Bicycle structural components, bicycle frame, bicycle equipped with structural components, and handlebar as a structural component

Abstract

The present invention relates to a structural component of a bicycle, the structural component comprising a core (2, 89) having at least one cavity (25, 25a, 46, 46a, 72, 95, 95a, 112, 112a, 129, 129a, 144, 144a, 158, 158a) and surrounding circumferential surfaces (2a, 89a), and a shell element (5, 90, 109, 126, 141, 155, 168), the core (2, 89) and the shell element Each of the elements (5, 90, 109, 126, 141, 155, 168) has a structural support function, and this support function is reinforced by an integral joint connection between the surrounding sides (2a, 89a) of the support core (2, 89) and the inner surfaces (5a, 90a, 126a, 141a, 155, 168a) of the support shell elements (5, 90, 109, 126, 141, 155, 168). The present invention relates to a bicycle frame comprising a plurality of frame components, wherein at least one of them is formed as a structural component. The present invention relates to a bicycle comprising at least one component formed as a structural component, and further relates to a handlebar formed as a structural component.

Description

Technical Field

[0001] The present invention relates to structural components of a bicycle. For the purposes of the present invention, the structural components are understood to mean, in particular, bicycle structural components related to safety, which in a narrow sense are bicycle structural components such as a bicycle frame, fork or steering knuckle, stem, handlebar, seat post, crank arm and pedal, and are related to the safety of the bicycle during riding. On the other hand, other elements understood to be bicycle structural components are, for example, frame components that can be fitted together to form a bicycle frame. More broadly, elements such as a wheel rim or wheel are also included. Further, the structural components according to the present invention may also include accessories such as a seat, brake and gear lever, fender or splash guard, bicycle support (stand), luggage carrier, luggage holder, child seat, etc.

[0002] The proposed structural components of a bicycle include bicycle structural components or those for a bicycle, and hereinafter will be more simply referred to as "structural components".

[0003] The structural components comprise a core having at least one internal cavity and an enclosing peripheral surface, and a shell element.

[0004] The present invention further relates to a bicycle frame comprising at least one of the above frame components configured as a structural component according to the present invention.

[0005] Furthermore, the present invention relates to a bicycle comprising at least one element configured as a structural component according to the present invention.

[0006] Furthermore, the present invention relates to a handlebar configured as a structural component according to the present invention.

Background Art

[0007] Patent Document 1 proposes several embodiments of bicycle frames and is known in the relevant art. One example proposes a bicycle frame having a core made of injection-molded plastic material. Outwardly oriented outer ribs are arranged on the injection-molded core. A covering is provided around the outer ribs, but this task is performed by the core having the outer ribs and is therefore preferably not required for structural purposes. The covering is, for example, a shrink-worn film of plastic, which is attached around the core so as to be in close contact with the core and then heated. Structural strength is provided in this example by the core having the outer ribs.

[0008] Another example in the same patent document reverses the principle of the above example, proposing instead an internal bladder that plays a role in generating the walls of the bicycle frame by the mold. The internal bladder is inserted as a core into the mold and may be filled with liquid or other material to withstand the pressure during injection of the thermoplastic material in which the bicycle frame is formed. Alternatively, the bladder may consist of a rib structure to withstand the dominant pressure, or lower pressures may be used. The walls of the bicycle frame are generated between the outer mold and the internal bladder, and the space between the bladder and the outer mold corresponds to the thickness of the walls of the finished bicycle frame.

[0009] Conventional techniques using internal bladders are unsatisfactory in terms of structural strength. This is also true in exemplary embodiments of bicycles having a core with external ribs. [Prior art documents] [Patent Documents]

[0010] [Patent Document 1] German Patent Application Publication No. 19581569 [Overview of the project]

[0011] The present invention proposes a structural component for a bicycle, comprising a core having at least one cavity and one surrounding surface, and a shell element, wherein both the core and the shell element have a structural support function, and this support function is reinforced by a material joint between the surrounding surface of the support core and the inner surface of the support shell element. The cavity of the core is preferably a geometrically defined cavity.

[0012] Material bonding can be achieved by fusing the material of the shell element to the material of the core. This fusion occurs between the circumferential surface of the core and the initial material of the shell element. The materials involved are in a state where they are at least partially molten. For material bonding, additional materials that can fuse with the materials involved may be added. It may be advantageous to use the same initial material for the core element and / or shell element. If used, the additional material for material bonding can be generated from the same initial material as the core element and / or shell element. Alternatively, material bonding may be achieved using an additional adhesive material placed between the surrounding circumferential surface of the core and the inner surface of the supporting shell element.

[0013] As in the prior art, the proposed structural component may be realized, for example, as a bicycle frame, and the structural component according to the present invention exhibits improved strength. On the other hand, the effect of the shell is not only to improve aerodynamics and appearance, but also to contribute to the inherent structural strength as a supporting shell element. This structural strength is further enhanced by the similarly inherent structural strength of the supporting core. Furthermore, the strength of the entire structural component is further improved by the material bonding that connects the supporting core to the supporting shell element. In the embodiment of the structural component as a bicycle frame, the shell element preferably contributes mainly to the strength and rigidity of the bicycle frame. Particularly preferably, the shell element is designed so that its contribution to the strength and rigidity of the bicycle frame is at least as great as the contribution of the core.

[0014] According to the present invention, the surrounding circumferential surface of the support core is a substantially smooth surface. It may be configured as a free-form surface, for example, similar to a curved body, or it may form a simple cylindrical circumferential surface, for example. The circumferential surface may be assembled from various parts, for example, parts of a cylindrical, prismatic, or conical basic shape. A surface having external ribs is not considered a substantially smooth circumferential surface for the purposes of the present invention. The shape of the surrounding circumferential surface is further appropriately adapted to the outer contour of the shell element. It is advantageous to provide a uniform thickness between the outer contour of the shell element and the circumferential surface of the core relative to the wall thickness of the shell element. The wall thickness of the shell element may vary somewhat in location to provide regions of higher strength and rigidity. It is advantageous to provide a gradual, continuous transition between regions of thin wall thickness and regions of thick wall thickness to prevent a notch effect.

[0015] Conveniently, either the core and / or the shell element is produced using a starting material that can flow in a plastic state within the mold cavity of the molding die. In a preferred embodiment, the shell element may be produced, for example, using an injection mold. For this purpose, it is advantageous that the core is located inside the injection mold. The mold cavity of the injection mold forms an inversion of the outer contour of the shell element. The remaining core forms the inner contour of the shell element. Simultaneously, the injection molding process creates a material bond by fusing the surface of the injected starting material of the shell element with the material of the circumferential surface of the core, thus bonding the materials of the shell element and the core together. The core is sufficiently stable to withstand the injection pressure during the injection molding of the starting material of the shell element by providing a sufficiently strong wall below its fused circumferential surface.

[0016] The injection mold is appropriately equipped with at least one fixed mold section and at least one movable mold section. The mold sections meet at a dividing line when closed. The injection mold can be opened and closed at the dividing line and repeatedly filled with starting material so that the finished molded workpiece can be removed after each molding process.

[0017] The structural strength and rigidity of the supporting shell element are beneficial when its initiating material can be injected into the mold cavity at high injection pressure. For this purpose, the core is preferably specially manufactured to withstand the high injection pressure from the flowable initiating material for the shell element without collapsing.

[0018] For this purpose, the circumferential surface of the core is preferably realized with a wall thickness that can withstand sufficiently high injection pressure to ensure that no holes are formed in which the starting material can penetrate into the core cavity.

[0019] Supporting shell elements primarily contribute to the structural strength of a structural component. Their contribution in terms of strength can be influenced by the selection and quality of the initial material and the shell thickness of the shell elements. Furthermore, the core, which possesses inherent structural strength, also contributes. The overall structural strength of the structural component is further reinforced by material bonding that firmly connects the supporting core to the supporting shell elements.

[0020] The quality of structural components, in terms of strength and rigidity, is based on the shell elements bonded to the core and the bonds between them. The quality of the core and material bonds is not evident in the lower or internal parts of the shell elements. Non-destructive testing can be performed using imaging material testing methods, such as computed tomography.

