 15 are solid in the present example . They serve at least mainly to fix the core element 3 for an injection molding process in an injection molding tool when it is assembled with the second core element 4 to form a core 2 . The holding sections 13 and 15 can either remain on the finished structural component after the injection molding process or later or alternatively be removed.

[0078] The central region has a semi-cylindrical central section 18. On both sides, halved conical sections 19 and 20 adjoin this and form the transition regions 11 and 12, respectively. The transition regions 11 and 12 are in turn adjoined by a semi-cylindrical section 21 and 22, each belonging to one of the gripping regions 9 and 10, respectively. The sections together form a wall 23 of the first core element 3, on the inner side 24 of which a groove-shaped cavity 25 is formed. The inner side 24 of the wall 23 is formed largely parallel to the contour of the outer surface 3a.

[0079] Arranged on the outer surface 3a are outwardly projecting positioning elements 26, 27, 28, 29, 30, 31 and 32. The positioning elements 26 have outer surfaces 26a, 27a, 28a, 29a, 30a, 31a and 32a which fix the assembled core 2 in place when it is inserted into the mold cavity of an injection molding tool. The positioning elements act as a spacer. For this purpose, the outer surfaces of the positioning elements come into contact with the inside of the closed mold cavity within the injection molding tool. As a result of this contact, the core 2 retains its shape and position during the injection molding process. This remains the case even when the flowable starting material of the shell element 5 is fed into the mold cavity under high injection pressure. The acting forces can neither deform the thus fixed core 2 nor change its position within the mold cavity.In this way, a defined shell wall thickness of the shell element 5 can be produced in the remaining mold cavity. In the grip region 9, the first core element 3 has two elongated positioning elements 26 and 27, one arranged distally and one proximally. The distally arranged elongated positioning element 26 extends in the circumferential direction of the outer surface 3a, while the proximally arranged elongated positioning element 27 extends parallel to a longitudinal direction of the grip region 9. The central region 7 has three point-shaped positioning elements 28, 29 and 30 which are arranged in a row. The positioning elements 31 and 32 are arranged in a mirror image of the positioning elements 26 and 27 and have a shape which corresponds mirror-inverted to them. The point-shaped positioning elements 28, 29 and 30 have an approximately cylindrical shape.All elongated as well as point-shaped positioning elements are designed with inclined side surfaces 26b, 27b, 28b, 29b, 30b, 31b and 32b, which form molding slopes in order to be able to easily demold the first core element 3 from the injection molding tool.

[0080] Fig. 2 shows a simplified view from the front of the first core element 3, as indicated by the arrow II in Fig. 1. The simplification consists in the fact that a representation of the position elements of the shell surface has been omitted in Fig. 2 in favor of the representation of internal stiffening elements 33. The stiffening elements 33 are provided on the inner side 24 of the channel-shaped cavity 25. In the present example, the stiffening elements 33 are parallel ribs 34 which intersect with parallel ribs 35, thereby promoting their stiffening effect. The crossed ribs 34 and 35 divide the channel-shaped cavity 25 into many small cavities 25a. The ribs 34 are designed with inclined lateral rib surfaces 34a and 34b and the ribs 35 with inclined lateral rib surfaces 35a and 35b, which as a molding slope promote demolding of the core element 3 from the injection molding tool.The front view of the first core element 3 indicates that the finished handlebar structural component is a handlebar 1 with a riser shape. Its gripping areas 9 and 10 are arranged with a slight height offset (rise) relative to the central area 7.

[0081] The thickness of the wall 23 of the core element 3 in the region of its outer surface 7, shown in Fig. 2, is to be understood schematically and is not necessarily proportional to the rod diameter in its various sections. In practice, the wall 23 is designed to be so thick that a composite core 2 can withstand a high injection pressure when inserted as a permanent core into the injection mold for forming the shell element 5.

[0082] Fig. 3 shows a perspective of the second core element 4, which is designed to be complementary to the first core element 3. The second core element 4 is located in the finished handlebar 1 on its rear side, which, when installed, is at the rear in the direction of travel of the bicycle. The second core element 4 has components that are complementary to the first core element 3. It is also provided with a central region 36 for clamping the handlebar. Two gripping regions 37 and 38 are provided towards the two ends of the second core element 4, which gripping regions also have a smaller cross-section than the central region 36. A transition region 39 or 40 is provided between each of the gripping regions and the central region of the second core element 4.The transition region 39 creates a continuous change in the cross-section between the large cross-section of the central region 36 and the smaller cross-section of the grip region 37 as well as the large cross-section of the central region 36 and the smaller cross-section of the grip region 38. At the free ends, the second core element 4 has a holding section 41 with holding surfaces 42 and a holding section 43 with holding surfaces 44, respectively, which serve to fix the second core element 4 in an injection molding tool when it is assembled with the first core element 3 to form a core 2. The holding sections 41 and 43 of the second core element 4 are also solid in the present example.

