Abstract: A method of making generally hollow components and assemblies for a bicycle frame from composite materials, such as unidirectional structural fibers impregnated with a heat curable synthetic resin. Opposing parts of at least two adjacent wall sections are overlapped to form a shell and the overlapped parts are compressed together between internal and external pressing members. The shell is then cured while under compression to provide a pressure cured juncture integrally uniting the wall sections and forming a generally hollow bicycle frame component.

Abstract: A method of molding generally hollow components and assemblies for a bicycle frame including molded composite materials, such as unidirectional structural fibers impregnated with a heat curable synthetic resin. Opposing parts of at least two adjacent wall sections are overlapped to form a shell and the overlapped parts are compressed together between an external mold and an internal pressing member, such as an inflatable bladder. The shell is then cured while under compression to provide a pressure molded juncture integrally uniting the wall sections and forming a generally hollow bicycle frame component.

Abstract: A cycle frame having a generally hollow unitary component of composite material connecting at least two support members. The frame component includes at least one pressure molded juncture comprising overlapping layers of resin impregnated fibrous material provided by overlapped parts of at least two adjacent wall sections.

Abstract: A bicycle frame of streamlined and aerodynamically shaped tubular members has the form of two open triangles with a common side. The entire frame may be formed as one continuous unit with a plurality of hollow junctions each common to two or more members for supporting a front wheel assembly, a pedal and chain wheels assembly, a seat assembly and a rear wheel assembly. The frame may be covered or visually open from the side. The tubular seat column member has a rear wall which is curved longitudinally with a radius that follows the circumference of the rear tire. The longitudinally curved rear wall also is concave in transverse cross-section to follow the transverse shape of the outer surface of the tire. One or more of the tubular frame members, including a pair of rear seat stays and a pair of rear chain stays may have non-circular aerodynamic shapes in transverse cross-section.

Abstract: A generally hollow bicycle frame of resin impregnated fibrous material having a main tubular portion and a cross tubular portion arranged in an X-shaped geometry as viewed from one side. A rear segment of the main portion may be slit to provide opposing rear stays for receiving a rear wheel assembly therebetween. The main tubular portion connects the head tube and the rear wheel supports and the cross tubular portion connects the bottom bracket and the seat sleeve. Both of these portions may be substantially straight and continuous from end to end and joined by a generally hollow common junction. Alternatively, the common junction may integrally unite a plurality of pre-formed tubular portions corresponding respectively to the supports for the front wheel assembly, the rear wheel assembly, the bottom bracket and the seat. The tubular portions may have round or non-circular aerodynamic cross-sectional shapes.

Abstract: A method of molding generally hollow components and assemblies for a bicycle frame of composite materials, such as heat curable synthetic resins reinforced with structural fibers. The entire bicycle frame may be one integrally united piece. Layers of the composite material are shaped to form a shell for the frame component. Uncured portions of this shell are then compressed against the surfaces of a mold by a pressing member such as an inflatable bladder routed to the outside through a passageway passing through a metal sleeve.

Abstract: Disclosed is an improved bicycle frame of composite materials and a method of molding generally hollow components and assemblies for such a bicycle frame. The entire bicycle frame may be one integrally united piece of molded composite materials, such as unidirectional structural fibers impregnated with a heat curable synthetic resin. Layers of the composite material may be shaped to form an uncured frame shell. This shell is compressed against the surfaces of a mold by an internal pressing member, such as an inflatable bladder routed to the outside through a passageway passing through a modified bottom bracket sleeve or a modified head tube sleeve. The shell is then cured while under compression in the mold.

Abstract: A one-piece, ultralight, generally hollow bicycle frame having no internal structural components, and a method of manufacturing such a frame, are disclosed.