[0021] The starting material for the core and / or shell elements is preferably a thermoplastic material. The plastic material may be a single-grade plastic material or a compound comprising a base plastic material mixed with at least one other plastic material. The single-grade plastic material or compound may also be provided with at least one filler, such as reinforcing fibers and / or other reinforcing particles.

[0022] The core may be of an integral construction or may be assembled from a plurality of core elements. Since the core has at least one cavity, for example, generation using 3D printing and a purpose-suited starting material is suitable for an integral structure. For other starting materials, for example, the lost wax molding method is suitable for generating an integral core. For this purpose, simply a lost wax mold may be generated, which has the same shape as the core and melts and disappears when molding the starting material.

[0023] The above generation method is equally applicable to a core assembled from a plurality of core elements, and the same applies to further manufacturing methods. The individual core elements can be generated, for example, by injection molding using a starting material that can be processed in a plastic state that is flowable, for example, within a mold cavity of an injection mold. This is preferably carried out using an injection mold having at least one fixed mold part and one movable mold part, which are openable and closable at a parting line in order to be able to carry out repeated injection molding cycles.

[0024] The core according to the present invention can have a complex shape. In its shape, there may be provided undercuts with respect to the shell element, and due to these undercuts, a reusable core provided in the mold becomes unusable.

[0025] It is advantageous for each core element to have an outer surface and an edge. The outer surfaces of the plurality of core elements form the peripheral surface of the core when assembled. The edges of the core elements are adjacent to each other when fitted to each other.

[0026] At least one split joint is formed at the edge of the outer surface of the assembled core element, and preferably, sealing means is provided for the split joint. In particular, when the shell element is generated in the injection mold and the core is placed in the mold cavity, effective sealing helps to prevent the flowable plastic starting material of the shell element from penetrating into or up to the split joint of the core.

[0027] Additional substances for material bonding, for example, simply an adhesive may be provided as a sealing means, or it may be advantageous for the sealing means to take the form of a sealing edge that mechanically interacts at the edge of the core element. Such a sealing edge is preferably of a complementary configuration, for example, in the form of a rabbet edge or an edge with a grooved element.

[0028] It is advantageous if at least one internal stiffening element is provided in at least one of the cores or core elements.

[0029] This measure reinforces the core. The reinforced core promotes the generation of the shell element around the core, especially when the shell element is produced by injection molding. For this purpose, the core is inserted into the injection mold to form the shell element and the central component of the structural part, but is hidden within the shell element and remains as a core for structural support.

[0030] The internal stiffening element simply takes the form of a strut or rib.

[0031] The strut or rib may be configured, for example, by injection molding so that the core element can be similarly produced in the mold cavity of the injection mold. The core element can be periodically and appropriately produced in the injection mold.

[0032] The positive effect from the perspective of the stability of the structural part can be enhanced when the struts or ribs of the core elements assembled to form the core support each other.

[0033] For shell elements produced by injection molding, it is advantageous to provide a core that is sufficiently stable to withstand the high injection pressure of the initiating material when the initiating material is injected into the mold cavity to give the shell element the desired shape. High injection pressure promotes the fluidity of the initiating material in its plastic state, i.e., in its molten, flowable state. The injection pressure favorably affects the viscosity of the initiating material in a manner that increases its viscosity. High viscosity means that thin wall-like regions of the mold cavity can be well filled. This means that struts or ribs can be optimized. These can be made as thin as possible to minimize the amount of material used, while still providing good support to the core when high injection pressure acts on their circumferential surface from the outside. In this way, material savings can be achieved, and the structural component can be sufficiently stable yet lightweight.

[0034] It is even more useful if the core has at least one protruding positioning element on its circumferential surface, the positioning element being provided to fix the core in place within the mold cavity of the molding die for generating the support shell element within the mold cavity.

[0035] It is advantageous to provide a sufficient number of protruding positioning elements on the core or core element. These are, for example, distributed around the circumferential surface when the shell element is injection molded, and hold the core in its desired shape and position. The molten, flowable initiating material exerts uneven forces on the core in place within the mold cavity, causing the core to deform under these forces and, in some cases, move from its desired position within the mold cavity. The protruding positioning elements advantageously mitigate changes in the core's shape or deviation from its desired position within the mold cavity.

[0036] The positioning element appropriately creates a distance that generates contact with the inside of the mold cavity, thereby easily enabling precise and desired positioning on the molding die. Furthermore, the positioning element has a favorable effect on the core's shape. The core maintains its shape by being fixed in place, even when high external pressure is acting on it.

[0037] Positioning elements on the circumferential surface of the core or core element further provide connecting elements for connection with the shell element. The positioning elements become undercuts by protruding into the completed shell element. The undercuts provide connecting elements for connections that aid in material bonding between the supporting core and the supporting shell element.

[0038] Alternatively, if at least one mold-side positioning element is located within the injection mold, the positioning element on the circumferential surface of the core can be omitted. Advantageously, the mold-side positioning element is located within the mold cavity and is appropriately incorporated into the interior of the mold cavity. When the injection mold is closed, the mold-side positioning element protrudes from the interior of the mold cavity and contacts the circumferential surface of the core to maintain its shape and hold it in the intended position within the mold cavity.

[0039] Furthermore, if the core has a suitable holding portion separated from its circumferential surface, and the injection mold has alignment means for fixing the position of the core within a closed mold cavity, it is also possible to produce the structural component according to the present invention without using positioning elements protruding from the circumferential surface of the core, and without using mold-side positioning elements protruding from the inside of the mold cavity toward the core.

[0040] In one embodiment, the support shell element may form the shape of a bicycle frame having a front end contour with a head tube portion, a lower contour with a lower bracket portion, an upper contour with a seat tube portion, and a rear end contour with a rear axle portion relative to the rear wheel axle.

[0041] In this embodiment, the shell element of the structural component is preferably a single unit when viewed from the outside. On the other hand, it includes a core, which is advantageously interlocked with a plurality of core elements, as a second support component within it. In terms of a bicycle frame, this structural component is configured to satisfy the requirements for bicycles specified in DIN EN ISO 4210:2015.

[0042] The present invention further proposes a bicycle frame comprising a plurality of frame components, some of which are configured as node elements, some of which are configured as frame elements, and the node elements and frame elements are interconnected, provided that at least one of the node elements and / or one of the frame elements are configured as structural components according to the present invention.

[0043] Frame components, as structural components, are advantageously configured to meet the safety requirements within a finished bicycle frame, as standardized for bicycles in DIN EN ISO 4210:2015. This applies in particular to all frame components of a bicycle frame configured as structural components according to the present invention. Other frame components that are not structural components for the purposes of the present invention may optionally also meet these requirements. These requirements are further met by the bicycle frame as a whole.

[0044] When a bicycle frame can be assembled from multiple frame components, this provides a high level of variability, for example, when it comes to adapting it to an individual's physique. For instance, the bicycle frame may be tailored to an individual's physical measurements, such as the length of their arms, legs, or back. Furthermore, consideration may be given to providing a bicycle frame that matches the individual's desired posture when straddling the bicycle, such as seat height, riding position, and back tilt.

[0045] Alternatively, the frame component in the form of a structural component according to the present invention may be provided as a modular system, for example, as modules of stepped sizes.

[0046] Material joints are provided as appropriate to connect node elements to frame elements.

[0047] The material joint is simply provided using additional material. The additional material may be, for example, a one-part adhesive or a two-part adhesive. Alternatively, the additional material may be a castable material that can be processed in a mold, for example, a flowable material that can be injection molded in the same manner as the injection molding initiation material for the shell element.

[0048] Preferably, at least one node element is provided with a fusion region, and at least one frame element is provided with a connection region that interacts with the fusion region of the node element. It is beneficial that the fusion region and the connection region define the relative positions of the node element and the frame element when they are fitted together.

