Abstract: An improved all composite bicycle frame has three integral mating portions for the main triangle, asymmetric bottom bracket, improved composite layup, wall thickness, and tube geometry providing lighter weight and increased strength in an economical manner, an improved telescoping seat attachment fitting an integral seat mast and a fork having improved strength, weight and performance properties.

Abstract: A complex-shaped carbon fiber structural member including a multiplicity of carbon epoxy fiber bundles surrounded by a unidirectional carbon fiber rope and its method of manufacture are provided. The fiber bundles are formed from large sheets of unidirectional carbon fiber materials cut into small strips, with the strips then being randomly oriented in the form of a sheet of randomized fiber bundles. The strips, and the fibers in the strips, cross over one another so as to form a layer of material that has a relatively uniform strength in all directions. The sheets of randomized carbon epoxy fiber bundles are cut into preforms for the structural part being made. Several preforms are stacked on top of each other in order to provide material to make the part of a desired thickness. To reinforce the bundles within the part, particularly along its outer periphery, the preforms are wrapped prior to molding with an elongated rope of unidirectional carbon fibers.

Abstract: A composite bicycle frame having at least a portion of the frame walls reinforced with an internal layer of honeycomb material is presented. The honeycomb material is essentially sandwiched between interior and exterior sections of the frame wall, with the interior and exterior sections of the frame wall each being comprised of a plurality of overlaid layers composite material. Each layer of composite material is comprised of a multiplicity of high strength, unidirectional carbon fibers embedded in an epoxy resin. Several layers of composite material are stacked on top of each other and arranged so that the fibers in one layer cross over the fibers in an adjacent layers. The layers are cut into shapes and molded together using a cavity mold and internal pressure bladder in order to construct a substantially hollow, unitary frame member.