[0083] The perspective of Fig. 3 provides a view of an inner side 45, which forms a groove-shaped cavity 46. The inner side 45 belongs to a wall 47, which forms an outer surface 4a on the outside. The outer surface 4a complements the outer surface 3a of the first core element 3; together they form a lateral surface 2a of the core 2. The outer surface 4a is, in principle, composed of partial surfaces, just like those sections of the first core element 3. In the groove-shaped cavity 46 of the second core element 4, inner stiffening elements 49 are arranged, which are designed as parallel ribs 50, which intersect with parallel ribs 51 and thereby improve the stiffening effect. The ribs

[0084] 50 are designed with inclined lateral rib surfaces 50a and 50b and the ribs 51 are designed with inclined lateral rib surfaces 51a and 51b, which, as a molding slope, promote demolding of the second core element 4 from the injection mold. In this case, the channel-shaped cavity 46 is divided into many small cavities 46a. The ribs 50 and

[0085] 51 of the second core element 4 are also designed with inclined lateral rib surfaces 50a and 50b as well as 51a and 51b, which, as molding bevels, promote the demolding of the second core element 4 from the injection mold. Furthermore, the ribs 34 and 35 of the first core element 3 and the ribs 50 and 51 of the second core element 4 are arranged congruently in the assembled state. The core element 3 has abutting surfaces 34c and 35c, which touch abutting surfaces 50c and 51c of the second core element 4 when the two core elements are assembled. The core 2, which is composed of these two core elements 3 and 4, can absorb very high compressive forces by means of the ribs which are butted against one another when forces from the outside act on the outer surface 3a of the first core element 3 and on the outer surface 4a of the second core element 4 and compressive forces are transferred into the ribs.

[0086] Fig. 4 shows a front view of the second core element 4, as indicated by the arrow IV in Fig. 3. The inner stiffening elements 49 can be seen, which are designed as intersecting ribs 50 and 51. In addition, positioning elements 52, 53, 53, 55, 56, 57 and 58 are shown as hidden dashed lines. In this view, the positioning elements are located on the rear outer surface 48 of the second core element 4 shown.

[0087] In the grip region 37, the second core element 4 has two elongated positioning elements 52 and 53, one arranged distally and one proximally. The distally arranged elongated positioning element 52 extends in the circumferential direction of the outer surface 48, while the proximally arranged elongated positioning element 53 extends parallel to a longitudinal direction of the grip region 37. The central region 36 has three point-shaped positioning elements 54, 55 and 56, which are arranged in a row. The positioning elements 57 and 58 are arranged as a mirror image of the positioning elements 52 and 53 and have a shape which corresponds mirror-inverted to them. The point-shaped positioning elements 54, 55 and 56 have an approximately cylindrical shape.All elongated as well as point-shaped positioning elements are designed with inclined side surfaces 52b, 53b, 54b, 55b, 56b, 57b and 58b, which form molding slopes in order to be able to easily demold the second core element 4 from the injection molding tool.

[0088] Fig. 5 shows the handlebar 1 as a finished structural component. It comprises the first core element 3 and the second core element 4 on the inside, which are assembled to form the core 2, and the shell element 5 on the outside. The shell element 5 has been injection-molded around the permanent core 2 using the aforementioned second injection-molding tool. During the injection-molding process of the shell element 5, the entire outer surface of the assembled core 2 has been melted and has thus bonded to the starting material of the shell element 5 on its inside 5a; its inner surface 5a is indicated in Fig. 5 by a dashed line. In addition, the protruding positioning elements (26, 27, 28, 29, 30, 31, 32, 52, 53, 53, 55, 56, 57, 58) provided on the outer surfaces 3a and 4a of the core elements 3 and 4 have been laterally surrounded by the starting material of the shell element 5.This creates an additional positive connection between the positioning elements and the shell element 5. Outer surfaces (26c, 27c, 28c, 29c, 30c, 31c) of the positioning elements are visible on the finished handlebar because they were in contact with the mold cavity of the injection molding tool during the injection molding process. They should not be covered by the starting material of the shell element 5 during injection molding and therefore remain visible.

[0089] At the free ends of the finished structural component are the assembled holding sections 13 / 41 and 15 / 43, each forming a hexagonal cross-section. In the present example, the holding sections are solid. When assembled, three holding surfaces 14 and three holding surfaces 42 form a holding surface hexagon. All six holding surfaces are arranged at a slight wedge angle. As a result, the hexagonal cross-section of the assembled holding sections 13 / 41 is somewhat larger proximally and somewhat smaller at the distal free end. The assembled holding sections 15 / 43 together also form six holding surfaces, which are arranged at a slight wedge angle.

[0090] The section line VI - VI marked in Fig. 5 indicates a detail which is shown enlarged in Fig. 6. The detail shows that in the area of ​​the holding sections 13 / 41 cooperating means are provided which position the complementary core elements 3 and 4 in the correct position relative to one another. The holding sections 13 / 41 each have an inner base surface 13a or 41a which touch in a parting plane 59 when assembled. In the holding section 13 of the first core element 3, the base surface 13a is laterally delimited by centering webs 60 and 61. The centering webs have centering surfaces 60a and 61a which are arranged inclined to one another in a V-shape. The holding section 41 of the second core element 4 has centering eyes 62 and 63 arranged laterally on its base surface 41a, which are designed to match the centering webs 60 and 61 of the first core element 3.An undesirable lateral displacement of the core elements 3 and 4 relative to each other can be counteracted in this way.