[0049] The additional bonding material or adhesive is simply placed between the fusion region of the node element and the connection region of the frame element. The fusion region and the connection region then form a bonding surface, between which a narrow gap is preferably formed for the adhesive.

[0050] Finally, a bicycle is proposed comprising at least one element from the group including a bicycle frame, fork, stem, handlebars, seatpost, and crank arms, wherein at least one of the aforementioned elements constitutes a structural component according to the present invention.

[0051] A handlebar for a bicycle, which takes the form of a structural component according to the present invention, is also proposed.

[0052] The proposed handlebars offer superior safety and can withstand high loads during riding. High loads primarily occur during acceleration and braking. When alternating leftward and rightward loads are applied to the handlebar grips, acceleration results in alternating loads. During braking, the two handlebar grips receive a more uniform load. Handlebar failure can lead to injury. Therefore, handlebars are one of the safety-related elements of a bicycle. For safety reasons, used handlebars after a given lifespan should be replaced with new ones, even if no obvious damage is observed. The safety of the proposed handlebars is based on the fact that they are supported by a support core and support shell element that provides inherent structural strength and rigidity, and that this strength and rigidity are further reinforced by material bonding between the core and shell element.

[0053] It is advantageous to provide a core that is assembled from at least two core elements, and the core elements are assembled by injection molding from a thermoplastic material.

[0054] Further advantages are provided when retaining parts are positioned at each of the free ends of the core elements, and the retaining parts are provided to fix the core elements in place within the injection mold. Precisely fixing the core elements or assembled cores in place facilitates the production of accurate shell elements, and the defined shell walls contribute to the desired strength and rigidity.

[0055] The core element holders have a complementary configuration, and each core element has means for positioning itself correctly by contacting a complementary core element.

[0056] It has also been found that it is advantageous for the core element holder to form a polygonal cross-section when assembled within the core. The assembled holder has an external holding surface that coincides with the polygonal cross-section. The holder interacts with a corresponding receiving area in the injection mold. In particular, this type of in-place fixation mitigates twisting of the core within the injection mold.

[0057] The retaining surface may be further inclined toward the free end of the handlebar. Thus, a retaining portion may be provided, the polygonal cross-section of which has a somewhat larger configuration proximally and a somewhat smaller polygonal cross-section distally with the same number of vertices.

[0058] The polygonal cross-section of the core is preferably a hexagonal cross-section. [Brief explanation of the drawing]

[0059] [Figure 1] This is a perspective view of the first core element for the handlebars, which is configured as follows: [Figure 2] Figure 1 shows the first core element indicated by arrow II. [Figure 3] This is a perspective view of a structural component according to the present invention in the form of a second core element for a handlebar. [Figure 4] Figure 3 shows the second core element, indicated by arrow IV. [Figure 5] This is a perspective view of a structural component according to the present invention in the form of a handlebar. [Figure 6] Figure 5 shows details related to the cutting line VI-VI. [Figure 7a] Figure 3 shows an exemplary embodiment of the edge of the second core element as a sealing edge related to the cutting line VII-VII. [Figure 7b] Figure 3 shows a first alternative exemplary embodiment of the edge of the second core element relating to the cutting line VII-VII. [Figure 7c] Figure 3 shows a second alternative exemplary embodiment of the edge of the second core element relating to the cutting line VII-VII. [Figure 7d] Figure 3 shows a third alternative exemplary embodiment of the edge of the second core element relating to the cutting line VII-VII. [Figure 8] This is a reduced schematic plan view of a bicycle frame given as a structural component according to the present invention. [Figure 9] Figure 8 shows a schematic cross-sectional view of a bicycle frame along the cutting line IX-IX. [Figure 10] This shows an alternative bicycle frame made up of frame components configured as structural components according to the present invention, which are fitted together. [Modes for carrying out the invention]

[0060] The present invention is illustrated below in the drawings and will be described in detail with reference to several of the drawings.

[0061] A first example of a bicycle structural component according to the present invention is described below with reference to Figures 1-5. The first example relates to a bicycle handlebar 1 realized as a structural component. Figure 5 shows a substantially completed handlebar 1. The handlebar 1 comprises a core 2 assembled from two core elements 3 and 4 and surrounded by a shell element 5. The core elements 3 and 4 are assembled after being molded in an injection mold from a thermoplastic material. The shell element 5 is similarly produced from a thermoplastic material, specifically using a second injection mold into which the assembled core 2 was previously inserted.

[0062] Figure 1 shows only the first core element 3 of the core elements. In the completed handlebar 1, the core element 3 is located on the front side 6 of the handlebar 1 and is located in the forward direction of travel of the bicycle when installed. The first core element 3 is provided with a central region 7 having the largest cross-section. In the completed structural component, the central region 7 is considered to be the clamping region 8 of the handlebar 1 and interacts with the handlebar clamp bracket in the completed bicycle. Clamping of the handlebar is conventionally achieved for this purpose using a stem element having a slotted stem lug. The completed handlebar 1 is configured to match such a stem lug. The stem lug can connect the clamping region 8 of the handlebar 1 to the stem element using a conventional slotted clamp. Therefore, it is advantageous that the cross-section of the central region 7 of the core element 3 is designed so that the clamping region of the completed handlebar structural component corresponds to the conventional dimensions of the stem element / stem lug. The core element 3 is formed with a smaller cross-section toward its ends than the central region 7. The end includes two grip regions 9 and 10 of the completed handlebar structural component. Outside each of them, grip region 9 has a subdivision surface 9a, and grip region 10 has a subdivision surface 10a. A transition region 11 is provided between the grip region 9 and the central region 7 of the first core element 3, and a transition region 12 is provided between the grip region 10 and the central region 7. Outside, the transition region 11 forms a subdivision surface 11a, and the transition region 12 forms a subdivision surface 12a. The transition regions 11 and 12 provide a continuous change in cross-section, that is, starting from the large cross-section of the central region 7, the cross-section decreases toward the grip regions 9 and 10. The subdivision surfaces 7a, 9a, 10a, 11a, and 12a together form the outer surface 3a of the first core element 3. Furthermore, a retaining portion 13 having a retaining surface 14 is located at one free end of the first core element 3, and a retaining portion 15 having a retaining surface 16 is located at the other free end. In this example, the retaining parts 13 and 15 are solid. In principle, they serve to fix the core element 3 in the appropriate place within the injection mold for the injection molding process when it is assembled together with the second core element 4 to form the core 2.The retaining parts 13 and 15 may remain on the completed structural component after the injection molding process, or they may be removed later.

[0063] The central region has a semi-cylindrical central portion 18, which is adjacent on both sides to bisecting cone portions 19 and 20 that form transition regions 11 and 12, respectively. Each of the transition regions 11 and 12 is similarly adjacent to a semi-cylindrical portion 21 or 22, each of which belongs to either the grip region 9 or 10, respectively. Together, these portions form the wall portion 23 of the first core element 3, with a channel-shaped cavity 25 formed inside 24. The interior 24 of the wall portion 23 is generally parallel to the contour of the outer surface 3a.

[0064] Positioning elements 26, 27, 28, 29, 30, 31, and 32 are positioned on the outer surface 3a, projecting outward. Positioning element 26 has outer surfaces 26a, 27a, 28a, 29a, 30a, 31a, and 32a that fix the core 2 in place within the mold cavity when the assembled core 2 is inserted into the mold cavity of the injection mold. The positioning elements act as spacers. For this purpose, the outer surfaces of the positioning elements contact the interior of the closed mold cavity within the injection mold. As a result of this contact, the core 2 maintains its shape and position during the injection molding process. This is also true when the flowable initiating material of the shell element 5 is supplied into the mold cavity under high injection pressure. The applied force cannot deform the core 2, which is thus fixed in place, or change its position within the mold cavity. The defined shell wall thickness of the shell element 5 can thus be generated within the remaining mold cavity. In the grip region 9, the first core element 3 has two elongated positioning elements 26 and 27, one positioned distally and the other proximal. The distally positioned elongated positioning element 26 extends circumferentially along the outer surface 3a, while the proximally positioned elongated positioning element 27 extends parallel to the longitudinal direction of the grip region 9. The central region 7 has three point-like positioning elements 28, 29, and 30 arranged in a row. Positioning elements 31 and 32 are mirror images of positioning elements 26 and 27 and have shapes corresponding to their mirror images. The shape of the point-like positioning elements 28, 29, and 30 is generally cylindrical. All elongated and point-like positioning elements are configured with obliquely oriented sides 26b, 27b, 28b, 29b, 30b, 31b, and 32b, which form a release bevel that allows for easy removal of the first core element 3 from the injection mold.

