DE202023102312U1 - Structural component of a bicycle, bicycle frame, bicycle comprising a structural component, and handlebars as a structural component - Google Patents

Abstract

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) and 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-locking 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).

Description

The invention relates to a structural component of a bicycle, whereby structural components in the sense of the invention are understood to mean, in particular, safety-relevant bicycle structural components; in the narrower sense, these are bicycle structural components such as bicycle frames, forks or steering knuckles, stems, handlebars, seat posts, crank arms and pedals, which are safety-relevant for the operation of the bicycle. However, bicycle structural components are also understood to mean other components such as frame components that can be joined together to form a bicycle frame. In the broader sense, components such as rims or wheels are also meant. In addition, accessory components can be provided as structural components according to the invention, for example saddles, brake and gear levers, mudguards or dirt deflectors, bicycle supports (stands), luggage racks, luggage containers, child seats, etc.

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.

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

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.

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

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

In the technical field concerned, the publication EN 195 81 569 T1 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 facing 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 sleeve made of plastic which is placed around the core and heated so that it fits tightly against the core. The structural strength is provided in this example by the core with its external ribs.

Another example from the same publication reverses the principle of the previous example and instead proposes an inner bladder used to create the walls of the bicycle frame using a mold. The inner bladder is inserted into the mold as a core and may be filled with a liquid or other material to withstand the pressure when injecting thermoplastic material that forms the bicycle frame. Alternatively, the bladder may be constructed with a ribbed structure to withstand the pressure present, 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.

With regard to the strength of the structure, the state of the art with the internal bladder is unsatisfactory. This also applies to the embodiment of the bicycle frame whose core has external ribs.

The invention now proposes a structural component for a bicycle, comprising a core with at least one cavity and an enveloping 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 connection between the enveloping 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.

The material-locking 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 melted at least in some areas. For the material-locking connection, an additional material can also be added that can fuse with the materials involved. Identical starting materials can advantageously be used for the core elements and/or for the shell element. Any additional material for the material-locking connection can be made from the same starting material as the core elements and/or the shell element. Alternatively, a material-locking The connection is made 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.

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 has an effect of improving 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 structural strength of the load-bearing core, which also has its own structural strength. Furthermore, the strength of the structural component as a whole is further improved by means of the material connection which connects the load-bearing core to the load-bearing shell element. 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. The shell element is particularly preferably 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.

According to the invention, the enveloping surface of the supporting core is a substantially smooth surface. It can be designed as a freely formed surface, e.g. similar to a curved vehicle body, or form a simple cylindrical surface, for example. 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 considered to be a substantially smooth surface in the sense 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 areas in order to be able to provide areas with greater strength and rigidity. Advantageously, a smooth, stepless transition is provided between smaller and larger wall thicknesses in order to prevent a notch effect.

Either the core and/or the shell element is expediently produced using a starting material that is flowable in a plastic state within the mold cavity of a shaping tool. In a preferred embodiment, the shell element can be produced using a shaping injection molding tool, for example. For this purpose, the core is advantageously placed within the injection molding tool. The mold cavity of the injection molding 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 injection molding process produces the material-locking connection in which the injected starting material of the shell element melts the material of the outer surface of the core on the surface and the materials of the shell element and core are bonded in this way. The core is made sufficiently stable so that a sufficiently strong wall is provided beneath its melted outer surface, which can withstand the injection pressure when the shell element starting material is injection molded.

The injection molding tool is suitably 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 be able to remove a finished workpiece after each shaping process.

The structural strength and rigidity of the supporting shell element is enhanced when its starting material can be injected into the mold cavity at a high injection pressure. For this purpose, the core is preferably specially prepared to withstand even a high injection pressure from the flowable starting material for the shell element without collapsing. 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.

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 structural strength of the structural component as a whole is further enhanced by the material-to-material connection, which firmly joins the load-bearing core to the load-bearing shell element.

The quality of the structural component, its strength and rigidity, is based on the shell element in combination with the core and the connection with each other. The quality of the core and the The material-locking connection is hidden beneath or within the shell element. They can be examined non-destructively using imaging methods for material testing, for example using computer tomography.

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 that comprises a base plastic that is 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.

The core can be made in one piece or it can be made up of several core elements. Because the core has at least one cavity, a one-piece construction can be produced using 3D printing using a suitable starting material. For other starting materials, an investment casting process is suitable for producing a core in one piece. For this purpose, a lost mold can easily be made from wax, which has the same shape as the core and which melts when the starting material is poured.

For a core that is composed of several core elements, the above manufacturing methods and other manufacturing methods are also applicable. Individual core elements can be manufactured, for example, using a starting material that can be processed in a flowable plastic state within the mold cavity of a molding 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.

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

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.

At least one parting line is formed on the edges of the outer surfaces of assembled core elements, with a sealing means preferably being provided for the parting line. In particular, when the shell element is produced in a forming tool and the core is placed in the mold cavity, the effective sealing helps to prevent any flowable, plastic starting material of the shell element from penetrating the parting lines of the core or into its cavity.