[0091] Fig. 7a shows an enlarged detail relating to the design of edges 64 and 65 of the second core element 4, specifically along the section line VI I - VI I, which is marked in Fig. 3. The edges are provided with sealing means. For ease of explanation, the first core element 3 is shown in dashed lines, specifically in the joined state with the second core element 4. The edges 64 and 65 shown of the second core element 4 each have an abutting surface 66 and 67 respectively, which interact with abutting surfaces of the first core element 3. The abutting surface 66 is, for example, in contact with an abutting surface 68 of the first core element 3 and forms a parting line 69 with the latter.

[0092] Using the parting line 69 as an example, Fig. 7a shows that the abutting surface 66 of the second core element 4 is further developed and has a sealing edge 66a as a sealing means S1, which is provided with a tongue profile 70 for this purpose. Matching this, the abutting surface 68 of the first core element 3 is provided with a sealing means S2, which is also designed as a sealing edge 68a and has a groove profile 71. When the sealing edges 66a and 68a are joined together, a good sealing effect is achieved by means of the tongue profile 70 and groove profile 71. According to the same principle, the abutting surface 67 of the second core element 4 interacts with the associated abutting surface of the first core element 3. In this way, the core 2 composed of the two core elements 3 and 4 can be used as a permanent core in an injection mold. In the injection molding tool, the shell element 5 is injection molded around the core 2 with a certain injection pressure.It must be prevented that molten starting material of the shell element 5 can penetrate into a parting line and possibly reach a cavity 72 of the core 2, or into the cavities 25a and 46a between the ribs of the core elements 3 and 4, respectively. In particular, a high injection pressure should be able to be used for injection molding the shell element 5, because a high injection pressure promotes the quality of the produced shell element 5.

[0093] In the region of the spring profile 70, the wall 47 of the second core element 4 has a material reinforcement 47a. The spring profile 70 is also arranged such that it protrudes from the abutment surface 66. Its design allows the second core element 4 to be manufactured by injection molding in an injection molding tool. For this purpose, the spring profile 70 is designed with lateral molding slopes 70a and 70b to provide easy demoldability of the second core element 4 from the injection molding tool.

[0094] The groove profile 71 of the first core element 3 is formed as a recess in its abutting surface 68. The wall 23 is provided with a material reinforcement 23a in the region of the groove profile 71. The groove profile is also designed for production of the first core element by injection molding in an injection molding tool. For this purpose, the groove profile has lateral molding slopes to facilitate removal of the first core element 3 from the injection molding tool.

[0095] Fig. 7b shows an alternative design of the edges 64 and 65 of the second core element, which also provide sealing means S 1 and S 2 as positive sealing edges. The view also relates to the section line VI I - VI I, which is noted in Fig. 3. The complementary core elements 3 and 4 have pairs of abutting surfaces 66 / 68, which form a parting line 69. In contrast to Fig. 7a, the second core element 4 of Fig. 7b has two spring profiles 73 and 74 next to one another on its abutting surface 67.

[0096] The first core element, shown in dashed lines, is provided with adjacent groove profiles 75 and 76 on its abutment surface 68. The double tongue profiles 73 and 74 and the double groove profiles 75 and 76 are designed so that the core elements 3 and 4 can also be manufactured by injection molding in one injection mold. The double tongue and groove profiles improve the sealing effect compared to the previous example in Fig. 7a.

[0097] Fig. 7c shows a further alternative for the design of the edges 64 and 65 of the second core element 4, which likewise provide sealing means S1 and S2 by means of form-fitting sealing edges. The view again refers to the section line VI I - VI I in Fig. 3. The matching first core element 3 is shown as a dashed line. Both complementary core elements 3 and 4 have abutting surfaces 66 and 68, respectively, which interact as a pair at the parting line 69. The abutting surfaces are further developed as sealing edges 66a and 68a, respectively, which are based on the design of the example in Fig. 7b. One difference, however, is that on the sealing edge 66a of the second core element 4, one of the double tongue profiles is replaced by a groove profile 77. To match this, a groove profile on the sealing edge 68a of the first core element 3 is replaced by a tongue profile 78.

[0098] The edge 65 of the second core element 4 is modified in the same way as its edge 64. This also applies to the associated edge of the first core element.

[0099] Each abutting surface 64 and 65 of the second core element 4 thus has a tongue profile and a groove profile. Each abutting surface of the first core element, shown in dashed lines, has a matching groove profile and a tongue profile. The combination of a tongue profile and a groove profile per abutting surface improves the sealing effect.

[0100] Fig 7d shows a fourth example of a design of the

[0101] Edges 64 and 65 of the second core element 4, which is provided with a sealing means S1 or S2 in the form of special sealing edges. The view also relates to the section line VI1-VI1 in Fig. 3. The first core element 3 is again shown as a dashed line. Both complementary core elements 3 and 4 have sealing edges on the abutting surfaces, which touch each other in a parting line 69. The second core element 4 is provided on an abutting surface 67 with a wedge profile 78 having a protruding wedge tip 79. The abutting surface 66 of the second core element 4, on the other hand, has a groove profile 80 with a groove base 81 that is arranged parallel to the abutting surface 66. The first core element 3, shown in dashed lines, is provided with a groove profile 82 that interacts with the wedge profile 78 of the second core element 4.The groove profile 82 also has a groove base 83 which is arranged parallel to the corresponding abutting surface of the first core element 3. The wedge tip 79 of the wedge profile 78 interacts with the groove profile 82 of the first core element 3. According to Fig. 7d, the wedge profile 78 clearly protrudes from the abutting surface 67 by an amount which is greater than the depth of the associated groove profile 82. In the assembled state, this results in the wedge tip 79 pressing against the groove base 83 and notching it. The notching of the groove base 83 is accompanied by a certain deformation of the wedge tip 79. In this way, a good sealing effect is achieved. The first core element 3 is also provided with a wedge profile with a wedge tip which interacts with the groove base 81 of the groove profile 80 of the second core element 4 in the same way, notching and sealing.

