HOLLOW COMPOSITE BICYCLE COMPONENT AND METHOD OF MANUFACTURING THE HOLLOW COMPOSITE BICYCLE COMPONENT

A bicycle component includes a composite laminate. The composite laminate includes a hollow container made of a first polymer-based material, a layer of a second polymer-based material disposed on the hollow container, and a layer of a composite material disposed on the layer of the second polymer-based material. The bicycle component also includes a water soluble core material disposed within hollow container. The water soluble core material is dissolvable and removable from the composite laminate after lamination of the composite laminate

BACKGROUND

1. Field of the Disclosure

The present disclosure is generally directed to manufacturing a composite bicycle component, and more particularly, manufacturing a hollow composite bicycle component.

2. Description of Related Art

Hollow bicycle components such as, for example, rims, crank arms, and handlebars may be formed of extruded metals or other materials that are bent and bonded into a circular shape having consistently shaped cross sections. Recently, other materials, such as fiber reinforced plastics, have been used in the manufacture of hollow bicycle components, which may be formed into circular shapes through non-extrusion based processes. Carbon fiber reinforced plastics may, for example, be used.

Manufacturing a hollow bicycle component may include molding a foam core prior to the manufacturing of the hollow bicycle component, and then stacking individual sheets of carbon fiber composite material, for example, to form structures of the hollow bicycle component. The carbon fiber composite sheets may be pre-pregnated with a resin (e.g., a thermoplastic resin or a thermosetting resin) or other matrix material that undergoes a curing process to form the hollow bicycle component. The foam core is left within the formed hollow bicycle component.

Application of the thermoplastic resin, which does not have a sticky surface at room temperature, uses extra equipment, such as a double-belt press machine and a hot-press machine, for tape consolidation and laminate production to obtain, for example, carbon fiber reinforced thermoplastic (CFRT) sheets with specific stacking angles of thermoplastic prepregs. Application of the thermosetting resin, which has a sticky surface at room temperature, requires personnel to lay out stacking angles of thermosetting prepregs.

SUMMARY

In one example, an intermediate product includes a composite laminate. The composite laminate includes a hollow container made of a first polymer-based material, a layer of a second polymer-based material disposed on the hollow container, and a layer of a composite material disposed on the layer of the second polymer-based material. The intermediate product also includes a water soluble core material disposed within the hollow container. The water soluble core material is dissolvable and removable from the composite laminate after lamination of the composite laminate.

In one example, the intermediate product is a crank arm.

In one example, the second polymer-based material is the same as the first polymer-based material. The first polymer-based material and the second polymer-based material are a thermoplastic material.

In one example, the composite material includes a matrix of a third polymer-based material and fibers of a reinforcing material. The third polymer-based material is a thermoplastic, a thermoset matrix, or a combination thereof, and the fibers of the reinforcing material are carbon fibers.

In one example, the intermediate product further includes a preformed connector disposed on the hollow container. The layer of the second polymer-based material and the layer of the composite material are disposed on the preformed connector, such that the preformed connector is integrated within the composite laminate.

In one example, the water soluble core includes salt, expandable microspheres, or salt and expandable microspheres.

In one example, the water soluble core further includes a binder.

In one example, the salt includes sodium chloride, potassium chloride, potassium sulfate, or any combination thereof. The binder includes gum Arabic, ethyl cellulose, sodium silicate, trehalose, starch, polyvinylpyrrolidone, polyethylene glycol, acrylamide, or any combination thereof.

In one example, the hollow container has a first side and a second side opposite the first side. The layer of the second polymer-based material is a first layer of the second polymer-based material, and the layer of the composite material is a first layer of the composite material. The first layer of the second polymer-based material is disposed on the first side of the hollow container. The composite laminate further includes a second layer of the second polymer-based material disposed on the second side of the hollow container, and a second layer of the composite material disposed on the second layer of the second polymer-based material.

In one example, a hollow bicycle component includes a composite laminate. The composite laminate includes a hollow container made of a first polymer-based material, a layer of a second polymer-based material disposed on the hollow container, and a layer of a composite material disposed on the layer of the second polymer-based material. The composite material includes a matrix of a third polymer-based material and fibers of a reinforcing material.

In one example, the composite laminate further includes a first outermost layer configured as a first cover. The first outermost layer is made of a thermoplastic material and is configured to cover at least part of the composite laminate at a first side of the hollow container. The composite laminate further includes a second outermost layer configured as a second cover. The second outermost layer is made of the thermoplastic material and is configured to cover at least a part of the composite laminate at a second side of the hollow container. The second side of the hollow container is opposite the first side of the hollow container.

In one example, the first outermost layer includes at least one first attachment feature, and the second outermost layer includes at least one second attachment feature. The at least one second attachment feature is attachable to the at least one first attachment feature before lamination of the composite laminate, such that the first layer of the second polymer-based material is pressed against the first side of the hollow container and the second layer of the second polymer-based material is pressed against the second side of the hollow container before the lamination.

In one example, the hollow bicycle component includes a connector disposed on the hollow container. The layer of the second polymer-based material and the layer of the composite material are disposed on the connector, such that the connector is integrated within the composite laminate.

In one example, the hollow container has a first side and a second side opposite the first side. The layer of the second polymer-based material is a first layer of the second polymer-based material, and the layer of the composite material is a first layer of the composite material. The first layer of the second polymer-based material is disposed on the first side of the hollow container. The composite laminate further includes a second layer of the second polymer-based material disposed on the second side of the hollow container, and a second layer of the composite material disposed on the second layer of the second polymer-based material.

In one example, the hollow container has a first end and a second end opposite the first end. The first end and the second end extend between the first side and the second side of the hollow container. The connector is a first connector disposed on the first end of the hollow container. The second layer of the second polymer-based material and the second layer of the composite material are disposed on the connector. The first layer of the second polymer-based material, the first layer of the composite material, the second layer of the second polymer-based material, and the second layer of the composite material are disposed on the second connector, such that the second connector is integrated within the composite laminate.

In one example, a method for manufacturing a hollow bicycle component includes forming a hollow container. The hollow container is made of a first polymer-based material. The method also includes preparing a core material mixture. The core material mixture includes a salt, expandable microspheres, or a combination thereof. The method also includes filling the hollow container with the core material mixture and forming a layup pattern. Forming the layup pattern includes positioning at least a layer of a second polymer-based material and a layer of a composite material on the hollow container. The method also includes forming a composite laminate including the hollow container, the layer of the second polymer-based material, and the layer of the composite material, and dissolving, removing, or dissolving and removing the core material mixture.

In one example, preparing the core material mixture includes preparing a powdered mixture and stirring a binder into the powdered mixture, or preparing a salt core and disposing the expandable microspheres on the salt core. Preparing the powdered mixture includes mixing the salt and the expandable microspheres. Preparing the salt core includes mixing the binder and the salt.

In one example, the method also includes positioning a metal connector, such that the metal connector is in contact with the hollow container. The layer of the second polymer-based material and the layer of the composite material are positioned on the hollow container, such that the layer of the second polymer-based material and the layer of the composite material are also positioned on the metal connector. Forming the composite laminate includes forming the composite laminate, such that the metal connector is integrated with the composite laminate.

In one example, the hollow container has a first side and a second side opposite the first side. Positioning at least the layer of the second polymer-based material and the layer of the composite material includes positioning a first outermost layer at the first side of the hollow container, such that a first part of the layup pattern is disposed within a pocket of the first outermost layer, and positioning a second outermost layer at the second side of the hollow container, such that a second part of the layup pattern is disposed within a pocket of the second outermost layer. The method also includes attaching the first outermost layer to the second outermost layer. The attaching includes attaching an attaching feature of the first outermost layer to an attaching feature of the second outermost layer.