[0065] Figure 2 shows a simplified front view of the first core element 3, indicated by arrow II in Figure 1. The drawing is simplified in that the circumferential positioning elements are not shown in Figure 2, in order to particularly favor the illustration of the internal stiffening element 33. The stiffening element 33 is provided on the interior 24 of the channel-shaped cavity 25. In this example, the stiffening element 33 is a parallel rib 34 intersecting a parallel rib 35, thereby enhancing its stiffening effect. The intersecting ribs 34 and 35 subdivide the channel-shaped cavity 25 into numerous small cavities 25a. The ribs 34 are realized by oblique lateral rib surfaces 34a and 34b, and the ribs 35 are realized by oblique lateral rib surfaces 35a and 35b, which act as demolding bevels to assist in demolding the core element 3 from the injection mold. The front view of the first core element 3 shows that the completed handlebar structural component consists of a riser-shaped handlebar 1. The grip areas 9 and 10 are positioned at a slightly different height (rise) relative to the central area 7.

[0066] The thickness of the wall portion 23 of the core element 3 in the circumferential region 7 shown in Figure 2 is schematic and should be understood as not necessarily proportional to the handlebar diameter in its various parts. In fact, when the wall portion 23 is inserted into the mold as a permanent core for forming the shell element 5, it has sufficient thickness to withstand the high injection pressure of the assembled core 2.

[0067] Figure 3 shows a perspective view of a second core element 4 configured to be complementary to the first core element 3. The second core element 4 is located at the rear of the completed handlebar 1 and, when mounted, faces rearward in the direction of travel of the bicycle. The second core element 4 has components that are complementary to the first core element 3. This includes a central region 36 for the handlebar clamp bracket. Towards the two ends of the second core element 4 are two grip regions 37 and 38, similarly with smaller cross-sections than the central region 36. Transition regions 39 or 40 are provided between each of the grip regions of the second core element 4 and the central region, respectively. The transition region 39 creates a continuous change in cross-section between the large cross-section of the central region 36 and the small cross-section of the grip region 37, and between the large cross-section of the central region 36 and the small cross-section of the grip region 38. At each free end, the second core element 4 has either a retaining portion 41 with a retaining surface 42 or a retaining portion 43 with a retaining surface 44, which serve to fix the second core element 4 in the appropriate place within the injection mold when assembled with the first core element 3 to form the core 2. In this example, the retaining portions 41 and 43 of the second core element 4 are also solid.

[0068] The perspective view in Figure 3 shows the interior 45 that forms the channel-shaped cavity 46. The interior 45 constitutes the portion of the wall 47 that forms the outer surface 4a from the outside. The outer surface 4a complements the outer surface 3a of the first core element 3, and together they form the circumferential surface 2a of the core 2. The outer surface 4a is, in principle, assembled from subdivided surfaces, similar to each part of the first core element 3. The internal stiffening element 49 is placed within the channel-shaped cavity 46 of the second core element 4 and is configured as a parallel rib 50 intersecting with a parallel rib 51, thereby improving the stiffening effect. The rib 50 is realized by oblique lateral rib surfaces 50a and 50b, and the rib 51 is realized by oblique lateral rib surfaces 51a and 51b, which act as demolding bevels that assist in demolding the second core element 4 from the injection mold. In this case, the channel-shaped cavity 46 is subdivided into a number of small cavities 46a. Similarly, the ribs 50 and 51 of the second core element 4 are realized by oblique lateral rib surfaces 50a and 50b and 51a and 51b, which act as release bevels to assist in releasing 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 aligned when assembled. Core element 3 has contact surfaces 34c and 35c that come into contact with the contact surfaces 50c and 51c of the second core element 4 when these two core elements are assembled. The core 2 assembled from these two core elements 3 and 4 can absorb very high pressures through the mutually contacting ribs when a force acts from the outside on the outer surface 3a of the first core element 3 and the outer surface 4a of the second core element 4 and the pressure is transmitted into the ribs.

[0069] Figure 4 shows a front view of the second core element 4 indicated by arrow IV in Figure 3. The drawing shows internal stiffening elements 49, which are realized as intersecting ribs 50 and 51. Furthermore, positioning elements 52, 53, 54, 55, 56, 57 and 58 are indicated by dashed lines on the back. In this figure, the positioning elements are located on the rear outer surface 48 of the illustrated second core element 4.

[0070] In the grip region 37, the second core element 4 has two elongated positioning elements 52 and 53, one positioned distally and the other proximal. The distally positioned elongated positioning element 52 extends circumferentially along the outer surface 48a, while the proximally positioned elongated positioning element 53 extends parallel to the longitudinal direction of the grip region 37. The central region 36 has three point-like positioning elements 54, 55, and 56 arranged in a row. Positioning elements 57 and 58 are mirror images of positioning elements 52 and 53 and have shapes corresponding to their mirror images. The shape of the point-like positioning elements 54, 55, and 56 is generally cylindrical. All elongated and point-like positioning elements are configured to have obliquely oriented sides 52b, 53b, 54b, 55b, 56b, 57b, and 58b, which form a release bevel that allows for easy removal of the second core element 4 from the injection mold.

[0071] Figure 5 shows the handlebar 1 as a completed structural component. It comprises a first core element 3 and a second core element 4 on the inside, which are assembled to form a core 2, and a shell element 5 on the outside. The shell element 5 is injection molded around the permanent core 2 using the second injection mold described above. During the injection molding process of the shell element 5, the entire circumferential surface of the assembled core 2 is melted and material-bonded with the starting material of the shell element 5 to its interior (inner surface) 5a. The inner surface 5a is shown by a dashed line in Figure 5. Furthermore, the positioning elements (26, 27, 28, 29, 30, 31, 32, 52, 53, 54, 55, 56, 57, 58) provided on the outer surfaces 3a and 4a of the core elements 3 and 4 are laterally surrounded by the starting material of the shell element 5. In this way, an additional connecting portion is provided between the positioning elements and the shell element 5. The outer surfaces of the positioning elements (26c, 27c, 28c, 29c, 30c, 31c) are visible on the finished handlebar because they are in contact with the mold cavity of the injection mold during the injection molding process. The outer surfaces are not covered by the starting material of the shell element 5 during injection molding and therefore remain visible.

[0072] The assembled retaining sections 13 / 41 and 15 / 43, both of which form a hexagonal cross-section, are located at the free end of the completed structural component. In this example, the retaining sections are solid. Three retaining surfaces 14 and three retaining surfaces 42 form a hexagonal retaining surface when assembled. All six retaining surfaces are inclined at a slight wedge angle. Thus, the hexagonal cross-section of the assembled retaining section 13 / 41 is somewhat larger proximally and somewhat smaller distally at the free end. The assembled retaining section 15 / 43 similarly forms six retaining surfaces, which are also inclined at a slight wedge angle.

[0073] The cutting line VI-VI shown in Figure 5 illustrates the details shown in the enlarged scale in Figure 6. The details indicate that interaction means are provided in the region of the retaining section 13 / 41 to correctly position the complementary core elements 3 and 4 relative to each other. Each of the retaining sections 13 / 41 has an internal bottom surface 13a or 41a that, when assembled, contacts each other in the dividing plane 59. In the case of the retaining section 13 of the first core element 3, the bottom surface 13a is laterally divided by centering fins 60 and 61. The centering fins have centering surfaces 60a and 61a that are arranged in a V-shape and inclined relative to each other. The retaining section 41 of the second core element 4 has centering chamfers 62 and 63 that are laterally positioned on its bottom surface 41a and are configured to coincide with the centering fins 60 and 61 of the first core element 3. This allows for the mitigation of undesirable lateral displacement of the core elements 3 and 4 relative to each other.