[0102] Fig. 8 schematically shows a reduced top view of a bicycle frame 84. The bicycle frame is designed as a structural component according to the invention. The top view shows a head tube section 85, a seat tube section 86, and a rear triangle section 87 of the bicycle frame. Furthermore, a connecting top tube element 88 can be seen between the head tube section 85 and the seat tube section 86.

[0103] Fig. 9 shows a schematic sectional view through the bicycle frame 84 of Fig. 8. The sectional view follows the section line IX-IX shown in Fig. 8. Because the bicycle frame 84 is constructed as a structural component according to the invention, it has a load-bearing core 89 and a load-bearing shell element 90, the inner surface 90a of which is materially connected to the core 89. The shell element 90 is produced in one piece from thermoplastic material in an injection mold. The core 89 is composed of three core elements. In the assembled state, the core has been inserted into the injection mold as a permanent core 89. To produce the shell element 90, the inserted core 89 is overmolded / cast with the starting material for the shell element 90. A first core element is shown in Fig. 8 as a dashed line.The first core element is designed as a right side core element 91 and is assigned to the right side of the bicycle frame 84. The right side core element 91 is also the side core element shown in the sectional view of Fig. 9. The second core element is a mirrored left version of the first core element, i.e. a left side core element 92. The third core element is an additional rear triangle core element 93, which is also shown as a dashed line in Fig. 8.

[0104] In this example, the rear triangle core element 93 is approximately V-shaped in the plan view according to Fig. 8, viewed from above. In this way, it complements both the right side core element 91 and the left side core element 92 in the area of ​​the rear triangle section 87. Alternatively, the rear triangle core element 93 can also be divided into a right rear triangle core element and a left rear triangle core element, so that the core 89 would be composed of a total of four core elements.

[0105] The right side core element 91 has a smooth outer surface 91a facing the shell element 5 and forms a cavity 95 facing away from the shell element 5. The left side core element 92 has a smooth outer surface 92a, and the rear core element 93 has a smooth outer surface 93a. The three aforementioned outer surfaces 91a, 92a, and 93a together form a lateral surface 89a of the composite core 89. In the region of the cavity 95, internal stiffening elements 96 in the form of intersecting ribs 97 and 98 are arranged. The cavity 95 is divided into many small cavities 95a by the ribs. In the area of ​​the head tube section 85, an opening 99 is provided for a fork or for a headset bearing, and in the area of ​​the seat tube section 86, an opening 100 is provided for a seat post. Furthermore, a bottom bracket section 101 is provided, which has an opening 102 for a pedal crank bearing.The opening 99 for the headset bearing and / or the opening 100 for the seat post and / or the opening 102 for the pedal crank bearing can be designed as a sleeve body, which, like the core 89, can be inserted into the injection molding tool. Such a sleeve body can be made of plastic or a metal, for example, from an aluminum tube.

[0106] The composite core 89 has parting lines between the individual composite core elements, i.e., the right side core element 91, the left side core element 92, and the rear core element 93. The parting lines are designed as sealing edges according to one of the principles proposed and described with reference to Figs. 7a-7d. As a result, the composite core 89 is sealed at the parting lines such that, during injection molding of the shell element 90, no flowable starting material can penetrate into the core 89, or into its cavity 95, or cavities 95a.

[0107] The outer surface 91a of the right side core element 91 is provided with protruding positioning elements 103. The left side core element 92 and the rear core element 93 are also provided with positioning elements on their outer surfaces 92a and 93a. In this way, the assembled core 89 can be correctly fixed within the injection molding tool. Precisely aligned positioning of the core 89 helps to achieve the correct wall thickness of the shell element 90.

[0108] Fig. 10 shows a cross-sectional view of an alternative bicycle frame 104. This bicycle frame is assembled from modular frame components. At least one of the frame components of the bicycle frame 104 must be designed as a structural component according to the invention. This means that it must have a structurally supporting shell element and a structurally supporting core. In the present example, all frame components of the bicycle frame 104 are designed as structural components.

[0109] Five of the structural components in Fig. 10 are designed as node elements and a further seven structural components are designed as frame elements which are provided as connecting links between the node elements. The node elements include a head tube node element 105, a seat tube node element 106, a bottom bracket node element 107 and two dropout node elements, of which the right dropout node element 108 is visible in Fig. 10. The dropout node element 108 comprises a dropout or has a means for receiving a mountable dropout.