In one example, forming the composite laminate comprises hot pressing the composite laminate.

DETAILED DESCRIPTION OF THE DISCLOSURE

The use of sheets or strips of carbon fiber to manufacture a composite bicycle component of the prior art provides a number of advantages compared to traditional components formed of extruded metals or other materials. For example, carbon fiber based bicycle components have a high tensile strength, a low weight, a high temperature tolerance, and a low thermal expansion compared to traditional bicycle components formed of extruded metals or other materials.

A hollow composite bicycle component (e.g., a rim or a crank arm) may be manufactured using a foam core that provides support during the curing process. The foam core remains within the finished component, which adds weight to the finished component. Further, the foam core itself is manufactured by, for example, molding and further processing. This adds time, cost, and complexity to the manufacturing process for the hollow composite bicycle component.

A core material of the present disclosure is simple to produce, is low-cost, and provides an internal pressure during molding of a resin shell, so that a structure of a hollow composite (e.g., carbon fiber composite) bicycle component has high performance with respect to mechanical properties. For example, a core material of the present disclosure may maintain an existing shape at 260° C. or higher without softening. Further, a core material of the present disclosure may be easily removed from a finished hollow composite bicycle component after molding.

A core material of the present disclosure may include salt, a binder, and expandable beads. Such a core material has a high temperature resistance and a high pressure resistance. The expandable beads provide internal pressure during hot pressing. The core material is water-soluble and is environmentally friendly.

A container that holds a core material of the present disclosure may be made from a same resin material (e.g., bendable fabric preform sheets) as a composite material of which the hollow composite bicycle component is made. Such a resin material may be characterized by a film (e.g., shell) structure and may be formed to an appropriate shape according to requirements of a design of the hollow composite bicycle component. Such a container may be formed to complex geometries, and during hot pressing (e.g., forming) of the composite material of the hollow composite bicycle component, the container becomes engaged with laminating and is joined into a structure of the composite material.

A method of manufacturing a core for manufacturing a hollow composite bicycle component includes forming a container, mixing a core material, and disposing the mixed core material within the formed container. The container may be made of a resin material (e.g., bendable fabric preform sheets) and may be formed to a shape according to a design of the hollow composite bicycle component to be manufactured. The mixing of the core material may be performed at room temperature and may include mixing the expandable beads and the salt to obtain a powdery mixture. The binder may be added to this powdery mixture (e.g., including the expandable beds and the salt), and the binder may be mixed into the powdery mixture to form the core material. A solution (e.g., water) may be added to (e.g., mixed into) the core material to obtain a particular density and allow the core material to be filled (e.g., poured) into the formed container.

In one embodiment, an optional act of the method includes drying the core material within the formed container. The drying may be performed with a heater (e.g., an oven) for any number of different times depending on a temperature of the heater applied. The drying may reduce the weight percentage of the solution (e.g., water) within the core material. The drying may, for example, solidify and fix a form of the core material within the formed container.

A method of manufacturing a hollow composite bicycle component may include, initially, the act(s) of the method of manufacturing the core and additional acts. For example, the method may also include laminating fabric sheets onto the manufactured core, hot forming the laminated fabric sheets, dissolving at least part of the manufactured core, and cleaning the manufactured core out of the hollow composite bicycle component. The method may include more, fewer, and/or different acts.

The laminating of the fabric sheets onto the manufactured core may include positioning a thermoplastic material (e.g., layers of thermoplastic resin) within a layup pattern before hot forming the laminated fabric sheets. Application of a layer of thermoplastic resin, which does not have a sticky surface at room temperature, may require extra equipment for, for example, tape consolidation (e.g., a double-belt press) and laminate production (e.g., a hot-press machine) to obtain, for example, carbon fiber reinforced thermoplastic (CFRTP) sheets with specific stacking angles of thermoplastic prepregs. Alternatively or additionally, the laminating of the fabric sheets onto the manufactured core may include positioning another thermoplastic material (e.g., layers of thermosetting resin) within the layup pattern before hot forming the laminated fabric sheets. Application of a layer of thermosetting resin, which is an epoxy with a sticky surface at room temperature, may require personnel to lay out appropriate stacking angles of thermosetting prepregs.

An interlocking mechanism of the present embodiments sets each CFRTP (e.g., collectively, the layup pattern), for example, prior to hot forming the laminated fabric sheets. Use of the interlocking mechanism of the present embodiments may save time and money in the production of a component (e.g., the hollow composite bicycle component), in that manufacturing processes such as, for example, tape consolidation and laminate production may be skipped, and expensive equipment such as, for example, a double-belt press may not be necessary. Further, the number of personnel necessary for manufacturing may be reduced.

The interlocking mechanism of the present embodiments may be made of a resin material (e.g., a thermoplastic resin or a thermosetting resin) and may form one or more outermost layers of the layup pattern. For example, the one or more outermost layers may include outermost layers at a top, a bottom, a right side, a left side, a front, and/or a rear of the layup pattern.

A first outermost layer of the interlocking mechanism includes at least one first extended structure (e.g., at least one first interlocking feature; square in shape), and a second outermost layer of the interlocking mechanism includes at least one second extended structure (e.g., at least one second interlocking feature; circular in shape). The first outermost layer and the second outermost layer are on opposite sides of the layup pattern. The at least one first extended structure and the at least one second extended structure may be any number of sizes. For example, a diameter of a circular cross-section of a second extended structure of the at least one second extended structure may be equal to a length of a side of a square cross-section of a first extended structure of the at least one first extended structure. Heights of the at least one first extended structure and the at least one second extended structure, respectively, may be the same. Other shapes and size may be provided.

1 Before latching the interlocking mechanism (e.g., latching corresponding interlocking features on the first outermost layer and the second outermost layer, respectively), multiple single layer CFRTP prepregs (e.g., the layup pattern) are positioned within a volume defined by (e.g., enclosed by) opposite outermost layers (e.g., the first outermost layer and the second outermost layer forming at least part of the interlocking mechanism). One or more sides of the first outermost layer are pivoted towards the layup pattern, such that the at least one first interlocking feature is also pivoted towards the layup pattern; one or more sides of the second outermost layer are pivoted towards the layup pattern, such that the at least one second interlocking feature is also pivoted towards the layup pattern. The one or more sides of the first outermost layer and the one or more sides of the second outermost layer are pivoted towards the layup pattern until the at least one first interlocking feature engages with the at least one second interlocking feature, respectively. The at least one first interlocking feature engages with the at least one second interlocking feature, respectively, by one interlocking feature (e.g., a second interlocking feature, circular in shape) on one of the first outermost layer and the second outermost layer moving into the other interlocking feature (e.g., a first interlocking feature, square in shape) on the other of the first outermost layer and the second outermost layer.

The first outermost layer and the second outermost layer, for example, may be sized, and the at least one first interlocking feature and the at least one second interlocking feature may be positioned on the first outermost layer and the second outermost layer, respectively, such that when the at least one first interlocking feature and the at least one second interlocking feature engage with each other, respectively, layers within the layup pattern are pressed against the hollow container and set. A pre-laminated CFRTP may then be subjected to final press molding, for example, and the hollow composite bicycle component may be obtained.

Turning now to the drawings,FIG.1generally illustrates a bicycle50that employs one or more components (e.g., rims, crank arms) constructed in accordance with the teachings of the present disclosure. The bicycle50includes a frame52, a front wheel54and a rear wheel56each rotatably attached to the frame52, and a drivetrain58. A front brake60is provided for braking the front wheel54, and a rear brake62is provided for braking the rear wheel56. The bicycle50also generally has a seat64near a rear end of the frame52and carried on an end of a seat post66connected to the frame52. The bicycle50also has handlebars68near a forward end of the frame52. A brake lever70is carried on the handlebars68for actuating the front brake60, the rear brake62, or both the front brake60and the rear brake62. If the brake lever70actuates only one of the front brake60and the rear brake62, a second brake lever (not shown) may also be provided to actuate the other brake. A front and/or forward riding direction or orientation of the bicycle50is indicated by the direction of the arrow A inFIG.1. As such, a forward direction for the bicycle50is indicated by the direction of arrow A. While the illustrated bicycle50depicted inFIG.1is a road bike having drop-style handlebars68, the present disclosure may be applicable to bicycles of any type, including mountain bikes with full or partial suspensions.