A material-bonding additive, e.g. adhesive, can be provided as a sealing agent, or mechanically interacting sealing edges are advantageously formed as a sealing agent on the edges of the core elements. Such sealing edges are preferably designed to be complementary, for example as folded edges or edges with tongue and groove elements.

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

This measure strengthens the core. The reinforced core facilitates the manufacture of the shell element around it, especially if the shell element is to be produced by injection molding. For this purpose, the core is inserted into an injection molding tool for forming the shell element and it remains a central part of the structural component as a structurally supporting core, but hidden within the shell element.

Simply put, the inner stiffening element is designed in the form of a strut or rib.

A strut or rib can advantageously be designed in such a way that the core element can itself be produced in a mold cavity of a molding tool, for example by injection molding. Core elements can expediently be produced cyclically in an injection molding tool.

The positive effect on the stability of the structural component can be enhanced if struts or ribs of core elements, which are assembled to form a core, support each other.

For a shell element 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 it is injected into the mold cavity to give the shell element the desired shape. A high injection pressure promotes the flow property of the starting material in its plastic State, ie in the molten, flowable state. The injection pressure has a beneficial effect on the viscosity of the starting material in that it increases the viscosity. The high viscosity means that thin-walled areas of a mold cavity can be filled better. This allows struts or ribs to be optimized. They can be designed to be as thin-walled as possible in order to use as little material as possible but still support the core well when a high injection pressure is applied to its outer surface from the outside. This saves material volume and the structural component can be designed to be as sufficiently stable as possible while still being light.

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 forming tool, within the mold cavity, for the production of the supporting shell element.

The core or core element is advantageously provided with a sufficient number of protruding positioning elements. These are distributed over the shell 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 be deformed under the influence of this force and lose its target position within the mold cavity. The protruding positioning elements advantageously counteract a change in the shape of the core or a departure from its target position within the mold cavity.

The positioning element conveniently forms a distance that makes contact with the inside of the mold cavity and in this way enables the desired exact positioning relative to the molding tool. The positioning elements also have a positive effect on the shape of the core. It retains its shape due to the fixation, despite high pressure forces acting on the core from the outside.

The positioning elements on the surface of the core or core elements also contribute a positive-locking component for the connection with 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.

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 shaping injection molding tool. The tool-side positioning element is advantageously arranged in its mold cavity and is expediently integrated into the inside of the mold cavity. When the injection molding tool is closed, the tool-side positioning element protrudes from the inside of the mold cavity and touches the outer surface of the core in order to hold it in shape and in its intended position within the mold cavity.

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.

In one embodiment, the supporting shell element can form the shape of a bicycle frame, comprising a front structure 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 structure contour with a rear axle section for a rear wheel axle.

In this design, the shell element of the structural component is preferably one-piece when viewed from the outside. However, it contains the core as a second load-bearing component inside, which is advantageously assembled from several core elements. As a bicycle frame, this structural component is designed to meet the requirements that are standardized for bicycles in the EN ISO 4210:2015 .

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.

The frame component as a structural component is advantageously designed so that it can be installed within the finished bicycle frame meets the safety requirements standardized for bicycles in the 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. In addition, these requirements are met by the bicycle frame as a whole.

If the bicycle frame can be assembled from several frame components, this offers a high degree of variability, for example to adapt it to a person's individual physical characteristics. For example, the bicycle frame can be adapted to the person's individual body measurements, such as their arm length, leg length, back length. In addition, the person's desired posture on the bicycle can be taken into account, such as seat height, sitting position, back inclination, etc., in order to provide the right bicycle frame.

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.

A material-to-material connection is expediently provided to connect the node element(s) to the frame element(s).

The material-locking connection is simply provided by means of an additional material. The additional material can be, for example, a one-component adhesive or a two-component adhesive. Alternatively, the additional material can be a pourable material that can be processed in a shaping tool, for example a flowable material that can also be injection molded like an injection molding starting material for the shell element.

Preferably, at least one node element is provided with a fusion region, wherein at least one frame element is provided with a connection region which interacts with the fusion region of the node element. It is useful if the fusion region and the connection region define the relative position of the node element and the frame element to one another in the assembled state.

The material-bonding additional 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 adhesive surfaces, between which a narrow gap for adhesive is preferably formed.

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.

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

The proposed handlebars are extremely safe. They can withstand heavy use when riding. High loads generally occur when accelerating and braking. Acceleration causes alternating loads, for example when the handlebars are pulled alternately on the left and right. When braking, the load on both handlebars can be more even. Handlebar failure can result in injury. Handlebars are therefore one of the safety-relevant components on a bicycle. For safety reasons, used handlebars should be replaced with new handlebars after a certain period of use. This should be done even if there is no obvious damage to the used handlebar. The safety of the proposed handlebars is based on a load-bearing core and a load-bearing shell element, each of which provides its own structural strength and rigidity, and on the fact that their strength and rigidity is further increased by means of the intended material connection between the core and the shell element.