[0110] The structure of the node elements (105, 106, 107, 108) is explained using the example of the head tube node element 105, which can be seen in the sectional view in Fig. 10. This head tube node element 105 comprises a shell element 109, which is produced in an injection mold, and a core, which is composed of a left head tube core element and a right head tube core element. The right head tube core element 110 is visible in the sectional view in Fig. 10. It has a smooth outer surface 111 facing the shell element 109 and forms a cavity 112 on its side facing away from the shell element 109. In the area of ​​the cavity 112, internal stiffening elements 113 in the form of intersecting ribs 114 and 115 are provided. The cavity 112 is divided into many small cavities 112a by the ribs.Furthermore, edges of the two head tube core elements, such as edge 116 of head tube core element 110, are provided with sealing means. The sealing means are advantageously designed as mechanically interacting sealing edges for the assembled outer surface, specifically according to the principles described above as alternatives for the sealing edges of the core elements of the handlebar according to Figs. 1 to 7d. Reference is made here to these alternatives. Positioning elements 117 are arranged on the outer surface of the core or of the shown head tube core element 110, which serve as spacers when the assembled core is inserted into the injection mold to produce the shell element 109.The positioning elements 117 fix the shape and position of the head tube core element 105 or the assembled core within the injection mold according to the principles which are also explained in detail above with respect to the handlebar according to Figs. 1 to 5, to which reference is made.

[0111] Furthermore, the head tube node element 105 has a receiving means 118 for a fork in order to mount a front wheel, or the receiving means 118 serves to receive a head bearing for a front wheel fork. The receiving means 118 is advantageously provided with an opening 119. The opening 119 can be created by means of two half-shell components, one half-shell component of which belongs to each of the two core elements. Alternatively, if the shell element 109 is produced in an injection mold, the opening can be provided by means of a sleeve body which is inserted into the injection mold in the same way as the core. Such a sleeve body can be made of plastic or a metal, for example from an aluminum tube.

[0112] The head tube node element 105 is connected to the seat tube node element 106 by means of a frame element that is designed as a top tube frame element 118. Furthermore, the head tube node element 105 is connected to the bottom bracket node element 107 by means of a down tube frame element 119. Between the seat tube node element 106 and the bottom bracket node element 107, a connection is provided by means of a seat tube frame element 120. A rear triangle section 121 of this bicycle frame comprises the dropout node elements, which are arranged next to one another at a distance to provide space between them for accommodating a rear wheel. The aforementioned right-hand dropout node element 108 is shown in the sectional view in Fig. 10.This dropout node element 108 is connected on the one hand by means of a seat stay frame element 122 to the seat tube node element 106 and on the other hand by means of a bottom bracket frame element 123 to the bottom bracket node element 107.

[0113] Because the bicycle frame 104 is constructed modularly using the frame components, means are provided to ensure a precise position between the node element and the frame element. For this purpose, each node element has a fusion region designed to fit a connecting means of the frame element. If another frame element needs to be attached to the same node element, this node element is advantageously provided with another fusion region for the other frame element, which in turn has a suitable connecting means for the other fusion region.

[0114] In this sense, the head tube junction element 105 is provided with a top tube fusion region for joining to the top tube frame element 118. Furthermore, the head tube junction element 105 is provided with a down tube fusion region 125 for joining to the down tube frame element 119.

[0115] Furthermore, a material-locking connecting means in the form of an additional material is expediently provided in order to create a firm connection between the head tube node element 105 and the joined top tube frame element 118 and the joined down tube frame element 119. The additional material is, for example, an adhesive. A gap for the adhesive is formed between the frame components to be joined (adhesive gap). For this purpose, the relevant fusion area of ​​the head tube node element and the connection area of ​​the associated frame element advantageously each provide a suitable adhesive surface. The adhesive surfaces are prepared in such a way that the adhesive gap has a gap size that is suitable for the selected adhesive in order to provide the required strength of the adhesive connection.

[0116] Simply, the head tube junction element 105 is constructed in the manner of a sleeve, which has inner fusion regions (124, 125) with an internal adhesive surface. Suitable for this, the top tube frame element 118 and the down tube frame element 119 can be provided with outwardly facing connection regions 118a and 119a, respectively, which form adhesive surfaces that mate with the corresponding internal adhesive surfaces of the head tube junction element 105 to form the required adhesive gap for the adhesive.

[0117] The bottom bracket node element 107, like the head tube node element 105, is formed from a shell element 126 which is injection-molded around a core and whose inner surface 126a is thereby materially connected to the core, the core being composed of a left bottom bracket core element and a right bottom bracket core element. The right bottom bracket core element 127 is visible in the sectional view in Fig. 10. It has a smooth outer surface 128 facing the shell element 126 and forms a cavity 129 on its side facing away from the shell element 126. In the region of the cavity 129, inner stiffening elements 130 in the form of intersecting ribs 131 and 132 are provided. The cavity 129 is divided into many small cavities 129a by the ribs.An edge 133 of the right bottom bracket core element 127 has a sealing means in the form of a sealing edge which interacts with an associated sealing edge of the left bottom bracket core element. In this way, a tight parting line of the assembled core is formed in this area, according to the principles which are described above for the sealing edges of the core elements of the handlebar according to Figs. 1 to 7d as alternatives, to which reference is made. Positioning elements 134 are arranged on the outer surface of the core or of the right bottom bracket core element 127 shown, which serve as spacers when the core is inserted into the injection mold for producing the shell element 126. The positioning elements 134 fix the shape and position of the bottom bracket core element 127 or of the assembled core within the injection mold according to the principles which are also described above with reference to the handlebar according to Figs.1 to 5 are explained in detail, to which reference is made.