The drivetrain58has a chain C and a front sprocket assembly72, which is coaxially mounted with a crank assembly74(e.g., including two crank arms) having pedals76. The drivetrain58also includes a rear sprocket assembly78coaxially mounted with the rear wheel56and a rear gear change mechanism, such as a rear derailleur80.

As is illustrated inFIG.1, the front sprocket assembly72may include one or more coaxially mounted chainrings, gears, or sprockets. In this example, the front sprocket assembly72has one sprocket F. The one sprocket F has teeth82around a respective circumference. As shown inFIG.1, the rear sprocket assembly78may include a plurality of coaxially mounted gears, cogs, or sprockets G. Each sprocket G1-G11also has teeth84arranged around a respective circumference. The number of teeth84on the rear sprockets G1-G11may gradually decrease from the largest diameter rear sprocket G1to the smallest diameter sprocket G11. Though not described in any detail herein, a front gear changer85may be operated to move from a first operating position to a second operating position to move the chain C between front sprockets F. Likewise, the rear derailleur80may be operable to move between different operating positions to switch the chain C to a selected one of the rear sprockets G1-G11. In an embodiment, the rear sprocket assembly78may have more or fewer sprockets G. For example, in an embodiment, the rear sprocket assembly78may have twelve or thirteen sprockets. Dimensions and configuration of the rear derailleur80may be modified to accommodate a specific implemented plurality of sprockets. For example, an angle and length of the linkage and/or the configuration of the cage of the derailleur may be modified to accommodate specific sprocket combinations.

The rear derailleur80is depicted as a wireless, electrically actuated rear derailleur mounted or mountable to the frame52, or frame attachment, of the bicycle50. The electric rear derailleur80has a base member86(e.g., a b-knuckle) that is mounted to the bicycle frame52. A linkage88has two links L that are pivotally connected to the base member86at a base member linkage connection portion. A movable member90(e.g., a p-knuckle) is connected to the linkage88at a moveable member linkage connection portion. A chain guide assembly92(e.g., a cage) is configured to engage and maintain tension in the chain and has one or more cage plates93with a proximal end that is pivotally connected to a part of the movable member90. The cage plate93may rotate or pivot about a cage rotation axis in a damping direction and a chain tensioning direction. Other gear changing systems, such as mechanically or hydraulically controlled and/or actuated systems may also be used.

A motor module may be carried on the electric rear derailleur80with a battery. The battery supplies power to the motor module. In one example, the motor module is located in the movable member90. However, the motor module may instead be located elsewhere, such as in one of the links L of the linkage88or in the base member86. The motor module may include a gear mechanism or transmission. As is known in the art, the motor module and gear mechanism may be coupled with the linkage88to laterally move the cage plate93and thus switch the chain C among the rear sprockets (e.g., G1-G11) on the rear sprocket assembly78.

The cage plate93also has a distal end that carries a tensioner cog or wheel. The wheel also has teeth around a circumference. The cage plate93is biased in a chain tensioning direction to maintain tension in the chain C. The chain guide assembly92may also include a second cog or wheel, such as a guide wheel disposed nearer the proximal end of the cage plate93and the movable member90. In operation, the chain C is routed around one of the rear sprockets (e.g., G1-G11). An upper segment of the chain C extends forward to the front sprocket assembly72and is routed around the one front sprocket F. A lower segment of the chain C returns from the front sprocket assembly72to the tensioner wheel and is then routed forward to the guide wheel. The guide wheel directs the chain C to the rear sprockets (e.g., G1-G11). Lateral movement of the cage plate93, the tensioner wheel, and the guide wheel may determine the lateral position of the chain C for alignment with a selected one of the rear sprockets (e.g., G1-G11).

The bicycle50may include one or more bicycle control devices100mounted to handlebars68. The bicycle control devices100may include one or more types of bicycle control and/or actuation systems. For example, the bicycle control devices100may include brake actuation systems to control the front brake60and/or the rear brake62, and/or gear shifting systems to control the drivetrain58. Other control systems may also be included. For example, the system may be applied, in some embodiments, to a bicycle where only a front or only a rear gear changer is used. Also, the one or more bicycle control devices may also include suspension, seat post, and/or other control systems for the bicycle50.

The front wheel54and/or the rear wheel56of the bicycle50may include a tire120attached to a radially outer tire engaging portion of a rim122. As shown inFIGS.1and2, a plurality of spokes124are attached directly to the rim122. Alternatively, the spokes124may be attached and/or secured to the rim122with other structural components. The spokes124extend from the rim122and attach to a central hub126. The spokes124are maintained with a tension between the rim122and the central hub126to provide the respective wheel54,56with an operational rigidity for use on the bicycle50. The central hub126is configured for rotational attachment to the bicycle frame52.

FIG.2illustrates a bicycle wheel having a rim122, spokes124, and a central hub126, such as the front wheel54ofFIG.1, removed from the rest of the bicycle50and without a tire attached. The rim122includes a tire engaging portion130to engage with the tire120, as is shown inFIG.1. The tire engaging portion130is configured radially outward of a spoke receiving surface132that is disposed along an inner circumference134of the rim122. In other words, the tire engaging portion130is a radially outer tire engaging portion. In an embodiment, the tire engaging portion130is disposed along an outer circumference135of the rim122. The tire engaging portion130is configured for attachment to tires using clincher tire attachment configurations for tires including beaded interlock attachments. Other configurations of the tire engaging portion130may also be provided to allow for the use of other types of tires on the rim122. For example, tubeless tires including beaded interlock attachment types may be used.

The rim122provides structure for attachment of the spokes124to the rim122at a receiving portion of the rim122, proximate to the spoke receiving surface132. As such, the spoke receiving surface132is part of a spoke engaging portion136(e.g., a radially inner portion) of the rim122. In an embodiment, the spoke engaging portion136of the rim122is disposed along the inner circumference134of the rim122. In another embodiment, the spoke receiving surface132and the spoke engaging portion136may be separate parts and/or portions of the rim122. For example, the spokes124may pass through the spoke receiving surface132, and the structure for attachment to the rim122may be provided proximate to the tire engaging portion130.

The rim122includes a first sidewall138and a second sidewall (not shown) that extend between the tire engaging portion130and the spoke engaging portion136. For example, the first sidewall138and the second sidewall extend radially outward from the spoke engaging portion136to the tire engaging portion130. The first sidewall138is spaced apart from the second sidewall. The rim122may be hollow between, for example, the first sidewall138, the second sidewall, the tire engaging portion130, and the spoke engaging portion136

At least part of the rim122(e.g., the first sidewall138and the second sidewall) is formed by one or more composite materials. In one embodiment, the entire rim122is formed by one or more composite materials. In one example, fiber reinforced plastic forms a one-piece unitary rim of a collection of layers including the tire engaging portion130, the first sidewall138, the second sidewall, and the spoke engaging portion136. Other configurations may also be provided. For example, a combination of plastic and carbon-fiber reinforced plastic forms a one-piece unitary rim of a collection of plastic layers and carbon-fiber layers including the tire engaging portion130, the first sidewall138, the second sidewall, and the spoke engaging portion136. Other configurations may also be provided.