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.

Another benefit is when a holding section is arranged at each of the free ends of the core elements and the holding section is prepared to fix the core element in an injection molding tool. The exact positional fixation of the core element or the assembled core facilitates the production of an exact shell element whose defined shell wall contributes to the desired strength and rigidity.

Preferably, the holding portions 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.

It has also proven to be useful that the holding sections of the core elements, when assembled as a core, 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 molding tool. In particular, this type of fixation counteracts twisting of the core within the injection molding tool.

The holding surfaces can also be inclined towards the free end of the handlebar. In this way, a holding section can 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.

The polygonal cross-section of the core is conveniently a hexagonal cross-section.

• 1 eine perspektivische Ansicht eines ersten Kernelements für einen Lenker, der als ausgebildet ist,
• 2 eine Ansicht des ersten Kernelements, wie in 1 mit dem Pfeil II vermerkt,
• 3 eine perspektivische Ansicht eines erfindungsgemäßes Strukturbauteil zweiten Kernelements für den Lenker,
• 4 eine Ansicht des zweiten Kernelements, wie in 3 mit dem Pfeil IV vermerkt,
• 5 eine perspektivische Ansicht des erfindungsgemäßen Strukturbauteils in Form des Lenkers,
• 6 ein Detail gemäß der in 5 vermerkten Schnittlinie VI - VI,
• 7a ein Ausführungsbeispiel der Ränder des zweiten Kernelements als Dichtungskanten gemäß der Schnittlinie VII - VII, wie in 3 vermerkt,
• 7b ein erstes alternatives Ausführungsbeispiel der Ränder des zweiten Kernelements gemäß der Schnittlinie VII - VII, wie in 3 vermerkt,
• 7c ein zweites alternatives Ausführungsbeispiel der Ränder des zweiten Kernelements gemäß der Schnittlinie VII - VII, wie in 3 vermerkt,
• 7d ein drittes alternatives Ausführungsbeispiel der Ränder des zweiten Kernelements gemäß der Schnittlinie VII - VII, wie in 3 vermerkt,
• 8 eine verkleinerte schematische Draufsicht eines Fahrradrahmens der als erfindungsgemäßes Strukturbauteil bereitgestellt ist,
• 9 eine schematische Schnittansicht des Fahrradrahmens gemäß Schnittverlauf IX - IX, wie in 8 vermerkt,
• 10 ein alternativer Fahrradrahmen, der zusammengefügt ist aus Rahmenbauteilen, die als erfindungsgemäße Strukturbauteile ausgebildet sind.

The invention is illustrated by way of example in a drawing below and described in detail using several figures. They show:

• 1 a perspective view of a first core element for a handlebar, which is designed as
• 2 a view of the first core element, as in 1 marked with arrow II,
• 3 a perspective view of a structural component according to the invention of a second core element for the handlebar,
• 4 a view of the second core element, as shown in 3 marked with arrow IV,
• 5 a perspective view of the structural component according to the invention in the form of the handlebar,
• 6 a detail according to the 5 marked section line VI - VI,
• 7a an embodiment of the edges of the second core element as sealing edges according to the section line VII - VII, as in 3 noted,
• 7b a first alternative embodiment of the edges of the second core element according to the section line VII - VII, as in 3 noted,
• 7c a second alternative embodiment of the edges of the second core element according to the section line VII - VII, as in 3 noted,
• 7d a third alternative embodiment of the edges of the second core element according to the section line VII - VII, as in 3 noted,
• 8 a reduced schematic plan view of a bicycle frame provided as a structural component according to the invention,
• 9 a schematic sectional view of the bicycle frame according to section line IX - IX, as shown in 8 noted,
• 10 an alternative bicycle frame which is assembled from frame components which are designed as structural components according to the invention.

Based on the 1 to 5 A first example of a bicycle structural component according to the invention is explained below. The first example relates to a handlebar 1 of a bicycle designed as a structural component. The essentially finished handlebar 1 is in 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 in an injection molding tool from thermoplastic material and then assembled. The shell element 5 is also made from thermoplastic material, specifically with a second injection molding tool, into which the assembled core 2 has previously been inserted.