[0118] Furthermore, the bottom bracket node element 107 has a receiving means 135 for a pedal crank or for a pedal crank bearing. The receiving means is advantageously provided with an opening 136 which can accommodate the pedal crank bearing. The opening 136 can be created by means of two sleeve-shaped components, one of which belongs to each of the two bottom bracket core elements; Fig. 10 contains the right-hand sleeve-shaped component 137 of the receiving means 135 for the pedal crank bearing. Alternatively, if the shell element 126 is produced in an injection mold, the opening 136 can be provided by means of an advantageously one-piece sleeve body which is inserted into the injection mold in the same way as the core. Such a sleeve body can be made of plastic or a metal, for example from an aluminum tube.Furthermore, the bottom bracket node element 107 is provided with four fusion areas to join frame elements, namely a fusion area 138 for the down tube frame element 119 and a fusion area 139 for the seat tube frame element 120 as well as two fusion areas 140 for the rear triangle section 121, each for joining a lower stay frame element 123.

[0119] The seat tube node element 106, like the head tube node element 105, is formed from a shell element 141 which is injection-molded around a core and whose inner surface 141a is thereby materially connected to the core, the core being composed of a left seat tube core element and a right seat tube core element, of which only the right seat tube core element 142 is visible in Fig. 10. It has a smooth outer surface 143 facing the shell element 141 and forms a cavity 144 on its side facing away from the shell element. In the area of ​​the cavity 144, inner stiffening elements 145 in the form of intersecting ribs 146 and 147 are provided. The cavity 146 is divided into many small cavities 144a by the ribs. The edge of the seat tube core element 142 is provided with a sealing means in the form of a sealing edge, which cooperates with an associated sealing edge of the left seat tube core element.In this way, a tight parting line of the assembled core is formed in this area, specifically according to the principles described above as alternatives for the sealing edges of the core elements of the handlebar according to Figs. 1 to 7d, to which reference is made. Positioning elements 148 are arranged on the outer surface of the core or of the right-hand seat tube core element 142 shown, which serve as spacers when the core is inserted into the injection mold for producing the shell element 141. The positioning elements 148 fix the shape and position of the seat tube core element 142 or of the assembled core within the injection mold according to the principles that are also explained in detail above with reference to the handlebar according to Figs. 1 to 5, to which reference is made. The seat tube node element 142 furthermore has a receiving means 149 for a seat post.Advantageously, the receiving means is provided with an opening 150, which can be produced by means of two sleeve-shaped components, one of which each belongs to one of the two seat tube core elements; Fig. 10 contains the right-hand sleeve-shaped component 151 of the receiving means 149 for the seat post. Alternatively, if the shell element 141 is produced in an injection mold, the receiving means, or the opening 150, can be provided by means of an advantageously one-piece sleeve body, which is inserted into the injection mold in the same way as the core. Such a sleeve body can be made of plastic or a metal, for example from an aluminum tube.

[0120] Furthermore, the seat tube node element 106 is provided with five fusion areas to join frame elements, namely a fusion area 152 for the top tube frame element 118 and a fusion area 153 for the seat tube frame element 120, as well as two fusion areas 154 for the rear section 121, each for joining a seat stay frame element 122.

[0121] The right dropout node element 108 has a shell element 155 which is injection-molded around a core and whose inner surface 155a is materially connected to the core, the core being composed of a left dropout core element and a right dropout core element. The right dropout core element 156 is visible in Fig. 10. It has a smooth outer surface 157 facing the shell element 155 and forms a cavity 158 on its side facing away from the shell element 155. In the region of the cavity 158, inner stiffening elements 159 in the form of intersecting ribs 160 and 161 are provided. The cavity 158 is divided into small cavities 158a by the ribs. An edge 162 of the right dropout core element 156 has a sealing means in the form of a sealing edge which cooperates with an associated sealing edge of the left dropout core element.In this way, a tight parting line of the assembled core of the right-hand dropout node element 108 is formed in this area, specifically according to the principles described above as alternatives for the sealing edges of the core elements of the handlebar according to Figs. 1 to 7d, to which reference is made. Positioning elements 163 are arranged on the outer surface of the core or of the right-hand dropout core element shown, which serve as a spacer when the core is inserted into the injection mold for producing the shell element 155. The positioning elements 163 fix the shape and position of the dropout core element 156 or of the assembled core within the injection mold according to the principles that are also explained in detail above with reference to the handlebar according to Figs. 1 to 5, to which reference is made.

[0122] The frame elements, such as the top tube frame element 118, down tube frame element 119, seat tube frame element 120, seat stay frame elements 122 and lower stay frame elements 123 are in the present example also designed as structural components according to the invention and each have a structurally supporting shell element and a structurally supporting core, which is advantageously composed of core elements. The structure of the aforementioned frame elements is explained using the example of the down tube frame element 119. This has a core composed of two down tube core elements, of which the right down tube core element 164 is shown. The down tube core elements are advantageously produced in an injection mold and preferably from thermoplastic material.An edge 165 of the right down tube core element 164 has a sealing means in the form of a sealing edge which interacts with an associated sealing edge of the left down tube core element. In this way, a tight parting line of the assembled core of the right down tube frame element 119 is formed in this area, specifically according to the principles described above as alternatives for the sealing edges of the core elements of the handlebar according to Figs. 1 to 7d, to which reference is made. Positioning elements 167 which serve as spacers are arranged on a circumferential surface 166 of the core or of the right down tube core element 164 shown. The core is then placed in an injection mold for the purpose of producing a shell element 168 which is injection molded around the core and whose inner surface 168a is integrally bonded to the circumferential surface 166 of the core.The positioning elements 167 fix the shape and position of the down tube core element 164 or the assembled core within the injection mold according to the principles which are also explained in detail above with respect to the handlebar according to Figs. 1 to 5, to which reference is made.