The front wheel54and the rear wheel56may include rims122configured for any size wheel. In an embodiment, the rims122are configured for use in wheels conforming to a 700C (e.g., a 622 millimeter diameter clincher and/or International Standards Organization 622 mm) bicycle wheel standard.

The front wheel54and the rear wheel56may rotate about the central hub126in either direction. For example, as shown inFIG.2, the front wheel54and the rear wheel56may be configured to rotate in a particular rotational direction about the central hub126. In another example, the front wheel54and the rear wheel56may be configured to rotate in a direction opposite the particular rotational direction.

In one embodiment, the first sidewall138, the second sidewall, the spoke engaging portion136, and the tire engaging portion130of the front wheel54and/or the rear wheel56of the bicycle50(e.g., the front wheel54and the rear wheel56in the example ofFIG.1) are at least partially formed by one or more layers of the one or more composite materials (e.g., layers of composite materials). Each of the one or more layers may include one or more fabric plies (e.g., pieces) of the respective composite material. Different layers of different composite materials may include different numbers of plies or pieces of the composite materials, respectively. At least some of the layers of composite material may be of different shapes and/or sizes. Alternatively, all of the layers of the composite material may be a same shape and/or size.

In one embodiment, at least some of the layers of composite material are shaped as strips. For example, strips of the one or more composite materials may form the first sidewall138and the second sidewall of the front wheel54. The strips of the one or more composite materials may be disposed about the central hub126of the front wheel54, respectively, and the central hub126of the rear wheel56, respectively, to form the first sidewall138and the second sidewall of the front wheel54and the rear wheel56, respectively.

In a manufacturing process, the layers of the front wheel54and the rear wheel56, respectively, are integrated with the spoke engaging portion136and the tire engaging portion130(e.g., layers of composite material forming the spoke engaging portion136and the tire engaging portion130) of the respective wheel54,56by, for example, a curing process, such that a one-piece unitary rim122is formed. The rims122of the front wheel54and rear wheel56, respectively, may be formed with other manufacturing processes.

Part of each of the rims122is hollow and may be manufactured using a core of the present disclosure. Other hollow bicycle components such as, for example, crank arms may be manufactured similarly.FIG.3illustrates one embodiment of a layup pattern of layers (e.g., first layers150and second layers152) of material(s) for a crank arm140prior to the curing process. The first layers150and the second layers152, for example, after the curing process, may be part of a one-piece unitary crank arm140. The resultant one-piece crank arm140may be at least partially formed by a laminate that includes one or more compressed layers of one or more materials. Any number of materials may be included within the laminate including, for example, a thermoplastic and/or a thermoplastic with reinforcing fiber material (e.g., bendable fabric preform sheets). The reinforcing fiber material may be any number of reinforcing materials including, for example, carbon. More, fewer, and/or different materials may be included within the laminate.

In one embodiment, the first layers150may be thermoplastic sheets, and the second layers152may be bendable fabric preform sheets (e.g., a thermoplastic with a reinforcing fiber material). The first layers150may be made of any number of different thermoplastics including, for example, acrylic, polyester, polypropylene, polystyrene, Nylon and Teflon. In one embodiment, one or more of the first layers150include one or more thermosetting resins. The one or more thermosetting resins may include any number of different thermosetting resins including, for example, epoxy. The second layers152may include any number of different reinforcing fiber materials including, for example, carbon fiber or Nylon. Each of the first layers150may include a plurality of stacked first sheets, and each of the second layers152may include a plurality of stacked second sheets.

Referring toFIG.3, the layup pattern may include a container154(e.g., a thermoplastic sheet container) that houses a core material156. The layup pattern including the container154and housing the core material156may form an intermediate product. The core material156may be any number of mixtures of materials including, for example, a salt mixture. Thermoplastic sheets158of the container154, for example, are bendable/formable, such that a shape of the container154corresponds to a shape of the bicycle component (e.g., the crank arm140) to be manufactured according to a design.

The core material156may be inserted (e.g., poured) into the container154. Other parts made of materials different than the core material156may also be inserted into the container154. For example, as shown in the embodiment ofFIG.3, metal lugs160a,160b(e.g., preformed connectors) may be inserted into (e.g., positioned adjacent to) the container154on opposite ends162,163of the container154, respectively. The metal lugs160a,160bmay be, for example, locations where the crank arm140is attached to other parts of the bicycle. For example, the lugs160may include threaded through-holes, and a pedal and a crank shaft of the bicycle may be attached to the crank arm140via the threaded through-holes through the lugs160a,160b, respectively. The lugs160a,160bmay be the same or may be different (e.g., may be different sizes and/or shapes, and/or may include different connectors). More, fewer, and/or different (e.g., made of different materials) parts may be included within the container154with the core material156.

The layup pattern includes a first layup pattern164on a first side166of the container154and a second layup pattern168on a second side170of the container154. The first side166of the container154may be opposite the second side170of the container154. The first layup pattern164includes alternating first layers150and second layers152. For example, the first layup pattern164includes a first layer150adisposed on the container154and the metal lugs160a,160b, for example, a second layer152adisposed on the first layer150a, a first layer150bdisposed on the second layer152a, and a second layer152bdisposed on the first layer150b. The first layup pattern164may include more, fewer, and/or different first layers150, second layers152, and/or other layers.

In one embodiment, at least some layers of the layup pattern may cover opposite ends of preformed components (e.g., the metal lugs160a,160b), respectively, to be integrated with the layup pattern. As shown in the example ofFIG.3, different layers of the first layup pattern164may have different sizes and/or shapes. For example, the first layer150aand the second layer152acover opposite ends172,174of the metal lugs160a,160b, respectively, while the first layer150band the second layer152bare straighter, do not cover the opposite ends172,174of the metal lugs160a,160b, respectively, and are shorter than the first layer150aand the second layer152a, respectively. Different sizes and/or shapes of the layers150, the layers152, and/or other layers may be provided according to a design of the bicycle component to be manufactured.

The second layup pattern168includes a first layer150cdisposed on the second side170of the container154and the metal lugs160a,160b, for example, and a second layer152cdisposed on the first layer150c. The second layup pattern168may include more, fewer, and/or different first layers150, second layers152, and/or other layers.

The first layer150cand the second layer152cdo not cover the opposite ends172,174of the metal lugs160a,160b, respectively. The layers of the second layup pattern168(e.g., the first layer150cand the second layer152c) may have different sizes and/or shapes compared to the layers of the first layup pattern164. For example, the first layer150cand the second layer152cmay be longer than the first layer150band the second layer152b, respectively, but may not cover the opposite ends172,174of the metal lugs160a,160b, respectively, like the first layer150aand the second layer152a. The first layer150aand the second layer152amay, however, overlap with the first layer150cand the second layer152c. Other configurations (e.g., shapes, sizes, materials, and/or number of layers) may be provided. For example, the second layup pattern168may include one or more additional first layers150and/or second layers152. In the embodiment shown inFIG.3, the second layup pattern168is thinner (e.g., includes fewer first layers150and second layers152and/or includes fewer sheets) than the first layup pattern164. In one embodiment, the second layup pattern168is as thick as or thicker than the first layup pattern164.

The core material156and ultimately the composite bicycle component (e.g., the crank arm140) may be manufactured in any number of ways. For example,FIG.4illustrates a method400for manufacturing a bicycle component (e.g., the rim122or the crank arm140) of a bicycle (e.g., the bicycle50). The acts of the method400presented below are intended to be illustrative. In some embodiments, the method400may be accomplished with one or more additional acts not described, and/or without one or more of the acts discussed. Additionally, the order in which the acts of the method400are illustrated inFIG.4and described below is not intended to be limiting.