[0074] Figure 7a is a detailed enlarged view of the configuration of the edges 64 and 65 of the second core element, specifically along the cutting line VII-VII shown in Figure 3. Sealing means are provided at the edges. For simplicity of explanation, the first core element 3 is shown by a dashed line and specifically fits together with the second core element 4. Each of the illustrated edges 64 and 65 of the second core element 4 has contact surfaces 66 and 67, respectively, that interact with the contact surface of the first core element 3. The contact surface 66, for example, contacts the contact surface 68 of the first core element 3, and together they form a split joint 69.

[0075] As an example of a split joint 69, Figure 7a shows that the abutment surface 66 of the second core element 4 is further expanded and has a sealing edge 66a provided with a convex profile 70 for this purpose as a sealing means S1. Coincidentally, the abutment surface 68 of the first core element 3 is provided with a sealing means S2, which also takes the form of a sealing edge 68a having a concave profile 71. When the sealing edges 66a and 68a are fitted together, a good sealing effect is obtained by the convex profile 70 and the concave profile 71. By the same principle, the abutment surface 67 of the second core element 4 interacts with the corresponding abutment surface of the first core element 3. In this way, the core 2 assembled from the two core elements 3 and 4 can be used as a permanent core in an injection mold. In the injection mold, the shell element 5 is injection molded around the core 2 with a given injection pressure. During the process, it is necessary to prevent the molten starting material of the shell element 5 from penetrating into the split joint and, in some cases, reaching the cavity 72 of the core 2, or actually reaching the cavities 25a and 46a between the ribs of the core elements 3 and 4, respectively. In particular, a high injection pressure may be used to injection mold the shell element 5, as this is beneficial to the quality of the resulting shell element 5.

[0076] In the region of the convex profile 70, the wall portion 47 of the second core element 4 has a thickened portion 47a. The convex profile 70 is further positioned to protrude from the contact surface 66. Its shape makes it possible to produce the second core element 4 by injection molding within the injection mold. For this purpose, the convex profile 70 is configured to have lateral release bevels 70a and 70b to facilitate the removal of the second core element 4 from the injection mold.

[0077] The concave profile 71 of the first core element 3 takes the form of a recess in its contact surface 68. In the region of the concave profile 71, the wall portion 23 is provided with a thickened portion 23a. The concave profile is similarly designed for the production of the first core element by injection molding in an injection mold. For this purpose, the concave profile has a lateral release bevel to assist in releasing the first core element 3 from the injection mold.

[0078] Figure 7b shows an alternative configuration for the edges 64 and 65 of the second core element, which similarly provide sealing means S1 and S2 in the form of connecting sealing edges. The figure similarly relates to the cutting line VII-VII shown in Figure 3. The complementary core elements 3 and 4 have a pair of contact surfaces 66 / 68 that form a split joint 69. Unlike Figure 7a, the second core element 4 in Figure 7b has two convex profiles 73 and 74 adjacent to each other on its contact surface 67.

[0079] To match these, the first core element, shown by the dashed line, is provided with adjacent concave profiles 75 and 76 on its contact surface 68. This pair of convex profiles 73 and 74 and the pair of concave profiles 75 and 76 are configured so that core elements 3 and 4 can similarly be produced by injection molding in an injection mold. The pair of concave and convex profiles improve the sealing effect compared to the example shown in Figure 7a.

[0080] Figure 7c shows further alternative configurations for the edges 64 and 65 of the second core element, which similarly provide sealing means S1 and S2 by connecting sealing edges. This figure again relates to the cutting line VII-VII in Figure 3. The first core element 3, which fits together, is shown by a dashed line. The two complementary core elements 3 and 4 have contact surfaces 66 and 68, respectively, which interact as a pair at the split joint 69. The contact surfaces are further developed as sealing edges 66a and 68a, respectively, which are based on the configuration of the example in Figure 7b, except that one of the pair of convex profiles is replaced by a concave profile 77 at the sealing edge 66a of the second core element 4. To match this, the concave profile is replaced by a convex profile 73 at the sealing edge 68a of the first core element 3.

[0081] The edge 65 of the second core element 4 is modified in the same way as its edge 64. This also applies to the corresponding edge of the first core element.

[0082] Therefore, each contact surface (edge) 64 and 65 of the second core element 4 has one convex profile and one concave profile. To match these, each contact surface of the first core element, shown by the dashed line, has one concave profile and one convex profile. The combination of one convex profile and one concave profile per contact surface improves the sealing effect.

[0083] Figure 7d shows a fourth example of the configuration of the edges 64 and 65 of the second core element 4, which are provided with sealing means S1 and S2, respectively, having special sealing edge forms. This figure also relates to the cutting line VII-VII in Figure 3. The first core element 3 is again shown by a dashed line. The two complementary core elements 3 and 4 have sealing edges at the contact surfaces that come into contact at the split joint 69. The second core element 4 is provided with a wedge-shaped profile 78 having a protruding wedge-shaped tip 79 at the contact surface 67. On the other hand, the contact surface 66 of the second core element 4 has a concave profile 80 having a concave bottom 81 positioned parallel to the contact surface 66. The dashed first core element 3 is provided with a concave profile 82 that interacts with the wedge-shaped profile 78 of the second core element 4. The concave profile 82 similarly has a concave bottom 83 positioned parallel to the corresponding contact surface of the first core element 3. The wedge-shaped tip 79 of the wedge-shaped profile 78 interacts with the concave profile 82 of the first core element 3. As shown in Figure 7d, the wedge-shaped profile 78 protrudes from the contact surface 67 by an amount greater than the depth dimension of the corresponding concave profile 82. This means that when fitted together, the wedge-shaped tip 79 presses against the concave bottom 83, forming a notch therein. The formation of the notch in the concave bottom 83 is achieved by a certain degree of deformation of the wedge-shaped tip 79. This results in a good sealing effect. The first core element 3 is also provided with a wedge-shaped profile having a wedge-shaped tip, and this wedge-shaped profile interacts with the concave bottom 81 of the concave profile 80 of the second core element 4 in the same manner as notch-forming sealing.

[0084] Figure 8 is a schematic scaled-down plan view of the bicycle frame 84. The bicycle frame is constructed as a structural component according to the present invention. This plan view shows the head tube portion 85, seat tube portion 86, and back end portion 87 of the bicycle frame. Furthermore, it can be seen that the connecting top tube element 88 is located between the head tube portion 85 and the seat tube portion 86.

[0085] Figure 9 shows a schematic cross-section through the bicycle frame 84 shown in Figure 8. The cross-sectional view follows the path of the cutting line IX-IX shown in Figure 8. Since the bicycle frame 84 is constructed as a structural component according to the present invention, it has a support core 89 and a support shell element 90, the inner surface 90a of which is material-bonded to the core 89. The shell element 90 is integrally produced from thermoplastic material in an injection mold. The core 89 is assembled from three core elements. Once assembled, the core is inserted into the injection mold as a permanent core 89. To produce the shell element 90, a starting material for the shell element 90 is (injection) molded around the inserted core 89. Figure 8 shows the first core element as a dashed line. The first core element is configured as a right-hand side core element 91 and is assigned to the right-hand side of the bicycle frame 84. The right-hand side core element 91 is also the side core element shown in the cross-sectional view of Figure 9. The second core element is a mirror image left-hand version of the first core element, i.e., the left-hand side core element 92. The third core element is an additional back-end core element 93, similarly shown as a dashed line in Figure 8.

[0086] In this example, the back-end core element 93 is roughly V-shaped when viewed from above in the plan view shown in Figure 8. In this way, the back-end core element 93 complements both the right-hand side core element 91 and the left-hand side core element 92 in the region of the back-end section 87. Alternatively, the back-end core element 93 may be similarly subdivided into a right-hand back-end core element and a left-hand back-end core element, after which the core 89 is assembled from a total of four core elements.