[0123] The other frame elements designed as structural components, such as the top tube frame element 118, seat tube frame element 120, seat stay frame elements 122 and lower stay frame elements 123, in principle have an identical structure to the down tube frame element 119. List of reference symbols Handlebar Core a Shell surface Core element a Outer surface Core element a Outer surface Shell element a Inner surface Front side Middle area a Partial surface Clamping area Grip area a Partial surface 0 Grip area 0a Partial surface 1 Transition area 1a Partial surface 2 Transition area 2a Partial surface Holding section Holding surface Holding section Holding surface Middle section Halved conical section Halved conical section Halved conical section Halved conical section Halved conical section Wall a Material reinforcement Inside Channel-shaped cavity a Small cavity Positioning element a Outer surface Positioning element a Outer surface Positioning element a Outer surface Positioning element aOuter surface Position element a Outer surface Position element a Outer surface Position element a Outer surface Stiffening element Ribs a Rib surface b Rib surface c Butt surface Ribs a Rib surface b Rib surface c Butt surface Central area Grip area Grip area Transition area Transition area Holding section Holding surface Holding section Holding surface Inside of a groove-shaped cavity a Small cavity Wall a Material reinforcement Outer surface Stiffening element Rib a Rib surface b Rib surface Rib a Rib surface b Rib surface Position element Position element Position element Position element Position element Position element Position element Parting plane Centering web a Centering surface Centering web a Centering surface Centering web a Centered surface Centering chamfer Centering chamfer Edge Edge Butt surface (second core element) a Sealing edge Butt surface (second core element) Butt surface (first core element) a Sealing edge (first core element) Parting line Tongue profile Groove profile Cavity Tongue profile Tongue profileGroove profile Groove profile Groove profile Wedge profile Wedge tip Groove profile Groove base Groove profile Groove base Bicycle frame Head tube section Seat tube section Rear triangle section Top tube element Core a Shell surface Shell element a Inner surface Side core element right a Outer surface Side core element left a Outer surface Rear triangle core element a Outer surface Cavity a Small cavity Stiffening element Ribs Ribs Opening (headset bearing) 0 Opening seat post 1 Bottom bracket section 2 Opening (crank bearing) 3 Position element 4 Bicycle frame 5 Head tube node element 6 Seat tube node element 7 Bottom bracket node element 8 Dropout node element 9 Shell element 0 Right head tube core element 1 Shell surface 2 Cavity 2a Small cavity 3 Stiffening element 4 Rib 5 Rib 6 Rim 7 Position element 8 Top tube frame element a Connection area

[0124] Under tube frame element a connection area

[0125] Seat tube frame element

[0126] Rear section

[0127] Seat stay frame element

[0128] Under strut frame element

[0129] Top tube fusion section

[0130] Under pipe fusion area

[0131] Shell element (bottom bracket node) a inner surface

[0132] Crank - core element

[0133] Shell surface

[0134] cavity a small cavity

[0135] stiffening element

[0136] rib

[0137] rib

[0138] edge

[0139] Position element

[0140] Recording equipment

[0141] Opening sleeve-shaped component

[0142] Fusion area down tube

[0143] Fusion area seat tube

[0144] Fusion area lower strut

[0145] Shell element (seat tube core element)a inner surface

[0146] Seat tube core element

[0147] Shell surface

[0148] cavity a cavity

[0149] stiffening element

[0150] Rib Rib Positioning element Receiving means Opening Sleeve-shaped component Fusion area Top tube Fusion area Seat tube Fusion area Seat stay Shell element a Inner surface Dropout core element right Shell surface Cavity a Cavity Stiffening element Rib Rib Edge Positioning element Down tube core element Edge Shell surface Positioning element Shell element a Inner surface Sealant Sealant

Claims

Patent claims 1. Structural component of a bicycle, comprising a core (2, 89) with at least one cavity (25, 25a, 46, 46a, 72, 95, 95a, 112, 112a, 129, 129a, 144, 144a, 158, 158a) and an enveloping shell surface (2a, 89a) as well as comprising a shell element (5, 90, 109, 126, 141, 155, 168) with the proviso that both the core (2, 89) and the shell element (5, 90, 109, 126, 141, 155, 168) each have a structurally supporting function, and that the supporting function is reinforced by means of a material connection between the enveloping Shell surface (2a, 89a) of the supporting core (2, 89) and an inner surface (5a, 90a, 126a, 141a, 155a, 168a) of the supporting shell element (5, 90, 109, 126, 141, 155, 168).

2. Structural component according to claim 1, characterized in that either the core (2, 89) and / or the shell element (5, 90, 109, 126, 141, 155, 168) is produced by means of a starting material which is flowable in a plastic state within the mold cavity of a shaping tool.