In act402, a material mixture (e.g., a salt mixture) for a core (e.g., the core material156) is produced. The salt mixture, for example, may include any number of components. For example, the salt mixture may include one or more binders (e.g., a binder), one or more salts (e.g., a salt), and one or more different types of expandable beads (e.g., expandable microspheres). The material mixture may include more, fewer, and/or different components. For example, the material mixture may include a binder and expandable beads, but not include a salt. In another example, the material mixture may include a salt and a binder, but not expandable beads.

The binder may be any number of different types of binders including, for example, a water-soluble compound with binding ability. For example, the binder may be gum Arabic, ethyl cellulose, sodium silicate, trehalose, starch, polyvinylpyrrolidone, polyethylene glycol, acrylamide, pyrodextrin, and/or another binder. The salt mixture may include two or more different binders.

The salt may be any number of different types of salts including, for example, a neutral salt soluble in water. For example, the salt may be sodium chloride, potassium chloride, magnesium chloride, sodium carbonate, potassium bromide, potassium sulfate, and/or another salt. The salt mixture may include two or more different salts.

The expandable beads may be any number of different types of expandable materials including, for example, a thermoplastic polymer that undergoes expansion. For example, the expandable beads may be expandable microspheres sold by Kurcha or AkZoNobel under the brand names Kureha Microspheres or Expancel®. Expancel® microspheres, for example, are a lightweight filler and blowing agent. The thermoplastic microspheres encapsulate a gas. With added heat, the gas within thermoplastic shells of the microspheres expands, the thermoplastic shells soften, and volumes of the microspheres respectively expand.

The salt mixture for the core may be mixed under any number of conditions including, for example, at room temperature. In one embodiment, a first mixture is produced by mixing the expandable beads and the salt uniformly with predetermined portions, respectively. The first mixture is, for example, a powdered mixture. A second mixture is then produced by adding the binder to the first mixture and mixing (e.g., stirring) the binder into the first mixture. In one embodiment, a solution may be added to and mixed (e.g., stirred) into the second mixture to obtain a desired density (e.g., a predetermined density) of the salt mixture, such that a container (e.g., defining a shape of the component to be manufactured; a shell container) may be filled. For example, the solution may be water, and the water may be stirred into the second mixture to obtain the desired density of the salt mixture.

In act404, the salt mixture produced in act402may be dried. Act404may be optional, in that the method400may move directly to act406after act402has been performed (see arrow403). When, however, act404is performed, the salt mixture may be dried in any number of different ways. For example, heat may be applied to the salt mixture to dry the salt mixture. In one embodiment, the salt mixture is dried using an oven. The drying may be at a low temperature (e.g., 100° C.) or a high temperature (e.g., 200 C) for a shorter period of time compared to drying at the low temperature. The drying process may reduce the solution (e.g., water) within the salt mixture, such that a lower weight percentage of the solution within the salt mixture is provided (e.g., after evaporation of water within the salt mixture).

A container (e.g., the container154) may be produced according to a design of the composite bicycle component to be manufactured. The container may be made of a thermoplastic resin material (e.g., bendable fabric preform sheets) that is formable to a shape according to the design of the composite bicycle component to be manufactured. The drying temperature in act404may be less than a softening temperature of the thermoplastic resin used for the container. The container may be filled with the salt mixture (e.g., the salt mixture may be poured into the container), and the salt mixture may be dried within the container, such that the salt core is formed within the container. In other words, a form of the salt core (e.g., a core form) is fixed within the container during the drying process.

FIGS.5and6show two embodiments of a material mixture disposed within a thermoplastic sheet container.FIG.5shows a first embodiment of a material mixture500within a container501. The material mixture500includes expandable beads502mixed into a salt mixture504(e.g., including a salt and a binder), as described above. The material mixture500is, for example, a powdered mixture of the salt, the binder, and the expandable beads502. As an example, such a material mixture500includes, before drying in act404, 68.40% weight percentage salt, 7.60% weight percentage expandable beads502, 8.00% weight percentage binder, and 16.00% weight percentage water. Other weight percentages may be provided. For example, a salt mixture may include 50.0%-80.0% weight percentage salt, 5.0%-20.0% weight percentage expandable beads, 4.0%-15% weight percentage binder, and 5%-25% weight percentage water.

Such a material mixture500includes, after drying in act404, 85.50% weight percentage salt, 9.5% weight percentage expandable beads502, and 5.00% weight percentage binder, with the water fully evaporated. The weight ratio of the salt to the expandable beads502may be nine to one. Different ratios of salt to expandable beads502may be provided after the drying in act404. For example, ratios of salt to expandable beads502of ten to one, eight to one, seven to one, or five to one may be provided. Other ratios of salt to expandable beads may be provided.

Table 1 below shows different examples of core material mixtures, including weight percentage ranges for salt, a binder, and expandable beads (e.g., expandable microspheres), respectively, for different types of cores (e.g., for the core material156).

As shown in Table 1, Core Type C1 represents an expandable core, C2 represents an expandable salt core, C3 represents a hard salt core, and C4 represents a composite salt core.

Table 2 below illustrates an example of an expandable core, Core Type C1.

A volume expansion rate of expandable microspheres may range from 7-20 times. Accordingly, the expandable microspheres may only fill 5-15% of the hollow container (e.g., the container154) before hot pressing. After hot pressing, for example, the expandable core illustrated in Table 2 may become sticky and shaped. Prior to the hot pressing, the expandable core illustrated in Table 2 may be capable of force pressure injection.

Table 3 below illustrates an example of an expandable salt core, Core Type C2.

For the expandable salt core illustrated in Table 3, after mixing of the salt, the binder, and the expandable microspheres, the core material mixture becomes a dry dough that is easy to knead, and filling the hollow container (e.g., the container154) with this core material mixture may be easy. This dry dough mixture does not stick to the hollow container. After hot pressing, for example, the dry dough mixture expands violently but does not collapse.

Table 4 below illustrates a first example of a hard salt core, Core Type C3.

For the hard salt core illustrated in Table 4, after mixing of the salt and the binder, the core material mixture may be close to wet dough that may be kneaded into a ball. This kneaded ball may stick to the hollow container (e.g., the container154), but filling the hollow container with this core material mixture may be easy. The core material mixture may be shaped by the hollow container after hot pressing, for example.

Table 5 below illustrates a second example of a hard salt core, Core Type C3.

For the hard salt core illustrated in Table 5, after mixing of the salt and the binder, the core material mixture becomes a dough with moderate dryness/wetness that is easy to knead, and filling the hollow container (e.g., the container154) with this core material mixture may be easy. The kneaded dough mixture may not stick to the hollow container. The core material mixture may be easily shaped within the hollow container after hot pressing, for example. The compressive strength of the core may, for example, reach 21 MPa during hot pressing, and a dissolution time of a 25 g core, after hot pressing, may be 30-60 minutes.

Table 6 below illustrates an example of a composite salt core, Core Type C4.

For the composite salt core illustrated in Table 6, a hard salt core (e.g., as illustrated in Table 4 or Table 5) is covered with an expandable core (e.g., as illustrated in Table 2). After hot pressing, for example, the hard salt core is partially shaped, and the expandable core expands.

FIG.6shows a second embodiment of a material mixture600within a container601(e.g., the container154). The material mixture600includes expandable beads602applied to an outer surface604of a salt mixture606(e.g., including salt and a binder). In other words, in act402, instead of the binder being added to the salt mixture504including the salt and the expandable beads502, as described above, the salt and the binder are mixed to form the salt mixture606, and the expandable beads602are applied to such a mixture600(e.g., as part of the drying act in act404). As an example, such a salt mixture606includes, before drying in act404, 82.0% weight percentage salt and 18.0% weight percentage binder. Water may not be added to this mixture. Other weight percentages may be provided. For example, a salt mixture may include 75.0%-90.0% weight percentage salt and 10.0%-25% weight percentage binder.