[0087] The right-hand 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-hand side core element 92 has a smooth outer surface 92a, and the back-end core element 93 has a smooth outer surface 93a. The three outer surfaces 91a, 92a, and 93a together form the circumferential surface 89a of the assembled core 89. Internal stiffening elements 96 are arranged in the region of the cavity 95 in the form of intersecting ribs 97 and 98. The cavity 95 is subdivided into numerous small cavities 95a by the ribs. An opening 99 for a fork or headset is provided in the region of the head tube section 85, and an opening 100 for a seatpost is provided in the region of the seat tube section 86. A lower bracket section 101 is also provided, having an opening 102 for a pedal crank bearing system. The opening 99 for the headset, the opening 100 for the seatpost, and / or the opening 102 for the pedal crank bearing system may take the form of a sleeve body that can be inserted into the injection mold, like the core 89. This sleeve body may be made of plastic or metal, for example, an aluminum tube.

[0088] The assembled core 89 has split joints between the individual assembled core elements, namely the right-hand side core element 91, the left-hand side core element 92, and the back-end core element 93. The split joints take the form of sealing edges according to the principles proposed and described with reference to Figures 7a-7d. In this way, the assembled core 89 is sealed at the split joints in such a manner that, during injection molding of the shell element 90, the flowable initiating material cannot penetrate the core 89 or the cavity 95 or, in fact, into the cavity 95a.

[0089] A protruding positioning element 103 is provided on the outer surface 91a of the right-hand side core element 91. Similarly, positioning elements are provided on the outer surfaces 92a and 93a of the left-hand side core element 92 and the back-end core element 93, respectively. In this way, the assembled core 89 can be correctly fixed in place within the injection mold. Precisely oriented positioning of the core 89 helps in generating the correct wall thickness for the shell element 90.

[0090] Figure 10 shows a cross-sectional view of an alternative bicycle frame 104. This bicycle frame is assembled modularly from frame components. At least one of the frame components of the bicycle frame 104 must take the form of a structural component according to the present invention, that is, it must have one structural support shell element and one structural support core. In this example, all frame components of the bicycle frame 104 take the form of structural components.

[0091] Five structural components in Figure 10 constitute node elements, and seven further structural components constitute frame elements provided as connecting members between the node elements. The node elements include a head tube node element 105, a seat tube node element 106, a lower bracket node element 107, and two dropout node elements, of which the right-hand dropout node element 108 is visible in Figure 10. The dropout node element 108 is equipped with a fork end, or has means to which an attachable fork end can be adapted.

[0092] The structure of the node elements (105, 106, 107, 108) will be illustrated with reference to the head tube node element 105 visible in the cross-sectional view of Figure 10. This head tube node element 105 comprises a shell element 109 produced in an injection mold, and a core assembled from a left-hand head tube core element and a right-hand head tube core element. The cross-sectional view of Figure 10 shows the right-hand head tube core element 110, which has a smooth circumferential surface 111 facing the shell element 109, and forms a cavity 112 on the side away from the shell element 109. In the region of the cavity 112, internal stiffening elements 113 are provided in the form of intersecting ribs 114 and 115. The cavity 112 is subdivided into numerous small cavities 112a by the ribs. Furthermore, sealing means are provided at the edges of the two head tube core elements, such as the edge 116 of the head tube core element 110. The sealing means, advantageously, specifically, take the form of a sealing edge that mechanically interacts with the assembled circumferential surface, according to the principle described above as an alternative to the sealing edge of the core element of the handlebar shown in Figures 1-7d. These alternative examples are referred to here. The positioning elements 117 are positioned on the circumferential surface of the core of the illustrated head tube core element 110, and they act 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 110 or the assembled core in the injection mold, according to the principle described similarly above with reference to the handlebar shown in Figures 1-5.

[0093] Furthermore, the head tube node element 105 has a receiving means 118 for a fork to mount the front wheel, or the receiving means 118 serves to adapt a headset for the front wheel fork. Advantageously, the receiving means 118 is provided with an opening 119. The opening 119 can be generated using two half-shell components, each of which belongs to one of two core elements. Alternatively, the opening may be provided during the generation of the shell element 109 in the injection mold by a sleeve body inserted into the injection mold, similar to the core. This sleeve body may be made of plastic material or metal, such as an aluminum tube.

[0094] The head tube node element 105 is connected to the seat tube node element 106 by a frame element specifically configured as the top tube frame element 118. The head tube node element 105 is also connected to the lower bracket node element 107 by the down tube frame element 119. The connection by the seat tube frame element 120 is provided between the seat tube node element 106 and the lower bracket node element 107. The rear end section 121 of this bicycle frame is equipped with dropout node elements, which are arranged adjacent to each other with space between them to accommodate the rear wheel. The cross-sectional view in Figure 10 shows the right-hand dropout node element 108 described above. This dropout node element 108 is connected to the seat tube node element 106 on one side by the seat stay frame element 122, and to the lower bracket node element 107 on the other side by the chain stay frame element 123.

[0095] Since the bicycle frame 104 is constructed modularly using frame components, means are provided for providing precise positioning between node elements and frame elements. For this purpose, each node element has a fusion region configured to match the connecting means of the frame elements. If further frame elements need to be added to the same node element, it is advantageous to provide further fusion regions for the further frame elements in this node element, which similarly have matching connecting means for the further fusion regions.

[0096] In this context, the head tube node element 105 is provided with a top tube fusion region for joining to the top tube frame element 118. Furthermore, the head tube node element 105 is provided with a down tube fusion region 125 for joining to the down tube frame element 119.

[0097] Furthermore, in order to create a strong connection of the head tube node element 105 to the fitted top tube frame element 118 and the fitted down tube frame element 119, it is advantageous to provide connecting means for material bonding in the form of additional material. The additional material is, for example, an adhesive. A gap (bonding gap) for the adhesive is formed between the frame components that are connected to each other. For this purpose, each of the relevant fusion regions of the head tube node element and the corresponding connection regions of the frame elements is advantageously provided with a suitable bonding surface. The bonding surface is such that the bonding gap has a gap dimension that is appropriate for the selected adhesive in order to provide the required adhesive bonding strength.

[0098] The head tube node element 105 is simply constructed in the manner of a lug and has an internal fusion region (124, 125) with an internal bonding surface. To match this, the top tube frame element 118 or the down tube frame element 119 may be provided with outward-facing connection regions 118a and 119a, respectively, which form bonding surfaces that interlock with the corresponding internal bonding surface of the head tube node element 105, in order to form the necessary bonding gap for the adhesive.

[0099] The lower bracket node element 107, like the head tube node element 105, is formed from a shell element 126 injection-molded around a core, its inner surface 126a being materially bonded to the core, and the core being assembled from the left lower bracket core element and the right lower bracket core element. The cross-sectional view in Figure 10 shows the right lower bracket core element 127. It has a smooth circumferential surface 128 facing the shell element 126 and forms a cavity 129 on the side away from the shell element 126. In the region of the cavity 129, internal stiffening elements 130 are provided in the form of intersecting ribs 131 and 132. The cavity 129 is subdivided into numerous small cavities 129a by the ribs. One edge 133 of the right lower bracket core element 127 has sealing means in the form of a sealing edge that interacts with the corresponding sealing edge of the left lower bracket core element. Thus, a tight, segmented joint of the assembled core is formed in this region, specifically as an alternative to the sealing edge of the core element of the handlebar shown in Figures 1-7d, according to the principle described above, and is referenced thereto. The positioning elements 134 are positioned on the circumferential surface of the core or the right lower bracket core element 127 shown, and act as spacers when the core is inserted into the injection mold to produce the shell element 126. The positioning elements 134 fix the shape and position of the lower bracket core element 127 or the assembled core in the injection mold, according to the principle similarly detailed above with reference to the handlebar shown in Figures 1-5.