3. Structural component according to claim 1 or 2, characterized in that the starting material is a thermoplastic.

4. Structural component according to one of claims 1 to 3, characterized in that the core (2, 89) is formed in one piece or is composed of several core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164).

5. Structural component according to claim 4, characterized in that each core element (3, 4, 91, 92, 93, 110, 127, 142, 156, 164) has an outer surface (3a, 4a) and edges, and in that the outer surfaces (3a, 4a, 17, 48, 91a, 92a, 93a) of several core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164) in the assembled state form the lateral surface (2a, 89a) of the core (2, 89).

6. Structural component according to claim 4 or 5, characterized in that a parting line (69) is formed on edges (64, 65, 116, 133, 162, 165) of the outer surfaces (3a, 4a, 48, 91a, 92a, 93a) of assembled core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164), and that a sealing means is provided for the parting line (69).

7. Structural component according to claim 6, characterized in that a material-locking additive is provided as the sealing means or mechanically cooperating sealing edges (66a, 68a) at the edges (64, 65, 116, 133, 162, 165) of the core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164).

8. Structural component according to one of claims 4 to 7, characterized in that the core (2, 89), or at least one of the core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164), is provided with at least one inner stiffening element (33, 49, 96, 113, 130, 145, 159).

9. Structural component according to one of claims 4 to 8, characterized in that the inner stiffening element (33, 49, 96, 113, 130, 145, 159) is designed in the form of a strut or rib (34, 35, 50, 51, 97, 98, 114, 115, 131, 132, 146, 147, 160, 161).

10. Structural component according to claim 9, characterized in that struts or ribs (34, 35, 50, 51, 97, 98, 114, 115, 131, 132, 146, 147, 160, 161) of core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164), which are combined to form a core (2, 89), support one another.

11. Structural component according to one of claims 2 to 10, characterized in that the core (2, 89) has at least one protruding positioning element (26, 27, 28, 29, 30, 31, 32, 52, 53, 54, 55, 56, 57, 58, 103, 117, 134, 148, 163, 167) on its outer surface (2a, 89a), and in that the positioning element is designed to fix the core (2, 89) in a mold cavity of a shaping tool in the mold cavity of the latter for the production of the supporting shell element (5, 90, 109, 126, 141, 155, 168).

12. Structural component according to one of claims 1 to 11, characterized in that the supporting shell element (5, 90, 109, 126, 141, 155, 168) forms the shape of a bicycle frame (84), comprising a front section contour with a head tube section (85), a substructure contour with a bottom bracket section (101), a superstructure contour with a seat tube section (86) and a rear section contour with a rear section section (87) for a rear wheel axle.

13. Bicycle frame (104) comprising a plurality of frame components, which are partially designed as node elements (105, 106, 107, 108) and partially as frame elements (118, 119, 120, 121, 122), wherein the node elements and frame elements are connected to one another, characterized in that at least one of the node elements (105, 106, 107, 108) and / or one of the frame elements (118, 119, 120, 121, 122) is designed as a structural component according to one of claims 1 to 11.

14. Bicycle frame (104) according to claim 13, characterized in that a material connection is provided to connect the node element (105, 106, 107, 108) to the frame element (118, 119, 120, 121, 122).

15. Bicycle frame (104) according to claim 14, characterized in that the material-locking connection is provided by means of a material-locking additional material.

16. Bicycle frame (104) according to one of claims 13 to 15, characterized in that at least one node element (105, 106, 107, 108) is prepared with a fusion region (124, 125, 138, 139, 149, 152, 153, 154), and that at least one frame element (118, 119, 120, 121, 122) is provided with a connecting region (118a, 119a) which cooperates with the fusion region of the node element.

17. Bicycle frame according to claim 16, characterized in that the material-fit additional material is arranged between the fusion region (124, 125, 138, 139, 149, 152, 153, 154) of the node element (105, 106, 107, 108) and the connecting region (118a, 119a) of the frame element (118, 119, 120, 121, 122).

18. A bicycle comprising at least one component from the following group: bicycle frame (84, 104), fork, stem, handlebar (1), seat post, crank arms; wherein at least one of said components is designed as a structural component according to one of claims 1 to 11.

19. Handlebar (1) for a bicycle, designed as a structural component according to one of claims 1 to 12.

20. Handlebar (1) according to claim 19, characterized in that a core (2) is provided which is composed of at least two core elements (3, 4), and that the core elements (3, 4) are injection-molded from a thermoplastic material.

21. Handlebar (1) according to claim 19 or 20, characterized in that a holding section (13, 15, 41, 43) is arranged and prepared at each of the free ends of the core elements (3, 4) in order to fix the core element (3, 4) in an injection molding tool.

22. Handlebar (1) according to claim 21, characterized in that the holding sections (13, 15, 41, 43) the core elements (3, 4) are designed to be complementary, and that each core element (3, 4) has means for correctly positioning it in contact with the complementary core element (3, 4).

23. Handlebar (1) according to claim 21 or 22, characterized in that the holding sections (13, 15, 41, 43) of the core elements (3, 4) form a polygonal cross-section in the assembled state as the core (2), and that the assembled holding sections (13, 15, 41, 43) have external holding surfaces (14, 16, 42, 44).

24. Handlebar (1) according to claim 21, characterized in that the polygonal cross-section of the core (2) is a hexagonal cross-section.

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