1 represents only the first of the core elements 3. It is located in the finished handlebar 1 on its front side 6, which is at the front in the direction of travel of the bicycle when installed. 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 is part of a clamping region 8 of the handlebar 1, which interacts with a handlebar clamp on the finished bicycle. 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 region 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 middle area 7. The ends include two grip areas 9 and 10 of the finished handlebar structural component. The grip area 9 has a partial area 9a on the outside and the grip area 10 has a partial area 10a on the outside. There is a transition area 11 between the grip area 9 and the middle area 7 of the first core element 3 and a transition area 12 between the grip area 10 and the middle A transition region 12 is provided in the first core element 3. The transition region 11 forms a partial surface 11a on the outside and the transition region 12 forms a partial surface 12a. The transition regions 11 and 12 create a continuous change in the cross-section, ie starting from the large cross-section of the middle region 7, the cross-section becomes smaller towards the handle regions 9 and 10. The partial surfaces 7a, 7a, 10a, 11a and 12a together form an outer surface 3a of the first core element 3. A holding section 13 with holding surfaces 14 is also arranged at one free end of the first core element 3 and a holding section 15 with holding surfaces 16 is arranged at the other free end. The holding sections 13 and 15 are solid in the present example. They serve at least primarily to fix the core element 3 in an injection molding tool for an injection molding process when it is assembled with the second core element 4 to form a core 2. The holding sections 13 and 15 can either remain after the injection molding process or later on the finished structural component or alternatively be removed.

The middle area has a semi-cylindrical middle section 18. On both sides, halved conical sections 19 and 20 adjoin this, which form the transition areas 11 and 12 respectively. The transition areas 11 and 12 are in turn adjoined by a semi-cylindrical section 21 and 22, which belongs to one of the handle areas 9 and 10 respectively. The sections together form a wall 23 of the first core element 3, on the inside 24 of which a channel-shaped cavity 25 is formed. The inside 24 of the wall 23 is formed largely parallel to the contour of the outer surface 3a.

Positioning elements 26, 27, 28, 29, 30, 31 and 32 are arranged on the outer surface 3a. 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 inside the injection molding tool come into contact with the inside of its closed mold cavity. This contact ensures that the core 2 retains its shape and position during the injection molding process. This also applies when the flowable starting material of the shell element 5 is fed into the mold cavity under high injection pressure. The forces acting on it can neither deform the core 2 fixed in this way 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 handle area 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 handle area 9. The central area 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 mirror images of the positioning elements 26 and 27 and have a shape which corresponds to them in mirror image. 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.

2 shows a simplified front view of the first core element 3, as indicated by arrow II in 1 The simplification consists in the fact that a representation of the position elements of the lateral surface in 2 has been omitted 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 cross 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 grip areas 9 and 10 are arranged with a slight height offset (rise) relative to the central area 7.

The 2 The thickness of the wall 23 of the core element 3 shown in the area of its lateral surface 7 is to be understood schematically and is not necessarily shown proportionally to the handlebar diameter in its different sections. In practice, the wall 23 is made so strong that a composite core 2 can withstand a high injection pressure when it is inserted as a permanent core in the injection molding tool for forming the shell element 5.

3 shows a perspective of the second core element 4, which is designed to complement the first core element 3. The second core element 4 is located in the finished handlebar 1 on its rear side, which is at the back in the direction of travel of the bicycle when installed. 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 the handlebar clamp. Two grip regions 37 and 38 are provided towards the two ends of the second core element 4, which are also designed with a smaller cross-section than the central region 36. A transition region 39 and 40 is provided between each of the grip 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 middle region 36 and the smaller cross-section of the handle region 37 as well as the large cross-section of the middle region 36 and the smaller cross-section of the handle 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, 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.

The perspective of 3 provides a view of an inner side 45, which forms a channel-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 channel-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 50 are designed with slanted lateral rib surfaces 50a and 50b and the ribs 51 with slanted lateral rib surfaces 51a and 51b, which as a molding slope promote demolding of the second core element 4 from the injection molding tool. The channel-shaped cavity 46 is divided into many small cavities 46a. The ribs 50 and 51 of the second core element 4 are also designed with slanted lateral rib surfaces 50a and 50b and 51a and 51b, which as a molding slope promote demolding of the second core element 4 from the injection molding tool. In addition, 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 contact abutting surfaces 50c and 51c of the second core element 4 when the two core elements are assembled. The core 2, which is assembled from these two core elements 3 and 4, can absorb very high compressive forces by means of the ribs which abut 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 to the ribs.

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

In the handle area 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 handle area 37. The central area 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 to them in mirror image. 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.

5 shows the handlebar 1 as a finished structural component. It comprises the first core element 3 and the second core element 4, 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 second injection molding tool mentioned above. During the injection molding process of the shell element 5, the entire surface of the assembled core 2 has been melted and has thus bonded to the starting material of the shell element 5. whose inner side 5a is integrally connected; its inner surface 5a is in 5 indicated 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 are 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 with the starting material of the shell element 5 during injection molding and therefore remain visible.

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

The 5 The marked section line VI - VI indicates a detail that is 6 is shown enlarged. 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 at an angle to one another in a V-shape. The holding section 41 of the second core element 4 has centering bevels 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.

7a shows an enlarged detail relating to the design of edges 64 and 65 of the second core element 4, according to the section line VII - VII, which in 3 is noted. The edges are provided with sealing means. For easier explanation, the first core element 3 is shown in dashed lines, namely in the assembled state with the second core element 4. The edges 64 and 65 of the second core element 4 shown each have an abutment surface 66 and 67, respectively, which interact with abutment surfaces of the first core element 3. The abutment surface 66 is, for example, in contact with an abutment surface 68 of the first core element 3 and forms a parting line 69 with it.