Such a material mixture600includes, after the application of the expandable beads602and the drying in act404, 89.3% weight percentage salt, 0.9% weight percentage expandable beads, and 9.8% weight percentage binder.

Other configurations may be provided. For example, Table 7 below illustrates an example of a hard salt core with reactive salts added.

For example, 3.3% reactive salts may be added to improve a dissolution rate. The compressive strength of the core is reduced, but the core may withstand the pressure of the hot pressing, for example. The compressive strength of the core is, for example, 3.96 MPA, and the dissolution time of a, for example, 25 g core may be one minute.

Reactive salts may trigger a rapid chemical reaction with mineral salts in water. Any number of different reactive salts including, for example, magnesium carbonate, sodium bicarbonate, sodium hydroxide, butanedioic acid, citric acid, malic acid, tartaric acid, another reactive salt, or any combination thereof may be included.

In act406, layers of a layup pattern are positioned on the container filled with the salt mixture (e.g., the dried salt mixture) according to the design of the composite bicycle component to be manufactured. In other words, fabric sheets are laminated according to the design of the composite bicycle component to be manufactured.

For example, the layup pattern includes a first layup pattern on a first side of the container and a second layup pattern on a second side of the container. The layup pattern may correspond to the layup pattern shown in the example ofFIG.3, though other layup patterns for the same bicycle component or other bicycle components may be provided. The layup pattern may include more than the first layup pattern and the second layup pattern. For example, the layup pattern may include at least a third layup pattern and a fourth layup pattern at sides extending between the first side and the second side of the container, respectively. The number of layup patterns within an overall layup pattern may be determined, for example, by a shape of a cross-section of a hollow portion of the bicycle component to be manufactured.

The layup pattern may include, for example, first layers and second layers. Each of the first layers may include a number of sheets of a thermoplastic material. Each of the second layers may include a number of sheets (e.g., bendable fabric preform sheets) of a thermoplastic material with one or more reinforcing fiber materials. For example, the second layers may be a carbon fiber reinforced thermoplastic. The layup pattern may include more, fewer, and/or different types of layers. For example, the layup pattern may only include the sheets of thermoplastic material or only the sheets of the thermoplastic material with the one or more reinforcing fiber materials. As another example, the layup pattern may include the second layers including a number of sheets made of a thermoplastic material with a first reinforcing fiber material, and third layers including a number of sheets made of the thermoplastic material with a second reinforcing fiber material that is different than the first reinforcing fiber material. Other configurations may be provided.

In one embodiment, a first layer may be positioned on a first side of the container (e.g., within the first layup pattern), and a first layer may be positioned on a second side of the container (e.g., within the second layup pattern), where the second side of the container is opposite the first side of the container. A second layer may then be positioned on the first layer at the first side of the container (e.g., within the first layup pattern), and a second layer may be positioned on the first layer at the second side of the container (e.g., within the second layup pattern).

Additional, fewer, and/or different layers may be positioned. For example, another first layer may be positioned on the second layer at the first side of the container, and another second layer may be positioned on the other first layer at the first side of the container (e.g., within the first layup pattern). This pattern and/or another pattern may be repeated at the first side of the container, the second side of the container, and/or one or more other sides of the container any number of times. More, fewer, and/or different layers may be positioned at the second side of the container, for example, within the second layup pattern.

In act408, the bicycle component (e.g., a composite laminate) may be formed. For example, the laminated fabric sheets positioned on the container in act406may be hot-pressed. Forming the composite laminate may include curing the composite laminate on the container and the salt core formed in act404, for example. The composite laminate may be cured in any number of ways including, for example, by press curing, autoclave curing, or oven curing the composite laminate. Other types of curing may be used.

More than one type of expandable beads may be included within the salt mixture produced in act402, such that more than two stages of internal pressure may be provided during, for example, the curing process of act408. The thermoplastic resin shell container, for example, not only acts as a support for shaping the salt mixture into the core, but also serves as resin impregnation of an overall composite material of the component to be manufactured using the method400.

In act410, the salt and the binder of the salt mixture are dissolved. The salt and the binder are dissolved using any number of solutions including, for example, water. The manufactured component may be permeable, and the solution may reach the salt mixture for the dissolution of the salt and the binder. Alternatively or additionally, the manufactured component may include a port via which the solution is introduced into the hollow portion of the manufactured component for dissolving of the salt and the binder. In one embodiment, the expandable beads may also be washed away with the solution or another solution. The dissolving and washing away of the salt mixture leaves a hollow part including the container and the hot-pressed laminated fabric sheets.

In one embodiment, the dissolving of the salt and the binder of the salt mixture may be performed more quickly by, for example, increasing a temperature of the solution for the dissolving and/or the washing, applying ultrasonic vibration to the salt mixture, and/or increasing a scour force.

The method400may be used to manufacture any number of different bicycle components. For example, in addition to bicycle crank arms, the method400may be used to manufacture rims, handlebars, stems, seat posts, seat rails, shifting levers, brake levers, derailleur cages, suspension fork components, and/or other bicycle components.

The positioning of layers of a layup pattern (e.g., in act406) on, for example, a container filled with a salt mixture may present issues based on, for example, the resin used. For example, with application of a thermoplastic resin, which does not have a sticky surface at room temperature, extra equipment (e.g., a double-belt press machine and a hot-press machine) may be used for tape consolidation and laminate production to obtain carbon fiber reinforced thermoplastic (CFRTP) sheets (e.g., the second layers152) with specific stacking angles of thermoplastic prepregs.

As another example, with application of a thermosetting resin (e.g., an epoxy), which does have a sticky surface at room temperature, the lamination process requires personnel to lay out stacking angles of the thermosetting prepregs.

State of the art manufacturing of a composite component (e.g., the crank arm140) may include a number of acts performed by expensive equipment. For example, the acts may include powder-coating with spread carbon fiber tows, a powder reservoir, an infrared heat source, and powder-coated tows. The acts may also include tape consolidation with a double-belt press, laminate production of a multi-ply laminate using, for example, a static hot-press machine, and thermoforming with another infrared heat source and a tool (e.g., a three-dimensional (3D) tool) for forming the composite component.

An attachment mechanism (e.g., an interlocking mechanism) of the present embodiments may set a layup pattern of layers (e.g., the first layers150and the second layers152; a plurality of CFRTP prepregs) together for forming of, for example, a composite component (e.g., the crank arm140). The interlocking mechanism may be included on outermost layers (e.g., outermost first layers150) of the layup pattern and may be configured to set (e.g., lock) the layup pattern of layers together before, for example, the thermoforming. Use of the interlocking mechanism of the present embodiments when manufacturing the composite component, for example, may reduce required personnel for manufacturing and may reduce time and cost for manufacturing, in that acts of the state of the art manufacturing process (e.g., tape consolidation and laminate production) and the corresponding equipment (e.g., a double-belt press and a static hot-press machine) may not be used.

FIG.7illustrates a layup pattern700including the interlocking mechanism of the present embodiments. The layup pattern700is similar to the layup pattern ofFIG.3, though other layup patterns may be provided. The layup pattern700includes the container154(e.g., a thermoplastic sheet container) that houses the core material156. The core material156may be any number of mixtures of materials including, for example, a salt mixture. Thermoplastic sheets158of the container154, for example, are bendable/formable, such that a shape of the container154corresponds to a shape of the bicycle component (e.g., the crank arm140) to be manufactured according to a design.

The layup pattern700includes the first layup pattern164on the first side166of the container154and the second layup pattern168on the second side170of the container154. As with the layup pattern ofFIG.3, the first layup pattern164includes the first layer150a(e.g., including three thermoplastic sheets) disposed on the container154and the metal lugs160a,160b, for example, the second layer152a(e.g., including nine fabric preform sheets) disposed on the first layer150a, the first layer150b(e.g., including one thermoplastic sheet) disposed on the second layer152a, and the second layer152b(e.g., including five fabric preform sheets) disposed on the first layer150b.