[0100] Furthermore, the lower bracket node element 107 has a receiving means 135 for a pedal crank or pedal crank bearing system. Advantageously, the receiving means is provided with an opening 136 to which the pedal crank bearing system can be adapted. The opening 136 may be produced using two sleeve-type components, each of which belongs to one of the two lower bracket core elements. Figure 10 shows the right-hand sleeve-type component 137 of the receiving means 135 for the pedal crank bearing system. Alternatively, the opening 136 may be provided during the production of the shell element 126 in the injection mold, advantageously by an integral sleeve body inserted into the injection mold along with the core. This sleeve body may be made of plastic material or metal, such as an aluminum tube. Furthermore, the lower bracket node element 107 is provided with four fusion regions for joining frame elements, specifically, one fusion region 138 for the down tube frame element 119, one fusion region 139 for the seat tube frame element 120, and two fusion regions 140 for the back end section 121, all for joining the chainstay frame element 123.

[0101] Like the head tube node element 105, the seat tube node element 106 is formed from a shell element 141 injection-molded around the core, thereby materially bonding its inner surface 141a to the core. The core is assembled from a left-hand seat tube core element and a right-hand seat tube core element, of which only the right-hand seat tube core element 142 is visible in Figure 10. It has a smooth circumferential surface 143 facing the shell element 141 and forms a cavity 144 on the side away from the shell element. In the region of the cavity 144, internal stiffening elements 145 are provided in the form of intersecting ribs 146 and 147. The cavity 144 is subdivided into numerous small cavities 144a by the ribs. The edge of the seat tube core element 142 is provided with sealing means in the form of a sealing edge that interacts with the corresponding sealing edge of the left-hand seat tube core element. Thus, tight, segmented joints of the assembled core are formed in this region, specifically as an alternative to the sealing edge of the core element of the handlebar shown in Figures 1-7d, in accordance with the principle described above, and are referenced thereto. Positioning elements 148 are positioned on the circumferential surface of the core or the illustrated right-hand seat tube core element 142, and they act as spacers when the core is inserted into the injection mold to produce the shell element 141. The positioning elements 148 fix the shape and position of the seat tube core element 142 or the assembled core in the injection mold in accordance with the principle similarly detailed above with reference to the handlebar shown in Figures 1-5.

[0102] The seat tube core element 142 further includes a receiving means 149 for a seat post. Advantageously, the receiving means is provided with an opening 150 that can be produced using two sleeve-type components, each of which belongs to one of the two seat tube core elements. Figure 10 includes the right-hand sleeve-type component 151 of the receiving means 149 for the seat post. Alternatively, the receiving means or opening 150 may be provided during the production of the shell element 141 in the injection mold, advantageously by an integral sleeve body inserted into the injection mold, similar to the core. This sleeve body may be made of plastic material or metal, such as an aluminum tube.

[0103] Furthermore, the seat tube node element 106 is provided with five fusion regions for joining frame elements. Specifically, one fusion region 152 is provided for the top tube frame element 118, one fusion region 153 for the seat tube frame element 120, and two fusion regions 154 for the back end section 121, all for joining the seat stay frame element 122.

[0104] The right-hand dropout node element 108 has an injection-molded shell element 155 around the core, with its inner surface 155a material-bonded thereto, and the core is assembled from the left-hand dropout core element and the right-hand dropout core element. Figure 10 shows the right-hand dropout core element 156, which has a smooth circumferential surface 157 facing the shell element 155 and forms a cavity 158 on the side away from the shell element 155. In the region of the cavity 158, internal stiffening elements 159 are provided in the form of intersecting ribs 160 and 161.

[0105] Frame elements such as the top tube frame element 118, down tube frame element 119, seat tube frame element 120, seat stay frame element 122, and chain stay frame element 123 are similarly configured as structural components according to the present invention in this example, and each advantageously has a structurally supporting shell element and a structurally supporting core assembled from a core element. The structure of the described frame elements will be explained with reference to the down tube frame element 119 as an example. This has a core assembled from two down tube core elements, of which the right-hand down tube core element 164 is shown.

[0106] The down tube core elements are advantageously produced in an injection mold and are preferably formed from a thermoplastic material. One edge 165 of the right-hand down tube core element 164 has sealing means in the form of a sealing edge that interacts with the corresponding sealing edge of the left-hand down tube core element. Thus, a tight split joint of the assembled core of the right-hand down tube frame element 119 is formed in this region, specifically, according to the principle described above as an alternative example to the sealing edge of the core elements of the handlebars shown in Figures 1-7d, and reference is made thereto. A positioning element 167, which acts as a spacer, is positioned on the circumferential surface 166 of the core of the illustrated right-hand down tube core element 164. The core is then inserted into an injection mold for the purpose of producing a shell element 168 that is injection molded around the core, the inner surface 168a of which material bonds to the circumferential surface 166 of the core. The positioning element 167 fixes the shape and position of the downtube core element 164 or the assembled core within the injection mold, in accordance with the principle similarly detailed above with reference to the handlebars shown in Figures 1-5.

[0107] Other frame elements that constitute structural components, such as the top tube frame element 118, seat tube frame element 120, seat stay frame element 122, and chain stay frame element 123, have, in principle, the same structure as that of the down tube frame element 119. [Explanation of symbols]

[0108] 1 Handlebar 2 cores 2a Circumferential surface 3 Core Elements 3a Exterior 4 Core Elements 4a Exterior 5 Shell elements 5a Inner Self 6. Front side 7 Central area 7a Subdivision plane 8 clamping area 9 Grip Area 9a Subdivision plane 10 Grip Areas 10a subdivision plane 11. Transition Area 11a Subdivision plane 12. Transition Area 12a Subdivision plane 13 Holding part 14 Holding surface 15 Holding part 16 Holding surface 18 Central part 19. Bisector cone 20. Bisector cone 21. Bisected cone section (semi-cylindrical section) 22. Bisected cone section (semi-cylindrical section) 23 Wall 23a Thick part 24 Internal 25 Channel-type cavities 25a Small cavity 26 Positioning elements 26a Exterior 27 Positioning elements 27a Exterior 28 Positioning elements 28a Exterior 29 Positioning elements 29a Exterior 30 Positioning elements 30a Exterior 31 Positioning element 31a External surface 32 Positioning elements 32a Exterior 33 Stiffening elements 34 Ribs 34a Rib surface 34b Rib surface 34c Contact surface 35 Rib 35a Rib surface 35b Rib surface 35c Contact surface 36 Central area 37 Grip Area 38 Grip Area 39 Transition Area 40 Transition Area 41 Holding part 42 Holding surface 43 Holding part 44 Holding surface 45 Internal 46 Channel-type cavities 46a Small cavity 47 Wall 47a Thick part 48 Exterior 49 Stiffening elements 50 Ribs 50a Rib surface 50b Rib surface 51 Ribs 51a Rib surface 51b Rib surface 52 Positioning elements 53 Positioning elements 54 Positioning elements 55 Positioning elements 56 Positioning elements 57 Positioning elements 58 Positioning elements 59 Splitting plane 60 Centering Fins 60a Centering surface 61 Centering Fins 61a Centering surface 62 Centering chamfered section 63 Centering chamfered section 64 Edge 65 Edge 66 Contact surface (second core element) 66a Sealing edge 67 Contact surface (second core element) 68 Contact surface (first core element) 68a Sealing edge (first core element) 69-part joint 70 Convex Profile 71 Concave Profile 72 Cavity 73 Convex Profile 74 Convex Profile 75 Concave Profile 76 Concave Profile 77 Concave Profile 78 Wedge-shaped profile 79 Wedge-shaped tip 80 Concave Profile 81 concave bottom 82 Concave Profile 83 concave bottom 84 Bicycle Frames 85 Head tube section 86 Seat tube section 87 Backend Section 88 Top tube elements 89 cores 89a Circumferential surface 90 shell elements 90a Inner surface 91 Side core element, right hand 91a External surface 92 Side core element, left hand 92a Exterior 93 Backend Core Elements 93a Exterior 95 Cavity 95a Small cavity 96 Stiffening elements 97 Rib 98 Ribs 99. Mouth opening (headset) 100 opening, seatpost 101 Lower bracket section 102 Opening (Pedal Crank Bearing System) 103 Positioning element 104 Bicycle Frame 105 Head tube node element 106 Seat tube node element 107 Lower bracket node element 108 Dropout node elements 109 Shell elements 110 Right-hand head tube core element 111 Peripheral surface 112 Cavity 112a Small cavity 113 Stiffening elements 114 Ribs 115 Rib 116 Edge 117 Positioning element 118 Top tube frame element (receiving means) 118a Connection area 119 Down tube frame element (opening) 119a Connection area 120 Seat Tube Frame Element 121 Backend Section 122 Seatstay Frame Elements 123 Chainstay Frame Elements 124 Top tube fusion area 125 Down tube fusion area 126 Shell elements (bottom bracket nodes) 126a Inner surface 127 Pedal Crank Core Elements 128 Peripheral surface 129 Cavity 129a Small cavity 130 Stiffening elements 131 Rib 132 Ribs 133 Edge 134 Positioning elements 135 Receiving means 136 Aperture 137 Sleeve-type component 138 Fusion area, down tube 139 Fusion area, seat tube 140 Fusion area, chainstay 141 Shell elements (seat tube core elements) 141a Inside 142 Seat tube core elements 143 Peripheral surface 144 Cavity 144a Cavity 145 Stiffening elements 146 Rib 147 Ribs 148 Positioning elements 149 Reception means 150 aperture 151 Sleeve-type component 152 Fusion area, top tube 153 Fusion area, seat tube 154 Fusion region, seat stay 155 shell elements 155a Inner surface 156 Dropout core elements, right hand 157 Peripheral surface 158 Cavity 158a Cavity 159 Stiffening elements 160 Rib 161 Rib 162 Edge 163 Positioning elements 164 Downtube Core Elements 165 Edge 166 Peripheral surface 167 Positioning elements 168 shell elements 168a Interior S1 Sealing means S2 Sealing means