Using the example of joint 69, 7a 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 spring profile 70 for this purpose. In a matching manner, 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, which 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 spring 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 molding tool. 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 favors the quality of the shell element 5 produced.

In the area 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 so that it protrudes from the abutment surface 66. Its design makes it possible to produce the second core element 4 by injection molding in an injection molding tool. For this purpose, the spring profile 70 is designed with lateral molding slopes 70a and 70b in order to provide easy demoldability of the second core element 4 from the injection molding tool.

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

7b shows an alternative design of the edges 64 and 65 of the second core element, which also provide sealing means S1 and S2 as form-fitting sealing edges. The view also refers to the section line VII - VII, which in 3 The complementary core elements 3 and 4 have pairs of abutting surfaces 66/68, which form a parting line 69. In contrast to 7a The second core element 4 of the 7b on its abutment surface 67, two spring profiles 73 and 74 next to each other.

The first core element shown in dashed lines is provided with groove profiles 75 and 76 arranged next to each other on its abutment surface 68. The double tongue profiles 73 and 74 and the double groove profiles 75 and 76 are designed in such a way that the core elements 3 and 4 can also be manufactured by injection molding in an injection molding tool. The double tongue and groove profiles improve the sealing effect compared to the previous example of the 7a .

7c shows a further alternative for the design of the edges 64 and 65 of the second core element 4, which also provide sealing means S1 and S2 by means of form-fitting sealing edges. The view again refers to the section line VII - VII in 3 . The matching first core element 3 is shown as a dashed line. Both complementary core elements 3 and 4 have abutment surfaces 66 and 68, respectively, which work together as a pair at the parting line 69. The abutment surfaces are further developed as sealing edges 66a and 68a, respectively, which are based on the design of the example of the 7b However, there is a difference in 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. In addition, on the sealing edge 68a of the first core element 3, a groove profile is replaced by a tongue profile 78.
The edge 65 of the second core element 4 is changed in the same way as its edge 64. This also applies to the associated edge of the first core element.

Each abutment surface 64 and 65 of the second core element 4 thus has a tongue profile and a groove profile. Each abutment 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 abutment surface improves the sealing effect.

7d shows a fourth example of a design of the 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 refers to the section line VII - VII in 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 in a parting line 69. The second core element 4 is provided with a wedge profile 78 on an abutting surface 67, which has 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, which is arranged parallel to the abutting surface 66. The first core element 3 shown in dashed lines is provided with a groove profile 82, which 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 7d the wedge profile 78 protrudes noticeably from the abutment surface 67 by a dimension that is greater than the depth dimension of the associated groove profile 82. In the assembled state, this leads to 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.

8 shows a schematically 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 section 87 of the bicycle frame. In addition, a connecting top tube element 88 can be seen between the head tube section 85 and the seat tube section 86.

9 shows a schematic sectional view through the bicycle frame 84 of the 8 . The sectional view follows the 8 drawn section line IX - IX. Because the bicycle frame 84 is constructed as a structural component according to the invention, it has a supporting core 89 and a supporting shell element 90, the inner surface 90a of which is integrally connected to the core 89. The shell element 90 is made in one piece from thermoplastic material in an injection molding tool. The core 89 is composed of three core elements. In the assembled state, the core is inserted into the injection molding tool as a permanent core 89. To produce the shell element 90, the inserted core 89 is molded/cast with the starting material for the shell element 90. In 8 a first core element is shown 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 which is shown in the sectional view of the 9 The second core element is a mirrored left version of the first core element, ie a left side core element 92. The third core element is an additional rear core element 93, which is also shown as a dashed line in 8 is marked.

In this example, the rear triangle core element 93 is shown in plan view according to 8 viewed from above, it is designed in a roughly V-shape. 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 section 87. Alternatively, the rear core element 93 can also be divided into a right rear core element and a left rear core element, so that the core 89 would be composed of a total of four core elements.

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 outer surfaces 91a, 92a and 93a mentioned together form a jacket surface 89a of the composite core 89. In the area of the cavity 95, inner stiffening elements 96 in the form of ribs 97 and 98 are arranged, which cross each other. 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 head 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 steering 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 can be inserted into the injection molding tool like the core 89. Such a sleeve body can be made of plastic or a metal, for example from an aluminum tube.

The composite core 89 has separating joints between the individual composite core elements, ie the right side core element 91, left side core element 92 and the rear core element 93. The separating joints are designed as sealing edges according to one of the principles as shown in the 7a-7d proposed and described. As a result, the assembled core 89 is sealed at the parting lines in such a way 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.

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 fixed in the correct position within the injection molding tool. An exact aligned positioning of the core 89 helps to produce a correct wall thickness of the shell element 90.

10 shows an alternative bicycle frame 104 in section. 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.