As with the layup pattern ofFIG.3, the second layup pattern168includes the first layer150c(e.g., including four thermoplastic sheets) disposed on the second side170of the container154and the metal lugs160a,160b, for example, and the second layer152c(e.g., including seven fabric preform sheets) disposed on the first layer150c. The first layup pattern164and/or the second layup pattern168of the layup pattern700may include more, fewer, and/or different first layers150, second layers152, and/or other layers.

For example, as shown inFIG.7, the layup first layup pattern164may include a first outermost layer702, and the second layup pattern168may include a second outermost layer704. The first outermost layer702and the second outermost layer704may be any number of shapes and/or sizes. For example, the first outermost layer702may be disposed on at least the second layer152band part of the second layer152a, and shaped and sized to cover the first layer150a, the second layer152a, the first layer150b, and the second layer152b. In one embodiment, the first outermost layer702also covers the opposite ends172,174of the metal lugs160a,160b, respectively. The second outermost layer704may be disposed on at least the second layer152c, and shaped and sized to cover the first layer150cand the second layer152c.

The first outermost layer702and the second outermost layer704may be made of any number of materials. For example, the first outermost layer702and the second outermost layer704may be thermoplastic sheets (e.g., polypropylene or polycarbonate sheets). The first outermost layer702and the second outermost layer704may be made of a same material or different materials. Layup patterns (e.g., the layup pattern700) may include more, fewer, and/or different outermost layers (e.g., different shapes, sizes, and/or made of different materials).

The first outermost layer702and the second outermost layer704include attachment features (e.g., interlocking features) that form the interlocking mechanism.FIG.8shows a top view of an example of an outermost layer800(e.g., a cover). The outermost layer800ofFIG.8may be used for the first outermost layer702, the second outermost layer704, or both the first outermost layer702and the second outermost layer704. The outermost layer800includes a base802(e.g., a base layer or sheet) that may be any number of different shapes and/or sizes. For example, the base802may be rectangular and may be sized based on a length, a width, and a height of the layup pattern700. For example, a length of the base802may be equal to the width of the layup pattern700plus two times the height of the layup pattern700, and the width of the base802may be approximately equal to the length of the layup pattern700(e.g., plus 20% or 30% of the length of the layup pattern700). Other shapes and/or sizes of the base802of the outermost layer800may be provided.

The outermost layer800also includes a pocket804(e.g., a cavity) that is recessed in a direction perpendicular to a surface of the base802(e.g., in a direction into the page). For example, the base802of the outermost layer800may have a first surface805(e.g., a top surface) and a second surface807(e.g., a bottom surface) opposite the first surface805. The pocket804may, for example, extend away from the second surface807(e.g., be recessed in a direction in which the second surface807faces).

The pocket804may be any number of sizes and shapes. For example, the pocket804is a rounded rectangle and is shaped such that the layup pattern700is positionable within the pocket804. The height of the layup pattern700may be greater than a depth of the pocket804, such that layup pattern700is not entirely disposable within the pocket804. Other shapes and/or sizes of the pocket804may be provided.

The outermost layer800also includes a plurality of interlocking features806. For example, the outermost layer800includes one or more interlocking features806adisposed between a first side808of the pocket804and a first side810of the base802, and one or more interlocking features806bdisposed between a second side812of the pocket804and a second side814of the base802. The first side808of the pocket804is opposite the second side812of the pocket804, and the first side810of the base802is opposite the second side814of the base802.

The outermost layer800may include any number of interlocking features806. For example, as shown inFIG.8, the outermost layer800may include six interlocking features806abetween the first side808of the pocket804and the first side810of the base, and six interlocking features806bbetween the second side812of the pocket804and the second side814of the base802of the outermost layer800. The six interlocking features806amay be positioned, such that two rows of the interlocking features806a, each with three uniformly spaced interlocking features806a, are formed. The six interlocking features806bmay be positioned, such that two rows of the interlocking features806b, each with three uniformly spaced interlocking features806b, are formed. Other configurations may be provided. For example, the outermost layer800may include more or fewer interlocking features806, the interlocking features806aand/or the interlocking features806bmay be positioned in more or fewer rows, and/or the interlocking features806aand/or the interlocking features806bmay be variably spaced relative to each other (e.g., within respective rows).

The interlocking features806(e.g., extended structures) extend away from the first surface805(e.g., the top surface) or the second surface807(e.g., the bottom surface) of the base802of the outermost layer800. For example, the outermost layer800ofFIG.8may be used for the first outermost layer702ofFIG.7, and the interlocking features806may extend away from the first surface805of the base802of the outermost layer800(e.g., in a direction out of the page ofFIG.8).

Each of the interlocking features806includes one or more walls820(e.g., one wall forming a hollow cylinder) that extend away from, for example, the first surface805of the base802of the outermost layer800, and a recessed wall822(e.g., relative to the first surface805of the base802of the outermost layer800). The one or more walls820extending away from the first surface805of the base802of the outermost layer800and the recessed wall822form a pocket or cavity824(e.g., cavities). The cavities824and the pocket804are accessible at different surfaces of the first surface805and the second surface807of the base802of the outermost layer800, respectively. For example, the pocket804may be accessible at the first surface805, and the cavities824may be accessible at the second surface807. In one embodiment, at least some of the cavities824(e.g., all of the cavities) and the pocket804are accessible at a same surface (e.g., the first surface805of the base802of the outermost layer800).

The interlocking features806may be any number of shapes. For example, the shape of an interlocking feature806may be defined by at least the one or more walls820extending away from the first surface805of the base802of the outermost layer800. In the example shown inFIG.8, each of the interlocking features806includes one wall820that forms a hollow cylinder. In other words, a cross section through the cavity824formed by the one wall820is circular. In other embodiments, the interlocking features806may be shaped differently. For example, each of the interlocking features806may be formed by more walls820(e.g., three or more walls820), such that differently shaped cavities824are provided. For example, at least one of the interlocking features806may include four walls820(seeFIG.9), such that a hollow cuboid is formed (e.g., with a square-shaped cross-section through the cavity824). In one embodiment, all of the interlocking features806are a same shape. In another embodiment, the interlocking features806include interlocking features of at least two different shapes (e.g., the interlocking features806aare hollow cylinders, and the interlocking features806bare hollow cuboids).

The interlocking features806may be any number of sizes. The interlocking features806may all be a same size, or the interlocking features806may include interlocking features having two or more different sizes (e.g., the interlocking features806amay be a different size than the interlocking features806b). In one embodiment, the interlocking features806are sized based on (e.g., size corresponds to) a size of interlocking features of another outermost layer.FIG.9illustrates an example of, for example, the other outermost layer.

FIG.9shows a top view of another example of an outermost layer900. The outermost layer900ofFIG.9may be used for the first outermost layer702, the second outermost layer704, or both the first outermost layer702and the second outermost layer704. In the example in which the outermost layer800is used for the first outermost layer702, the outermost layer900may be used for the second outermost layer704. The outermost layer900includes a base902(e.g., a base layer or sheet) that may be any number of different shapes and/or sizes. For example, the base902, like the base802of the outermost layer800ofFIG.8, may be rectangular and may be sized based on a length, a width, and a height of the layup pattern700. For example, a length of the base902may be equal to the width of the layup pattern700plus two times the height of the layup pattern700, and the width of the base902may be approximately equal to the length of the layup pattern700(e.g., plus 20% or 30% of the length of the layup pattern700). Other shapes and/or sizes of the base902of the outermost layer900may be provided.