Claims

1. A structural component of a bicycle, comprising a core (2, 89) having at least one cavity (25, 25a, 46, 46a, 72, 95, 95a, 112, 112a, 129, 129a, 144, 144a, 158, 158a) and one surrounding circumferential surface (2a, 89a), and comprising shell elements (5, 90, 109, 126, 141, 155, 168), A structural component in which both the core (2, 89) and the shell elements (5, 90, 109, 126, 141, 155, 168) have a structural support function, which is reinforced by material bonding between the surrounding circumferential surfaces (2a, 89a) of the support core (2, 89) and the inner surfaces (5a, 90a, 126a, 141a, 155, 168a) of the support shell elements (5, 90, 109, 126, 141a, 155, 168).

2. The structural component according to claim 1, wherein any of the cores (2, 89) and / or the shell elements (5, 90, 109, 126, 141, 155, 168) is produced using an initiating material that can flow in a plastic state within the mold cavity of a molding die.

3. The structural component according to claim 1 or 2, wherein the initial material is a thermoplastic material.

4. The structural component according to any one of claims 1 to 3, wherein the core (2, 89) is a single unit or is assembled from a plurality of core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164).

5. The structural component according to claim 4, wherein each core element (3, 4, 91, 92, 93, 110, 127, 142, 156, 164) has an outer surface (3a, 4a) and an edge, and the outer surfaces (3a, 4a, 17, 48, 91a, 92a, 93a) of the plurality of core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164) form the surrounding circumferential surface (2a, 89a) of the core (2, 89) when assembled.

6. The structural component according to claim 4 or 5, wherein a split joint (69) is formed on the edges (64, 65, 116, 133, 162, 165) of the outer surfaces (3a, 4a, 48, 91a, 92a, 93a) of the assembled core elements (3, 4, 91, 92, 93, 164), and a sealing means is provided for the split joint (69).

7. The structural component according to claim 6, wherein an additional material for material bonding is provided as a sealing means, or the sealing means (S1, S2) takes the form of sealing edge portions (66a, 68a) that mechanically interact with the edges (64, 65, 116, 133, 162, 165) of the core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164).

8. A structural component according to any one of claims 4 to 7, wherein at least one internal stiffening element (33, 49, 96, 113, 130, 145, 159) is provided on at least one of the core (2, 89) or the core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164).

9. The structural component according to any one of claims 4 to 8, wherein the internal stiffening elements (33, 49, 96, 113, 130, 145, 159) take the form of struts or ribs (34, 35, 50, 51, 97, 98, 114, 115, 131, 132, 146, 147, 160, 161).

10. The structural component according to claim 9, wherein the 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) assembled to form the core (2, 89) support each other.

11. The structural component according to any one of claims 2 to 10, wherein 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 circumferential surface (2a, 89a), the positioning element being provided in the mold cavity of a molding die for generating the supporting shell elements (5, 90, 109, 126, 141, 155, 168) to fix the core (2, 89) in the appropriate place inside the mold cavity of the molding die, the structural component according to any one of claims 2 to 10.

12. The structural component according to any one of claims 1 to 11, wherein the supporting shell elements (5, 90, 109, 126, 141, 155, 168) form the shape of a bicycle frame (84) having a front end contour with a head tube portion (85), a lower contour with a lower bracket portion (101), an upper contour with a seat tube portion (86), and a rear end contour with a back end portion (87) relative to the rear wheel axle.

13. A bicycle frame (104) comprising a plurality of frame components, some of which are configured as node elements (105, 106, 107, 108), some of which are configured as frame elements (118, 119, 120, 121, 122), and the node elements and frame elements are interconnected. A bicycle frame (104) wherein at least one of the node elements (105, 106, 107, 108) and / or one of the frame elements (118, 119, 120, 121, 122) is configured as a structural component according to any one of claims 1 to 11.

14. The bicycle frame (104) according to claim 13, wherein material connecting parts are provided for connecting the node elements (105, 106, 107, 108) to the frame elements (118, 119, 120, 121, 122).

15. The aforementioned material bonding portion is provided using additional material for bonding materials, the bicycle frame (104) according to claim 14.

16. A bicycle frame (104) according to any one of claims 13 to 15, wherein at least one node element (105, 106, 107, 108) is provided with fusion regions (124, 125, 138, 139, 149, 152, 153, 154), and at least one frame element (118, 119, 120, 121, 122) is provided with connection regions (118a, 119a) that interact with the fusion regions of the node element.

17. The bicycle frame (104) according to claim 16, wherein additional bonding material is placed between the fusion regions (124, 125, 138, 139, 149, 152, 153, 154) of the node elements (105, 106, 107, 108) and the connection regions (118a, 119a) of the frame elements (118, 119, 120, 121, 122).

18. A bicycle comprising at least one element from the group including a bicycle frame (84, 104), a fork, a stem, a handlebar (1), a seat post, and a crank arm, wherein at least one of the elements is configured as a structural component according to any one of claims 1 to 11.

19. A handlebar for a bicycle (1) configured as a structural component according to any one of claims 1 to 12.

20. The handlebar (1) according to claim 19, comprising a core (2) assembled from at least two core elements (3, 4), wherein the core elements (3, 4) are injection molded from a thermoplastic material.

21. The handlebar (1) according to claim 19 or 20, wherein the retaining portions (13, 15, 41, 43) are arranged on each of the free ends of the core elements (3, 4) and are provided to fix the core elements (3, 4) in the appropriate place within the injection mold.

22. The handlebar (1) according to claim 21, wherein the holding portions (13, 15, 41, 43) of the core elements (3, 4) are complementary in configuration, and each core element (3, 4) has means for correctly positioning itself by bringing it into contact with the complementary core elements (3, 4).

23. The handlebar (1) according to claim 21 or 22, wherein the retaining portions (13, 15, 41, 43) of the core elements (3, 4) form a polygonal cross-section when assembled within the core (2), and the assembled retaining portions (13, 15, 41, 43) have external retaining surfaces (14, 16, 42, 44).

24. The handlebar (1) according to claim 21, wherein the polygonal cross-section of the core (2) is a hexagonal cross-section.

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