Five of the structural components of the 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 10 the right dropout node element 108 is visible. The dropout node element 108 comprises a dropout or has a means for receiving a mountable dropout.

The structure of the node elements (105, 106, 107, 108) is explained using the example of the head tube node element 105, which is shown in the sectional view of the 10 This head tube node element 105 comprises a shell element 109, which is manufactured in an injection molding tool, and a core, which consists of a left head tube core element and a right head tube core element ment. In the sectional view of the 10 the right head tube core element 110 is visible. 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, inner stiffening elements 113 in the form of ribs 114 and 115 are provided, which cross each other. The cavity 112 is divided by the ribs into many small cavities 112a. Furthermore, edges of the two head tube core elements, such as the edge 116 of the 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, in accordance with the principles described above for the sealing edges of the core elements of the handlebar according to the 1 to 7d are described as alternatives. Reference is made here to these alternatives. Positioning elements 117 are arranged on the outer surface of the core or the shown head tube core element 110, which serve as a distance when the assembled core is inserted into the injection molding tool in order 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 molding tool according to the principles which are also described above with respect to the handlebar according to the 1 to 5 are explained in detail what is referred to.

Furthermore, the head tube node element 105 has a receiving means 118 for a fork to support 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, of which one half-shell component 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 that is placed in 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.

The head tube node element 105 is connected to the seat tube node element 106 by means of a frame element which 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. A connection is provided between the seat tube node element 106 and the bottom bracket node element 107 by means of a seat tube frame element 120. A rear section 121 of this bicycle frame comprises the dropout node elements which are arranged next to one another at a distance in order to provide space between them for accommodating a rear wheel. In the sectional view of the 10 the mentioned right dropout node element 108 is shown. 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 stay frame element 123 to the bottom bracket node element 107.

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

In this sense, the head tube node element 105 is provided with a top tube fusion region for joining to the top tube frame element 118. In addition, the head tube node element 105 is provided with a down tube fusion region 125 for joining to the down tube frame element 119.

Furthermore, a material-bonded connecting means in the form of an additional material is expediently provided in order to produce a firm connection of the head tube node element 105 with 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 connected (adhesive gap). For this purpose, the relevant fusion area of the head tube node element and the connection area of the associated frame element each advantageously 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.

The head tube node element 105 is simply constructed in the manner of a sleeve, which has inner fusion areas (124, 125) with an internal adhesive surface. The top tube frame element 118 or For example, the down tube frame element 119 may be provided with outwardly facing connecting areas 118a and 119a, respectively, which form adhesive surfaces that match the associated inner adhesive surfaces of the head tube node element 105 in order to form the required adhesive gap for the adhesive.

The bottom bracket node element 107 is, like the head tube node element 105, formed from a shell element 126 which is injection-molded around a core and whose inner surface 126a is thereby firmly connected to the core, wherein the core is composed of a left bottom bracket core element and a right bottom bracket core element. In the sectional view of the 10 the right bottom bracket core element 127 is visible. 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 area of the cavity 129, inner stiffening elements 130 in the form of ribs 131 and 132 are provided, which cross each other. 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 separating joint of the assembled core is formed in this area, in accordance with the principles described above for the sealing edges of the core elements of the handlebar according to the 1 to 7d are described as alternatives to which reference is made. Positioning elements 134 are arranged on the outer surface of the core or the right bottom bracket core element 127 shown, which serve as a distance when the core is inserted into the injection molding tool for producing the shell element 126. The positioning elements 134 fix the shape and position of the bottom bracket core element 127 or the assembled core within the injection molding tool according to the principles which are also described above with respect to the handlebar according to the 1 to 5 are explained in detail what is referred to.

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 receive the pedal crank bearing. The opening 136 can be created by means of two sleeve-shaped components, of which one sleeve-shaped component belongs to each of the two bottom bracket core elements; 10 contains the right sleeve-shaped component 137 of the receiving means 135 for the pedal crank bearing. Alternatively, when the shell element 126 is manufactured in an injection molding tool, the opening 136 can be provided by means of an advantageously one-piece sleeve body which is inserted into the injection molding tool 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 in order 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 section 121 in order to join one lower strut frame element 123 each.

The seat tube node element 106 is, like the head tube node element 105, 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, wherein the core is composed of a left seat tube core element and a right seat tube core element, of which 10 only the right seat tube core element 142 is visible. 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 ribs 146 and 147 are provided, which cross each other. 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 interacts with an associated sealing edge of the left seat tube core element. In this way, a tight separating joint of the assembled core is formed in this area, in accordance with the principles described above for the sealing edges of the core elements of the handlebar in accordance with the 1 to 7d are described as alternatives to which reference is made. Positioning elements 148 are arranged on the lateral surface of the core or the right seat tube core element 142 shown, which serve as a distance when the core is inserted into the injection molding tool for producing the shell element 141. The positioning elements 148 fix the shape and position of the seat tube core element 142 or the assembled core within the injection molding tool according to the principles which are also described above with respect to the handlebar according to the 1 to 5 are explained in detail what is referred to.