The outermost layer900also includes a pocket904(e.g., a cavity) that is recessed in a direction perpendicular to a surface of the base902(e.g., in a direction into the page). For example, the base902of the outermost layer900may have a first surface905(e.g., a top surface) and a second surface907(e.g., a bottom surface) opposite the first surface905. The pocket904may, for example, extend away from the second surface907(e.g., be recessed in a direction in which the second surface907faces).

The pocket904may be any number of sizes and shapes. For example, the pocket904is a rounded rectangle and is shaped such that part of the layup pattern700is positionable within the pocket904. The height of the layup pattern700may be greater than a depth of the pocket904, such that layup pattern700is not entirely disposable within the pocket904. Other shapes and/or sizes of the pocket904may be provided.

The outermost layer900also includes a plurality of interlocking features906. For example, the outermost layer900includes one or more interlocking features906adisposed between a first side908of the pocket904and a first side910of the base902, and one or more interlocking features906bdisposed between a second side912of the pocket904and a second side914of the base902. The first side908of the pocket904is opposite the second side912of the pocket904, and the first side910of the base902is opposite the second side914of the base902.

The outermost layer900may include any number of interlocking features906. For example, as shown inFIG.9, the outermost layer900may include six interlocking features906abetween the first side908of the pocket904and the first side910of the base902, and six interlocking features906bbetween the second side912of the pocket904and the second side914of the base902of the outermost layer900. The six interlocking features906amay be positioned, such that two rows of interlocking features906a, each with three uniformly spaced interlocking features906a, are formed. The six interlocking features906bmay be positioned, such that two rows of interlocking features906b, each with three uniformly spaced interlocking features906b, are formed. Other configurations may be provided. For example, the outermost layer900may include more or fewer interlocking features906, the interlocking features906aand/or the interlocking features906bmay be positioned in more or fewer rows, and/or the interlocking features906aand/or the interlocking features906bmay be variably spaced relative to each other (e.g., within respective rows).

The interlocking features906(e.g., extended structures) extend away from the first surface905(e.g., the top surface) or the second surface907(e.g., the bottom surface) of the base902of the outermost layer900. For example, the outermost layer900ofFIG.9may be used for the second outermost layer704ofFIG.7, and the interlocking features906may extend away from the first surface905of the base902of the outermost layer900(e.g., in a direction out of the page ofFIG.9).

Each of the interlocking features906includes one or more walls920(e.g., four walls forming a hollow cuboid) that extend away from, for example, the first surface905of the base902of the outermost layer900, and a recessed wall922(e.g., relative to the first surface905of the base902of the outermost layer900; parallel with the first surface905of the base902of the outermost layer900). The one or more walls920extending away from the first surface905of the base902of the outermost layer900and the recessed wall922form a pocket or cavity924(e.g., a cavity). The cavities924and the pocket904are accessible at different surfaces of the first surface905and the second surface907of the base902of the outermost layer900, respectively. For example, the pocket904may be accessible at the first surface905, and the cavities924may be accessible at the second surface907. In one embodiment, at least some of the cavities924(e.g., all of the cavities) and the pocket904are accessible at a same surface (e.g., the first surface905of the base902of the outermost layer900).

The interlocking features906may be any number of shapes. For example, the shape of an interlocking feature906may be defined by at least the one or more walls920extending away from the first surface905of the base902of the outermost layer900. In the example shown inFIG.9, each of the interlocking features906includes four walls920that form a hollow cuboid. In other words, a cross section through the cavity924formed by the four walls920is a square. In other embodiments, the interlocking features906may be shaped differently. For example, each of the interlocking features906may be formed by more or fewer walls920(e.g., three or fewer walls920), such that differently shaped cavities924are provided. For example, at least one of the interlocking features906may include one wall920(seeFIG.8), such that a hollow cylinder is formed (e.g., with a circular cross-section through the cavity924). In one embodiment, all of the interlocking features906are a same shape. In another embodiment, the interlocking features906include interlocking features of at least two different shapes (e.g., the interlocking features906aare hollow cuboids, and the interlocking features906bare hollow cylinders).

The interlocking features906may be any number of sizes. The interlocking features906may all be a same size, or the interlocking features906may include interlocking features having two or more different sizes (e.g., the interlocking features906amay be a different size than the interlocking features906b). In one embodiment, the interlocking features906are sized based on (e.g., to correspond to) a size of interlocking features of another outermost layer. For example, a length of a side of the square cross-section through the cavity924of a respective interlocking feature906may be the same as size as a diameter of the circular cross-section through the cavity824of a respective interlocking feature806. Other sizes may be provided.

Referring toFIG.7, assuming, for example, the first outermost layer702is formed by the outermost layer800ofFIG.8and the second outermost layer704is formed by the outermost layer900ofFIG.9, the layup pattern700is positioned within the pocket904of the outermost layer900, such that the outermost layer900may cover at least the second layer152cof the layup pattern700(e.g., and may cover additional layers of the layup pattern700). The outermost layer800is positioned on the layup pattern700, such that the layup pattern700is also positioned within the pocket804of the outermost layer800. For example, the outermost layer800may cover at least the second layer152b(e.g., and may cover additional layers of the layup pattern700).

The first side910and the second side914of the base902of the outermost layer900are pivoted (e.g., upwards) towards the layup pattern700disposed within the pocket904of the outermost layer900. The first side910and the second side914of the base902of the outermost layer900may be pivoted towards the layup pattern700until the base902of the outermost layer900is in contact with opposite sides of the layup pattern700, respectively.

The first side810and the second side814of the base802of the outermost layer800are pivoted (e.g., downwards) towards the layup pattern700disposed within the pocket804of the outermost layer800. The first side810and the second side814of the base802of the outermost layer800may be pivoted towards the layup pattern700until the outermost layer800comes into contact with the outermost layer900. In one embodiment, movement of the outermost layer800and the outermost layer900is switched. For example, the first side810and the second side814of the outermost layer800may be pivoted (e.g., downwards) towards opposite sides of the layup pattern700, respectively, and the first side910and the second side914of the outermost layer900may be pivoted (e.g., upwards) towards the layup pattern700until the outermost layer900comes into contact with the outermost layer800.

FIGS.10aand10brespectively illustrate before and after engagement of one of the interlocking features806of the outermost layer800with one of the interlocking features900of the outermost layer900. Referring toFIG.10b, the one interlocking feature806of the outermost layer800is disposed within the cavity924defined by the walls920of the one interlocking feature906of the outermost layer900.

Referring toFIGS.8and9, for example, the six interlocking features806adisposed between the first side808of the pocket804and the first side810of the base802engage with the six interlocking features906adisposed between the first side908of the pocket904and the first side910of the base902, respectively, and the six interlocking features806bdisposed between the second side812of the pocket804and the second side814of the base802engage with the six interlocking features906bdisposed between the second side912of the pocket904and the second side914of the base902. The interlocking features806a,806bmay be positioned within (e.g., with a friction fit relative to) the cavities924of the interlocking features906a,906b, respectively, such that layers of the layup pattern700, for example, are set and the layers of the layup pattern700are pressed towards the container154.

Other configurations may be provided. For example, the outermost layer800may include square-shaped interlocking features806, and the outermost layer900may include circular-shaped interlocking features906. The circular-shaped interlocking features906of the outermost layer900may be positioned within (e.g., with a friction fit relative to) the square-shaped interlocking features806of the outermost layer800.

As another example, portions of the base802of the outermost layer800may be removed (e.g., cut away), such that strips including rows of interlocking features806a,806b(e.g., four rows of three interlocking features806a,806b) and extending away from the pocket804are provided. Such strips allow individual rows of interlocking features806a,806bto be pivoted relative to the pocket804independently of each other. The same configuration may be provided for the base902of the outermost layer900.