The seat tube node element 142 further comprises a receiving means 149 for a seat post. The receiving means is advantageously provided with an opening 150, which can be created by means of two sleeve-shaped components, of which one sleeve-shaped component is connected to one of the both seat tube core elements; 10 contains the right sleeve-shaped component 151 of the receiving means 149 for the seat post. Alternatively, the receiving means, or the opening 150, when the shell element 141 is produced in an injection molding tool, can be provided by means of an advantageously one-piece sleeve body which is inserted into the injection molding tool 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 seat tube node element 106 is provided with five fusion areas for joining 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.

The right dropout node element 108 has a shell element 155 which is injection-molded around a core and whose inner surface 155a is integrally connected thereto, wherein the core is composed of a left dropout core element and a right dropout core element. 10 the right dropout core element 156 is visible. 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 area of the cavity 158, inner stiffening elements 159 in the form of ribs 160 and 161 are provided, which cross each other. 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 interacts with an associated sealing edge of the left dropout core element. In this way, a tight separating joint of the assembled core of the right dropout node element 108 is formed in this area, in accordance with the principles described above for the sealing edges of the core elements of the handlebar according to the 1 to 7d are described as alternatives to which reference is made. Positioning elements 163 are arranged on the lateral surface of the core or the right dropout core element shown, which serve as a distance when the core is inserted into the injection molding tool for producing the shell element 155. The positioning elements 163 fix the shape and position of the dropout core element 156 or the assembled core within the injection molding tool according to the principles which are also described above with respect to the handlebar according to the 1 to 5 are explained in detail what is referred to.

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 also designed as structural components according to the invention in the present example and each have a structurally supporting shell element and a structurally supporting core, which is advantageously composed of core elements. The structure of the frame elements mentioned 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 manufactured in an injection mold and preferably from thermoplastic. 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 joint of the assembled core of the right down tube frame element 119 is formed in this area, according to the principles described above for the sealing edges of the core elements of the handlebar according to the 1 to 7d are described as alternatives to which reference is made. Positioning elements 167 are arranged on a surface 166 of the core or the right down tube core element 164 shown, which serve as a spacer. The core is then placed in an injection molding tool for the purpose of producing a shell element 168 which is injection molded around the core and whose inner surface 168a is integrally connected to the 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 molding tool according to the principles which are also described above with respect to the handlebar according to the 1 to 5 are explained in detail what is referred to.

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, have in principle an identical structure to the down tube frame element 119.

List of reference symbols

1

Handlebar

2

core

2a

Shell surface

3

Core element

3a

Exterior surface

4

Core element

4a

Exterior surface

5

Shell element

5a

Inner surface

6

front

7

Middle range

7a

Subarea

8

Clamping range

9

Grip area

9a

Subarea

10

Grip area

10a

Subarea

11

Transition area

11a

Subarea

12

Transition area

12a

Subarea

13

Holding section

14

Holding surface

15

Holding section

16

Holding surface

18

middle section

19

halved conical section

20

halved conical section

21

halved conical section

22

halved conical section

23

Wall

23a

Material reinforcement

24

inside

25

channel-shaped cavity

25a

small cavity

26

Position element

26a

Exterior surface

27

Position element

27a

Exterior surface

28

Position element

28a

Exterior surface

29

Position element

29a

Exterior surface

30

Position element

30a

Exterior surface

31

Position element

31a

Exterior surface

32

Position element

32a

Exterior surface

33

Stiffening element

34

Ribs

34a

Rib surface

34b

Rib surface

34c

Impact surface

35

Ribs

35a

Rib surface

35b

Rib surface

35c

Impact surface

36

Middle range

37

Grip area

38

Grip area

39

Transition area

40

Transition area

41

Holding section

42

Holding surface

43

Holding section

44

Holding surface

45

inside

46

channel-shaped cavity

46a

small cavity

47

Wall

47a

Material reinforcement

48

Exterior surface

49

Stiffening element

50

rib

50a

Rib surface

50b

Rib surface

51

rib

51a

Rib surface

51b

Rib surface

52

Position element

53

Position element

54

Position element

55

Position element

56

Position element

57

Position element

58

Position element

59

Separation plane

60

Centering bar

60a

Centering surface

61

Centering bar

61a

Centering surface

62

Centering chamfer

63

Centering chamfer

64

edge

65

edge

66

Impact surface (second core element)

66a

Sealing edge

67

Impact surface (second core element)

68

Impact surface (first core element)

68a

Sealing edge (first core element)

69

Separation joint

70

Spring profile

71

Groove profile

72

cavity

73

Spring profile

74

Spring profile

75

Groove profile

76

Groove profile

77

Groove profile

78

Wedge profile

79

Wedge tip

80

Groove profile

81

Groove base

82

Groove profile

83

Groove base

84

Bicycle frame

85

Head tube section

86

Seat tube section

87

Rear section

88

Top tube element

89

core

89a

Shell surface

90

Shell element

90a

Inner surface

91

Side core element right

91a

Exterior surface

92

Side core element left

92a

Exterior surface

93

Rear triangle core element

93a

Exterior surface

95

cavity

95a

small cavity

96

Stiffening element

97

Ribs

98

Ribs

99

Opening (control bearing)

100

Seat post opening

101

Bottom bracket section

102

Opening (crank bearing)

103

Position element

104

Bicycle frame

105

Head tube node element

106

Seat tube node element

107

Bottom bracket node element

108

Dropout node element

109

Shell element

110

right head tube core element

111

Shell surface

112

cavity

112a

small cavity

113

Stiffening element

114

rib

115

rib

116

edge

117

Position element

118

Top tube frame element

118a

Connection area

119

Downtube frame element

119a

Connection area

120

Seat tube frame element

121

Rear section

122

Seat stay frame element

123

Under-brace frame element

124

Top tube fusion section

125

Downtube fusion area

126

Shell element (bottom bracket node)

126a

Inner surface

127

Crank core element

128

Shell surface

129

cavity

129a

small cavity

130

Stiffening element

131

rib

132

rib

133

edge

134

Position element

135

Recording equipment

136

opening

137

sleeve-shaped component

138

Fusion area down tube

139

Fusion area seat tube

140

Fusion area lower strut

141

Shell element (seat tube core element)

141a

Inner surface

142

Seat tube core element

143

Shell surface

144

cavity

144a

cavity

145

Stiffening element

146

rib

147

rib

148

Position element

149

Recording equipment

150

opening

151

sleeve-shaped component

152

Fusion area top tube

153

Fusion area seat tube

154

Fusion area seat stay

155

Shell element

155a

Inner surface

156

Dropout core element right

157

Shell surface

158

cavity

158a

cavity

159

Stiffening element

160

rib

161

rib

162

edge

163

Position element

164

Downtube core element

165

edge

166

Shell surface

167

Position element

168

Shell element

168a

Inner surface

S1

Sealants

S2

Sealants

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• EN 19581569 T1 [0007]

Cited non-patent literature

• DIN EN ISO 4210:2015 [0039, 0041]

Claims (24)

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) and 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-locking 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). 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 manufactured by means of a starting material which is flowable in a plastic state within the mold cavity of a shaping tool. Structural component according to Claim 1 or 2 , characterized in that the starting material is a thermoplastic. Structural component according to one of the Claims 1 until 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). 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 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 jacket surface (2a, 89a) of the core (2, 89). Structural component according to Claim 4 or 5 , characterized in that a separating joint (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 separating joint (69). Structural component according to Claim 6 , characterized in that a material-bonding additive is provided as the sealing means or mechanically interacting sealing edges (66a, 68a) are formed as the sealing means (S1, S2) on the edges (64, 65, 116, 133, 162, 165) of the core elements (3, 4, 91, 92, 93, 110, 127, 142, 156, 164). Structural component according to one of the Claims 4 until 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). Structural component according to one of the Claims 4 until 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). 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 assembled to form a core (2, 89), support one another. Structural component according to one of the Claims 2 until 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 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 molding tool for the production of the supporting shell element (5, 90, 109, 126, 141, 155, 168). Structural component according to one of the Claims 1 until 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 structure contour with a head tube section (85), a substructure contour with a bottom bracket section (101), an upper structure contour with a seat tube section (86) and a rear structure contour with a rear structure section (87) for a rear wheel axle. 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 the Claims 1 until 11 is trained. Bicycle frames (104) by Claim 13 , characterized in that a material-locking connection is provided to connect the node element (105, 106, 107, 108) to the frame element (118, 119, 120, 121, 122). Bicycle frames (104) by Claim 14 , characterized in that the material-locking connection is provided by means of a material-locking additional material. Bicycle frame (104) according to one of the Claims 13 until 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 connection region (118a, 119a) which cooperates with the fusion region of the node element. Bicycle frame according to Claim 16 , characterized in that the material-locking 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 connection region (118a, 119a) of the frame element (118, 119, 120, 121, 122). 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 the Claim 1 until 11 . Handlebar (1) for a bicycle, designed as a structural component according to one of the Claims 1 until 12 . Handlebar (1) after 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. Handlebar (1) after Claim 19 or 20 , characterized in that a holding section (13, 15, 41, 43) is arranged and prepared at the free ends of the core elements (3, 4) in order to fix the core element (3, 4) in an injection molding tool. Handlebar (1) after Claim 21 , characterized in that the holding sections (13, 15, 41, 43) of 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). Handlebar (1) after 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 a core (2), and that the assembled holding sections (13, 15, 41, 43) have external holding surfaces (14, 16, 42, 44). Handlebar (1) after Claim 21 , characterized in that the polygonal cross-section of the core (2) is a hexagonal cross-section.

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